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

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

6890

R

Rear Flue Lengths

STD FLUE PACK 75 mm to 469 mm

1m FLUE PACK 75 mm to 961 mm

2m FLUE PACK 75 mm to 1961mm

4 Flue

4.4 Flue Collar Kit

A flue collar kit, part No.443286 (with instructions) is available.
This can be used to cover the flue, as shown in diagram 4.4
Please note, the use of this collar will mean that the flue lengths

will need to be altered, full instructions are given in the kit.

3774

3m FLUE PACK 75 mm to 2941mm

Diagram 4.2

S

Side Flue Lengths

STD FLUE PACK 310 mm to 585 mm

1m FLUE PACK 310 mm to 1080 mm

Diagram 4.4FLUE COLLAR KIT

6891

2m FLUE PACK 310 mm to 2080 mm

3m FLUE PACK 310 mm to 3060 mm

Diagram 4.3

221504A

12

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

5 Preparation

5.1 Unpacking

Open the carton and check the items supplied against the list on
the flap, see diagram 5.1.

Place the boiler on one side, until required.

USER
LITERATURE

INSTALATION
LITERATURE

FITTINGS PACK

4796

5.2 Flue Preparation

All flue assemblies are designed for internal installation, given
that there is sufficient clearances opposite to the flue exit for
installation of the flue and the fixing of side panels.

If there are insufficient clearances the flues can be installed
externally from outside.

For a wall thickness up to 300mm, provided there is sufficient
space available, the flue can be fully installed from the inside.

For a wall thickness of over 300mm the external cut hole will
need to be made good from the outside.

5.3 Rear and Side Flue Application

Select the boiler location and flue application, with due regard
to the terminal position:

Take the template from the boiler pack and temporarily position
it on the wall, making sure that the minimum clearances are
maintained, see diagram 3.1.

Note: The template has “Fixture’s” alignment marks for ease of
installation.

For rear flue, mark the position of the flue as diagram 5.3.
For side flue, extend the centre line horizontally left or right to

the corner of the adjacent surface where the flue is required to
exit to outside. Mark the position of the centre of the flue, as
diagram 5.3

TEMPLATE

CARTON

3286

115mm
MINIMUM
HOLE

122mm

REAR FLUE

SIDE FLUE

BOILER

WALL TEMPLATE

BOILER PACK CONTENTS

Diagram 5.1

(Side and Rear)

13

Diagram 5.3

221504A

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

5 Preparation

TEMPLATE

5.5

5.5

No. 10x

ø

3

/

16

ø

PLUG

1

/2 in.

5mm

0064M

0064M

TOP BOILER

MOUNTING

HOLES

MOUNTING PLATE

FIXING POINT

SECURING

ø

SCREW (2)

3

/

16

ø

PLUG

BOILER MOUNTING and
PLATE FIXING POINTS

5.4 Flue Hole Cutting

Having marked out the flue centre cut a hole for the flue using,
preferably, a 115mm minimum core drill.

Note: If required, an optional Wall Liner Kit, part No.900862, is
available, complete with fixing instructions.

5.5 Wall Mounting Bracket

Reposition the template, ensuring dimensional alignment with
the flue hole.

Mark the boiler securing screws and mounting plate position,
see diagram 5.4.

Drill holes and plug, to suit No10x50mm woodscrews, fit the
screws allowing sufficient clearance to accept the keyhole fixing
brackets.

Secure the boiler mounting plate to the wall with No.10x50
woodscrews and plugs, see diagram 5.4.

5.6 Flue Duct (Standard or Long)

Mark the duct to the length required (this length allows for
expansion), see diagram 5.5 for Rear flue and diagram 5.6 for
Side flue, then cut square and remove any burrs.

MOUNTING
PLATE

Diagram 5.4

FLUE DUCT

*

Q plus 70mm

*Increase dimension by 15mm if the

“Optional Flue Collar” is to be fitted.

Q

6893

221504A

14

Diagram 5.5FLUE DUCT (REAR FLUE)

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

5 Preparation

5.7 Air Duct/Terminal (Standard or Long)

Mark the duct length, see diagram 5.7 for Rear flue and diagram

5.8 for Side flue, then cut square and remove any burrs.

5.8 Air Duct/Terminal and Flue Duct Assembly

Locate the flue duct into the air duct/terminal, see diagram 5.9.
Fully locate the flue elbow into the air/terminal and flue duct

assembly as shown, ensuring correct alignment of the “Top”,
see diagram 5.10.

Mark the position of securing holes through the flue elbow
outlet, see diagram 5.10.

Drill two 3mm diameter holes, see diagram 5.10.

LONG FLUE
TERMINAL

STANDARD FLUE
TERMINAL

*

Q plus 60mm

6894

5.9 External Flue Installation

Remove the flue elbow from the air duct/terminal and flue duct
assembly.

Note: Do not insert the flue assembly but place on one side until
required.

Continue at “Boiler Preparation”

6892

*Increase dimension by 15mm if the

“Optional Flue Collar” is to be fitted.

Q

REAR FLUE
AIR DUCT / TERMINAL

LONG FLUE
TERMINAL

STANDARD
FLUE
TERMINAL

Diagram 5.7

6895

*

S Minus 52mm

* S minus 37mm

(If flue collar is to be fitted overall

dimension increased by 15mm)

BOILER
CENTRE
LINE

s

Diagram 5.6FLUE DUCT (SIDE FLUE)

(If flue collar is to be fitted overall

dimension increased by 15mm)

BOILER
CENTRE
LINE

SIDE FLUE
AIR DUCT / TERMINAL

15

*

S plus 60mm

* S minus 47mm

s

Diagram 5.8

221504A

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

5 Preparation

5.10 Internal Flue Installation

If access to the outside wall is not practical, the flue system can
be installed from inside. Use of the optional wall liner kit
recommended.

Secure the flue elbow to the air duct/terminal with the two self
tapping screws supplied in the fittings pack, see diagram 5.10.

Place the sealing tape from the fittings pack around the flue
elbow as diagram 5.10.

Place the flue assembly to one side until required.
Continue at “Boiler Preparation”.

5.11 Wall Liner

If a wall liner is used, fit self adhesive seal as follows:
For wall thicknesses up to 300mm fit the self adhesive seal to the

air duct, see diagram 5.11, make sure the joint is on top.
For wall thicknesses over 300mm see diagram 5.12..
When installed the seal will be within the wall.

DRILL SIZE

SEAL WITH
TAPE SUPPLIED

3mm

AIR DUCT/TERMINAL &
FLUE DUCT ASSEMBLY

FLUE ELBOW
ASSEMBLY

3294

LHD/RHD

3293

RHD

REAR FLUE
SECURING POINTS

FLUE ELBOW ASSEMBLY

SIDE FLUE
SECURING POINTS

Diagram 5.10

LHD

FOAM SEAL

*

10mm

*Increase dimension by 15mm if the

“Optional Flue Collar” is to be fitted.

6896

AIR DUCT / TERMINAL
ASSEMBLY

FLUE
DUCT

AIR DUCT /
TERMINAL ASSEMBLY

221504A

Diagram 5.9

FOAM SEAL
(Wall Thickness up to 300mm)

16

Q

Diagram 5.11

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

5 Preparation

5.12 Boiler Preparation

Remove the controls tray and outer case and place on one side
until required, see diagram 5.13.

Discard packing piece from between front cover and inner case
Note: If convenient, a connection can be made to the gas

service cock at this time.
Lift the boiler into position above the boiler mounting plate,

lowering the boiler into position at the same time locating the
key hole slots of the boiler on to the securing screws, when
located secure the screws, see diagram 5.14.

CONTROL
TRAY

FRONT COVER

CASE REMOVAL Diagram 5.13

4810

FOAM SEAL

Q minus 25mm

3550

KEYHOLE SLOT
MOUNTING BRACKET

6897

Q

MOUNTING
PLATE

BOILER MOUNTING

FOAM SEAL
(Wall Thickness over 300mm)

Diagram 5.12

17

Diagram 5.14

221504A

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

6 Water Connections

Make the water connection to the heating system, see diagram

6.1.
The boiler has compression connections, with nuts and olives

supplied loose in the fittings pack, to accept 28mm outside
diameter copper tubing to BS2871.

The right hand connection is the flow from the boiler.

COPPER
TUBING

UNION NUT

OLIVE

WATER
CONNECTION

3551

7 Flue Assembly Installation

7.1 Flue Assembly Preparation.

Remove the inner case by releasing the securing screws, place
on one side until required, see diagram 7.1.

Remove the violet (or blue) and red electrical connections from
the fan see diagram 7.2.

Break the air pressure switch tube(s) connection(s), see diagram

7.2.
Slacken but do not remove the flue hood securing angle wing

nuts, see diagram 7.2.
Remove the fan and mounting plate assembly by removing the

two securing screws, see diagram 7.2.

7.2 External Flue Installation

Offer the air duct/terminal flue duct assembly into and through
the hole and wall.

Secure the flue elbow to the air duct/terminal with the two self
tapping screws, supplied in the fittings pack, into the holes
previously drilled.

Place the sealing tape from the fittings pack around the flue
elbow as diagram 5.11.

Continue at “Flue/Boiler Connection”.

RETURN

WATER CONNECTION

SECURING
SCREW (4)

FLOW

DATA LABEL

Diagram 6.1

3552

INNER
CASE

INNER CASE

221504A

18

SERIAL
NO PLATE

PILOT
VIEWING
WINDOW

Diagram 7.1

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

7 Flue Assembly Installation

7.3 Internal Flue Installation

Push the flue assembly into and through the wall, see diagram

7.3.

7.4 Flue/Boiler Connection

Secure the flue elbow and gasket to the boiler with the three
screws and washers, previously removed, see diagram 7.4.

Replace the fan and mounting plate assembly ensuring
engagement of the fan into the flue elbow and the fan retaining
bracket, see diagram 7.5 and secure with the two screws
previously removed.

Connect the air pressure switch tubes and electrical connections.
Make good around the flue and flue terminal and fit the terminal

guard.

693435543344

GASKET

Diagram 7.3INTERNAL FLUE ASSEMBLY

FAN ELECTRICAL
CONNECTIONS

FAN / MOUNTING
PLATE ASSY.
SECURING
SCREW (2)

AIR PRESSURE
SWITCH TUBES

RED

CLEAR

3303

WASHER (3)

FLUE ASSEMBLY /
BOILER CONNECTION

SECURING
SCREW (3)

Diagram 7.4

COMBUSTION
CHAMBER
FRONT PANEL

FLUE HOOD
WING NUTS

SECURING
SCREW (4)

FLUE PREPARATION

Diagram 7.2

FLUE ELBOW SPIGOT

19

FLUE ELBOW
SPIGOT

FAN RETAINING
BRACKET

Diagram 7.5

221504A

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

Make the gas connection, refer to diagram 8.1.

8 Gas Connection

GAS VALVE
(cover removed for clarity)

GAS SERVICE
COCK (shown on )

Diagram 8.1

3301

9 Electrical Connection

9.1 Electrical Connection

WARNING. This boiler must be earthed.
Take the two plastic cable retaining clips, from the loose items

pack, peel off the backing paper and position them as shown in
diagram 9.1.

Remove the control box by supporting it and removing the fixing
screw, lower slightly and pull forward to disengage, support the
box on the lip bracket at the front, see diagram 9.2.

Take care not to damage any internal wiring and capillaries.

o

Using heat resistant (85

0.75mm
and of a suitable length, thread the cable through the cable
clamp secure into the plastic clips and connect to the appropriate
terminals, see diagram 9.3 and 13.5.

Standard colours are, brown - live, blue - neutral and Green and
Yellow - earth.

The mains cable outer insulation must not be cut back external
to the cable clamp, see diagram 9.3.

When making connections, make sure that the earth conductor
is made of greater length than the current carrying conductors,
so that if the cable is strained the earth conductor would be the
last to become disconnected.

CAUTION. It

2

(24/0.2mm) to the current issue of BS6500 Table 16,

is essential that the polarity is correct.

9.2 Pump Connection

The pump must be connected directly to the control box, as
shown in diagram 9.3 and 13.5 threading the cable through the
cable clamp in the side of the control box.

C) PVC insulated cable of at least

9.3 Testing - Electrical

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

After installation of the system, preliminary electrical system
checks as below should be carried out:

1. Test insulation resistance to earth of mains cables.

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

3. Test the polarity of the mains.

3555

SELF ADHESIVE
BACKED CABLE
CLIPS

9.3 External Controls

Remove the red link between 9 and SL in the control box when
using any external controls.

Always make sure that all cables are secured and clear of hot
surfaces.

CABLE RETAINING CLIPS

221504A

20

Diagram 9.1

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

9 Electrical Connection

CONTROL BOX

FIXING SCREWS

LIP BRACKET

Diagram 9.2

3308

3310

PUMP
CABLE

CABLE
CLAMPS

MAINS
CABLE

Remove red ink between 9 & SL When fitting
a time control etc (if no switch is fitted, link
will make the circulation pump run constantly)

10 Commissioning

10.1 Preliminaries

The system must be thoroughly flushed out with cold water
without the pump in position.

Refit the pump and fill the system, making sure that all the air
is properly vented from the system and pump.

10.2 Sealed Systems

Flush the whole system with cold water without the pump in
position. Refit the pump and fill until the pressure gauge
registers 2.7 bar (40lbf/in
leakage.

Check the operation of the safety valve preferably by allowing
the water pressure to rise until the valve lifts. This should be
within +/- 0.3bar (+/- 4.3lbf/in
this is not possible a manual check should be carried out.

Release the cold water to initial design pressure.

10.3 Initial Lighting, Testing and Adjustment

Identify the controls by reference to diagram 10.1.
Check that the main electrical supply to the boiler is switched

off and that the boiler thermostat is turned to “O”, see diagram

10.1.
Turn on the main gas supply at the gas service cock.
Test the pilot supply tube and its connections for gas soundness

as follows: Remove the terminal cover from the gas valve, see
diagram 10.1.

2

). Clear any air locks and check for

2

), of the preset pressure. Where

CONTROL BOX TERMINAL

Note:
control box shown in
service position.

Diagram 9.3

SETTING
POINT

THERMOSTAT
CONTROL KNOB

OVERHEAT
THERMOSTAT
CONTROL KNOB

RESET

BUTTON

GAS VALVE TERMINAL
COVER SCREW

INDICATOR SLOT

(shown on)

BOILER CONTROLS Diagram 10.1

3311

21

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

10 Commissioning

Temporarily disconnect the black cable from the main solenoid
and insulate the connector with tape.

Remove the combustion chamber front panel, securing screws,
see diagram 10.2.

Switch on the electrical supply to the boiler and heating system.
Make sure that any remote controls are calling for heat.

WARNING. The gas valve, fan and control box operate on
mains voltage, terminals will become “Live”.

To complete this test it is necessary to operate the boiler without
its inner case, BUT UNDER ALL OTHER CIRCUMSTANCES
the inner case must be correctly fitted and sealed.

Turn the boiler thermostat knob fully clockwise and the fan will
operate. Sparks will be generated and the pilot burner will light.

Test for gas soundness around the pilot connections using
suitable leak detection fluid.

At this time check that the flame lengths are as shown in diagram

10.3.
The pilot gas rate is preset fully open and no adjustment should

be necessary, but, if required, turn the pilot burner regulator
screw on the gas valve, shown in diagram 10.4 clockwise, to
decrease.

Refer to diagram 10.3 for flame length.
Turn the thermostat knob to “O” and isolate the boiler from the

electrical supply.
Remove the insulation tape and reconnect the black cable

ensuring that the insulating boot is fitted to the main solenoid,
see diagram 10.4.

Refit the combustion chamber front panel, secure the fluehood
securing angle wing nuts and inner case with the screws
previously removed.

For reference attach the self adhesive arrow indicator, from the
fittings pack, to the data badge against the rating the boiler is
going to be set to.

Loosen the main burner pressure test point screw and fit a
suitable pressure gauge, see diagram 10.5.

WARNING. The gas valve, fan and control box operate on
MAINS voltage, terminals will become “Live”.

Note: The neon indicator lights on the control board (PCB) are
an aid to fault finding.

Make sure that any remote controls are calling for heat.
Switch on the electrical supply to the boiler and heating system.
Turn the boiler thermostat knob fully clockwise to the maximum

setting.
The lighting sequence is automatic, as follows:
The fan operates
The spark ignition operates
The pilot solenoid opens
The pilot burner lights
The ignition spark stops,
The main solenoid opens ­and after a short period of time the main burner will light, view

through window, see diagram 10.6.
The main burner will remain alight until switched off, either by the

boiler thermostat or a remote system control.
When the boiler switches “Off”, both the pilot and main burner go

out. The automatic lighting sequence will operate again when
heat is required.

FLUE HOOD
WING NUTS

COMBUSTION
CHAMBER
FRONT PANEL

SECURING
SCREW (4)

COMBUSTION CHAMBER

12 to 14 FLAME LENGTH

SPARK GAP

FLAME LENGTH

3 to 4.5

AND SPARK GAP

BLACK LEAD

MAIN BURNER
FLOW RATE
REGULATOR SCREW

PILOT BURNER
REGULATOR SCREW

GAS VALVE ADJUSTMENT

3312

Diagram 10.2

3345

Diagram 10.3

3314

Diagram 10.4

221504A

22

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10 Commissioning

10.4 Testing - Gas

With the boiler on proceed as follows:
Test for gas soundness around the boiler gas components

using a suitable leak detection fluid, in accordance with the
current issue of BS6891.

Check the main burner gas pressure at least 10 minutes after
the boiler has lit, refer to Data label.

If necessary adjust the main burner flow rate regulator screw to
obtain the required gas pressure setting, turn clockwise, to
decrease the pressure as shown in diagram 10.4.

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

The gas rates shown in Table 6 are for guidance only, dependent
on the heat setting.

Turn the boiler thermostat knob fully anti-clockwise to “O”.
Remove the pressure gauge from the test point and refit the
screw, ensuring that a gas tight seal is made.

When the boiler thermostat is turned to the “O” position, by
hand, wait at least 30 seconds before turning “On” again.

There may be an initial smell given off from the boiler when new,
this is quite normal and it will disappear after a short period of
time.

Refit the gas valve terminal cover.
Refit the electrical controls box.
Note: Make sure that the air pressure switch tubes do not kink.

3315

PRESSURE TEST
POINT SCREW

10.5 Heating System

Check that all remote controls are calling for heat.
Turn the boiler thermostat knob fully clockwise to the maximum

setting.
Allow the system to reach maximum temperature and examine

for water leaks. The boiler should then be turned off and the
system drained off as rapidly as possible whilst still hot.

Refill the system, vent and again check for water soundness.
For sealed systems adjust to initial design pressure. The set

pointer on the pressure gauge should be set to coincide with the
indicating pointer.

The overrun thermostat will keep the pump running when the
boiler shuts down, so long as the temperature within the boiler
is above a predetermined level.

When commissioning the system the boiler should be fired on
full service, that is, central heating and domestic hot water. The
system should then be balanced, adjusting the pump and
lockshield valve as necessary. Having achieved a satisfactory
condition operate the boiler with the bypass fully closed on
minimum load, normally this will be central heating with one
radiator, in the main living area working. The valve should be
gradually opened to achieve the minimum flow rates given in
Section 2. This can be checked by measuring the water
temperature difference between the boiler flow and return
connections. The difference MUST NOT exceed 16

If necessary readjust the pump.
Under NO circumstances should this valve be left in the FULLY

CLOSED position.

o

C.

PRESSURE TEST POINT

Diagram 10.5

TABLE 6

APPROX.GAS RATE min med max

ECONOMY
PLUS 60F

m3/h

ft3/h

1.8 1.9 2.1

63.0 68.5 74.0

10.6 Operational Checks

Adjust the boiler thermostat and any system controls to their
required settings.

Do not attempt to adjust the thermostat calibration screw.
Operate the boiler again on full service and check that the

balancing is satisfactory, making further adjustments as
necessary to the system, radiator valves and bypass.

On open vented systems there must be no pumping over of
water or entry of air at the vent above the feed and expansion
cistern.

If thermostatic radiator valves are fitted care must be taken to
ensure that there is an adequate flow rate through the boiler and
bypass when the valves are closed, refer to the current issue of
BS7478 for guidance.

Refit the outer case using the screws from the fittings pack, see
diagram 10.7.

23

221504A

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10 Commissioning

SECURING

SCREW (4)

INNER
CASE

DATA LABEL

PILOT
VIEWING
WINDOW

Diagram 10.6VIEWING WINDOW

3556

SECURING
SCREW (2)

SECURING
SCREW

OUTER CASE

3775

WING
NUT

FRONT
COVER

CONTROLS TRAY

Diagram 10.7

11 Completion

11.1 User Information

Hand the Instructions for Use to the user for their retention.
Instruct and demonstrate the efficient and safe operation of the

boiler, heating system and if fitted, the domestic hot water
system.

Refit the controls tray, see diagram 10.7.
Advise the user of the precautions necessary to prevent damage

to the system and building in the event of the heating system
being out of use during frost and freezing conditions.

Advise the user, that to ensure the continued efficient and safe
operation of the boiler it is recommended that it is checked and
serviced at regular intervals. The frequency of servicing will
depend upon the particular installation 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.

It is the Law that servicing is carried out by a competent person.
Reminder, leave these instructions with the user.

221504A

24

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

12 Servicing

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

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

Before starting a service remove the front panel by pulling it
forward at the base and lifting off, see diagram 11.4.

As an aid to servicing the air pressure switch tube connection
can be used to obtain a products of combustion reading.

Remove the RED tube from the connection on the air pressure
switch and insert the analyser probe into the tube.

Turn on gas supply.
Switch on the electrical supply, turn the boiler thermostat fully

clockwise and the boiler will operate.
On completion of the test, switch off the electrical and gas

supplies and reconnect the red tube to the air pressure switch.
Isolate the boiler from the electrical supply and turn the gas

supply off at the gas service cock, see diagram 10.1.
Unless stated otherwise, parts removed for servicing should be

replaced in the reverse order to removal.
After completing any servicing of gas carrying components,

ALWAYS test for gas soundness and carry out functional check
of controls.

12.1 Heat Exchanger Cleaning

Remove the inner case, see diagram 10.6
Disconnect the fan air pressure tubes, electrical connections

and remove the fan assembly securing screws and fan, see
diagram 7.2.

Remove the fluehood securing angle wing nuts the securing
angle and fluehood, see diagram 7.2.

Note: 1. Before refitting the flue hood make sure that it is clean,
for example, by washing thoroughly.

2. Remove the combustion chamber front panel, see diagram

7.2.

3. When replacing the combustion chamber front panel, refer to
diagram 14.9 and make sure that the sides are in the top
location.

4. When refitting the flue hood make sure that it is correctly
located under the rear combustion chamber mounting plate
return lip.

Disconnect the ignition lead from the electrode, taking care not
to damage the lead insulation.

Unscrew the tubing nut at the base of the pilot burner, see
diagram 12.1.

Remove the burner support bracket, see diagram 12.1.
To release the pilot burner/electrode assembly remove the pilot

burner securing screws and washers and withdraw see diagram

12.1.
Spring the pilot tube downward sufficiently to allow the main

burner to move forward to disengage from the injector at the
rear. Raise the burner up through the combustion chamber and
remove.

Take care not to damage the insulation inside the combustion
chamber.

Protect the pilot tube and olive.

Place a sheet of paper in the base of the combustion chamber
and clean the heat exchanger thoroughly with a suitable stiff
brush.

Do not use a brush with metallic bristles.
Remove the paper and any deposits.

PILOT BURNER
SECURING SCREW (2)

IGNITION
LEAD

PILOT
TUBE NUT

BURNER SUPPORT
BRACKET SECURING
SCREW AND WING NUT

Diagram 12.1PILOT BURNER ASSEMBLY

MAIN BURNER
INJECTOR

3348

3340

25

Diagram 12.2MAIN BURNER INJECTOR

221504A

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

12 Servicing

12.2 Burner and Injector Cleaning

With the main burner removed, brush off any deposits from the
burner, ensuring that the flame ports are unobstructed.

Do not use a brush with metallic bristles.
Check the main burner injector, see diagram 12.2, for blockage

or damage and remove if necessary.
Note: make sure that, if removed, the injector is replaced using

an approved sealant.
Do not clean the hole in the injector with a wire or a sharp

instrument.
Make sure that the main burner is pushed fully home on to the

injector.

12.3 Pilot Burner/Electrode and Pilot Injector

Clean the pilot burner and electrode.
When removing and replacing the pilot injector from the pilot

burner take care not to damage the electrode, see diagram

12.3, clean the injector by blowing through it.
Check that the spark gap is as shown in diagram 10.3.

12.4 Operational Checks

After completing a service, before fitting the casing, check the
inner casing seal to ensure that it is in good condition, renew if
necessary.

Light the boiler and carryout the functional checks as described
in Section 9 and 10.

PILOT BURNER

PILOT BURNER/
ELECTRODE and
PILOT INJECTOR

ELECTRODE

PILOT INJECTOR

Diagram 12.3

3323

13 Fault Finding

Neon Indicators - An Aid to Fault Finding

THE NEON INDICATORS ARE AN AID TO FAULT FINDING ONLY. FAILURE OF ANY OF THE NEON INDICATORS DOES NOT

Is neon 3 lit?

WARRANT THE REPLACEMENT OF AN OTHERWISE SATISFACTORY PRINTED CIRCUIT BOARD (P.C.B).

NO

Is neon 1 lit?

YES

NO

Is neon 2 lit?

YES

NO

YES

Fault with mains supply or PCB fuse

Overheat cut off device tripped or
thermostat, overheat cut off device
faulty- see detailed fault finding chart.

Air flow proving fault - that is fan or air
pressure switch - see detailed fault
finding chart.

NEON

Is neon 4 lit?

Is main burner
operating?

YES

YES

NO

NO

Ignition, pilot or flame proving fault ­see detailed fault finding chart.

Gas valve/harness problem - see
detailed fault finding chart.

INDICATORS

3324

System satisfactory

221504A

26

Diagram 13.1NEON INDICATORS

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

13 Fault Finding

13.1 Electrical

Important. On completion of the Service/Fault Finding task
which has 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.

Refer to Neon Indicators - “An Aid to Fault Finding” diagram

13.1, Functional Flow diagram 13.2, Boiler Fault Finding diagram

13.3, Pump Overrun Fault Finding diagram 13.4, and Pictorial
Wiring diagram 13.5.

13.2 Electrical Supply Failure

Failure of the electrical supply will cause the burner to go out.
Operation will normally resume on restoration of the electrical

supply. If the boiler does not relight after an electrical supply
failure the overheat device may need resetting.

Remove the controls cover and press the reset button on the
control box, see diagram 10.1.

If the cutoff operates at any other time press the reset button and
the burner should relight. If the fault persists refer to fault finding
chart.

bk BLACK w WHITE
br BROWN r RED
br BLUE y YELLOW

br br

LL

THERMOSTAT
PUMP
OVERRUN

SPARK
ELECTRODE

FUSE
TYPE F1A
1 AMP

7

PURPLE

br

78

O/H CUTOFF

w

y

KEY

8

PUMP

br

b

br

r

y

63

99

SL

*

b

RED
LINK

N

3325

N

b

N

b

CONTROL STAT

r

FAN N N

r

AIR
PRESSURE
SWITCH

y

br b
PILOT
SOLENOID

bk b

MAIN
SOLENOID

v

b

(N/O) (C)

(N/C)

N

b

N

*

Remove red link between 9 & SL when fitting
a time control etc. (If no switch is fitted, link
will make the circulation pump run constantly)

N

N

N

FUNCTIONAL FLOW WIRING

27

AIR PRESSURE SWITCH CONNECTIONS
MAIN TERMINAL STRIP CONNECTIONS
CONTROL THERMOSTAT CONNECTIONS
PRINTED CIRCUIT BOARD CONNECTIONS

Diagram 13.2

221504A

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

13 Fault Finding

Before detailed checking of electrical components ensure that remote controls are calling for heat. Check the gas supply is free of

Check the overheat cutoff has not operated. Isolate the electrical supply and physically check ALL cables, connections and the printed

circuit board fuse. Check the air tubes to the air pressure switch. Switch on the electrical supply and check for correct polarity.

NO

Is neon 1 lit?

Turn the control thermostat to its maximum setting. Also check fuses.

Is there 240V~ between 12 and
10 and between 11 and 10 ?

YES

Is neon 2 lit?

YES

Is neon 3 lit?

Is there 240V~ between yellow
connection on overheat device and 10 ?

NO

YES

Is there 240V~ between 6 on
thermostat and 10 ?

NO

Is there 240V~ between 1 on air
pressure switch and 10 ?

YES

Is there 240V~ between 3 on air
pressure switch and 10 ?

obstructions and purged of air.

NO

YES

NO

YES

NO

NO

YES

NO

Correct power supply problem

Check overheat reset.
If satisfactory replace overheat device

Replace thermostat.

Check yellow cable between printed circuit
board and air pressure switch.
If satisfactory replace printed circuit board.

Replace air pressure switch.

YES

Does fan run?

YES

Does fan Hunt?

NO

Replace fan.

YES

Is there 240V~ between motor connections
on fan ?

YES

Isolate electrical supply test fan harness
continuity.
If satisfactory replace printed circuit board.

Replace printed circuit board.

NO

Is Neon 4 lit?

YES

Does main burner
light?

YES

System satisfactory

221504A

NO

Is there 240V~between 2 on air
pressure switch and 10 ?

YES

Is there 240V~ between pilot gas
valve solenoid blue and brown

NO

connections?

YES

Does discharge tube flash on
printed circuit board during ignition
attempt?

YES

Is there a spark at pilot burner?

YES

Does pilot light?

YES

YES

With pilot lit does spark stop?

NO

Is there 240V~ between main gas
valve solenoid black and blue cables?

YES

Replace gas valve.

28

NO

NO

Inspect air tubes for leaks, kinks and
correct fitting. If satisfactory replace faulty
air pressure switch.

Isolate supply, test harness continuity.
If satisfactory replace printed circiut board.

NO

Replace printed circuit board.

NO

NO

NO

NO

A I R P R E S S U R E S W I T C H
M A I N T E R M I N A L S T R I P
C O N T R O L T H E R M O S T A T

Check lead continuity and inspect electrode
and lead for damage.

Check for pilot jet blockage, incorrect
electrode adjustment. If satisfactory
replace gas valve.

Inspect electrode lead /connection
for poor contact. Check electrical supply
polarity and correct if necessary.
If satisfactory replace printed circuit board.

Isolate supply, test harness and replace as
required.

Diagram 13.3

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

13 Fault Finding

Pump overrun Operation

The Control Thermostat has a pump overrun facility built into it, when the Control Thermostat is set at maximum only,

the pump overrun will keep the pump running to allow the boiler to cool down after which it will stop, providing the remote controls are

Turn boiler Control Thermostat to maximum, with the remote controls calling for heat,

does the pump continue to run after the appliance has shut down on boiler control thermostat?

NOT calling for heat.

Fault Finding

YES

Turn off remote controls, does
the pump stop after a short
period of time

YES

Faulty Pump overrun.
Replace Control
Thermostat

Pump overrun in order.

NO

NO

Is there 240V~ on 11 ?

YES

Is there 240V~ on 9
connection on thermostat?

YES

NO

NO

Faulty permanent live feed.
Replace.

Faulty connections between
thermostat and main terminal strip.
Repair.

Is there 240V~ on 9 for
pump?

YES

Faulty pump / wiring ? Replace
or repair as necessary.

29

NO

Faulty internal wiring between
main terminal strip and
thermostat. Repair.

Diagram 13.4

221504A

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

13 Fault Finding

RED

YELLOW

NC

NO

C

AIR
PRESSURE
SWITCH

BLACK

BLUE

FLAME SENSE/

SPARK ELECTRODE

RED

BLACK

BLUE

FAN

3326

DOUBLE SOLENOID GAS VALVE

GRN/
YEL.

3-PLUGS

BROWN

9
8

6

YELLOW

7

3

CHASSIS EARTH

GRN/YEL

GRN/YEL

SEQUENCE

F1A

BOARD

1 AMP
FUSE

BROWN

BROWN

RED

WHITE

YELLOW

COMBINED THERMOSTAT
AND PUMP OVERRUN

PURPLE

BLUE

BRN

BLUE

GREEN/YELLOW

Remove red link between 9 & SL when fitting

✽

a time control etc (if no switch is fitted, link
will make the circulation pump run constantly)

7
8

SL

✽

L
N

OVERHEAT
CUTOFF

BROWN

CHASSIS
EARTH

GREEN/YELLOW

BROWN

BLUE

BROWN

BLUE

GREEN/YELLOW

SWITCH
CONTROL,
TIME SWITCH,
PROGRAMMER ETC.
(if fitted)

E

CIRCULATION

L

PUMP

N

L

240~50 Hz

N

PERMANENT
MAINS

E

SUPPLY
FUSED
AT 3-AMP

PICTORIAL WIRING

221504A

30

Diagram 13.5

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

14 Replacement of Parts

Notes

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

Before replacing any parts isolate the boiler from the electrical
supply and turn the gas supply off at the gas service cock, see
diagram 10.1.

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

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

14.1 Pilot Burner Assembly

Gain access as the servicing section “Heat Exchanger”.

14.2 Electrode Assembly

Gain access as the servicing Section “Heat Exchanger” and
“Pilot Burner/Electrode and Pilot Injector”.

Remove the electrode securing screw to release the electrode.

14.3 Ignition Lead

Gain access as the servicing section “Heat Exchanger”.
Remove the control box, refer to Section 9.
Loosen the cable ties, see diagram 14.1.
Pull off the ignition lead at the control board (PCB) and electrode.
Release but do not remove the gland plate securing screw, see

diagram 14.1 and pass the lead through and secure as the one
removed.

14.4 Control Board (PCB): Diagram 14.2.

Remove the control box, refer to Section 9.
Disconnect the three electrical plugs and ignition lead.
Release the cables from the plastic retaining clip and disconnect

the cables, including the earth connection, from the PCB to the
main terminal strip, boiler thermostat and overheat cutoff.

Release the main terminal strip and plastic insulation.
Carefully pull the board away from its supports.
When refitting refer to wiring diagram 13.5.

14.5 Control Thermostat and Overheat Cutoff:
Diagram 14.3.

Remove the inner case.
Remove the control box, refer to Section 9.

ELECTRICAL

PLUGS

CONTROL
THERMOSTAT
ELECTRICAL
NO.6 "YELLOW" CABLE

3328

GLAND PLATE

SECURING
SCREW

CABLE TIES

3327

CHASIS
EARTH
CONNECTION

MAIN TERMINAL
STRIP SECURING
SCREW (2)

ELECTRICAL
CONNECTION
SL BROWN CABLE

PLASTIC RETAINING
CLIP

OVERHEAT
CUTOFF
ELECTRICAL
CONNECTION
"WHITE" CABLE

SUPPORT
POST (2)

IGNITION
LEAD

ELECTRICAL
CONNECTION
N BLUE CABLE

CABLE TIES

Diagram 14.1

CONTROL BOARD (PCB)

31

Diagram 14.2

221504A

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

14 Replacement of Parts

14.6 Control Thermostat - diagram 14.3

Pull off the control thermostat knob.
Remove the electrical connections from the thermostat body.
Disconnect the air pressure switch connector plug from the

PCB.
Remove the thermostat securing screws.
Release the capillary from the base and plastic retaining clip

then remove it from the split grommet.

14.7 Overheat Cutoff - diagram 14.3

Remove the electrical connections.
Disconnect the air pressure switch connect plug from the PCB.
Remove the locking nut from the overheat cutoff.
Release the capillary from the plastic retaining clip then remove

it from the split grommet.

14.8 Control Thermostat and Overheat Cutoff
Capillaries and Phials - diagram 14.4

Remove the cable ties retaining the capillary(s), see diagram

14.1.
Remove the gland plate.
Remove the split pin and withdraw the two phials from the heat

exchanger pocket.
Withdraw the capillary(s) through the boiler casing gland plate.
Note: On replacement the phials should be positioned as

illustrated and smeared with the heat sink compound supplied.
Neatly coil any surplus capillary.

14.9 Air Pressure Switch: Diagram 14.5

Remove the control box, refer to Section 9.
Disconnect the air pressure switch tubes.
Disconnect the electrical plug from the PCB, see diagram 14.3.
Remove the two securing screws to release the air pressure

switch and cable assembly.
Remove the cables and fit to the replacement air pressure

switch.

CONTROL THERMOSTAT
ELECTRICAL CONNECTIONS (5)
BROWN 9 , RED 8
PURPLE 7 YELLOW 6 & 3

AIR PRESSURE
SWITCH PLUG

SPLIT
GROMMET

RETAINING
CLIP

OVERHEAT
CUTOFF

LOCK NUT

3329

PHIAL
RETAINING
PIN

OVERHEAT
CUTOFF
PHIAL

CONTROL
THERMOSTAT
PHIAL

GLAND PLATE

3330

CONTROL
THERMOSTAT
KNOB

SECURING SCREW (2)

CONTROL THERMOSTAT/
OVERHEAT CUTOFF

221504A

Diagram 14.3

CONTROL THERMOSTAT
and OVERHEAT CUTOFF

32

Diagram 14.4

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

14 Replacement of Parts

14.10 Gas Valve: Diagram 14.6

Remove the gas valve cover, retaining screw, see diagram

10.1.
Disconnect the electrical connections at the gas valve.
Disconnect the pilot tube nut at the gas valve.
Support the gas valve, remove the four extended screws from

the flanged connections at each end of the valve and remove
the valve by easing the flanges apart.

Make sure that the new “O” rings are in place in the flanged
connections when replacing.

It will be necessary to purge the pipework and valve before
relighting and checking the pressure settings, refer to section
“Commissioning”.

14.11 Solenoid: Diagram 14.7

Remove the gas valve cover, retaining screw see diagram 10.1.
Disconnect the electrical connections of the solenoid that is to

be replaced.
To remove the retaining clip, put a screw driver blade into the

hole of the clip, lever off to the left and remove the solenoid.

ELECTRICAL
CONNECTIONS

EXTENDED
SECURING SCREW (4)

AIR PRESSURE

SWITCH TUBES

SECURING
SCREWS

CLEAR

RED

3331

GAS VALVE

EARTH
CONNECTION

PILOT TUBE
NUT

ELECTRICAL
CONNECTIONS

Diagram 14.6

3333 3332

RETAINING
CLIP HOLE

AIR PRESSURE SWITCH

Diagram 14.5

SOLENOID

33

RETAINING

SOLENOID

CLIP

Diagram 14.7

221504A

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

14 Replacement of Parts

14.12 Fan: Diagram 7.2

Gain access as described in the servicing section for “Heat
Exchanger Cleaning”.

Fit new fan.

COMBUSTION
CHAMBER
FRONT COVER

3341

14.13 Main Burner

Gain access as described in Servicing to remove and replace
the burner.

14.14 Main Burner Injector

Gain access as described in the Servicing Section and replace
the burner.

14.15 Insulation: Diagram 14.8

Remove the inner case, see diagram 7.1.
Remove the combustion chamber front panel, see diagram 7.2.
Remove the screw securing the front insulation and slide out.
The side insulation panels can be removed by sliding them

forward.
Note: To remove the rear insulation panel it is first necessary

to remove the burner, refer to Servicing Section “Heat Exchanger
Cleaning”.

Pull the rear insulation panel forward off the retaining angle at
the bottom, allow the panel to drop, then slide the top of the
panel forward.

14.16 Heat Exchanger: Diagram 14.9

Gain access as described in the servicing section for “Heat
Exchanger Cleaning”.

Drain the boiler circuit of water.
A drain point is provided for the draining of residual water from

the heat exchanger.
Remove the retaining clip and thermostat phials as previously

described in this section.
Disconnect the flow and return unions.
Remove the heat exchanger retaining plate, see diagram 14.9.
The heat exchanger can now be removed, on replacement use

the new sealing washers provided and ensure the lugs on the
combustion chamber locate into the cutouts on the heat
exchanger.

INSULATION
SECURING
SCREW

SIDE INSULATION
PANELS

REAR INSULATION
PANEL

Diagram 14.8INSULATION

3343

DRAIN
PLUG

LOCATING
LUG

HEAT EXCHANGER

221504A

34

UNION

FLOW

SECURING SCREW (2)

RETAINING PLATE

Diagram 14.9

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

14 Replacement of Parts

14.17 Pilot Viewing Window: Diagram 14.10

Remove the two screws and then the viewing window.
Replace the damaged component(s).
When replacing take care not to damage the gasket.

INNER
CASE
SEAL

3336

14.18 Inner Case Seal: Diagram 14.10

Remove the inner case.
When removing the seal make sure that all the old adhesive is

removed.
When fitting the new seal make sure that it fits correctly and has

not buckled.

GASKET

GLASS

FRAME

PILOT VIEWING WINDOW

INNER
CASE

PILOT
VIEWING
WINDOW

SECURING
SCREW (2)

Diagram 14.10

15 Spare Parts

15.1 Part Identification

The key number in diagram 15.1 and the list will help to identify
the part.

Key No Part No. Description GC Number

1 417517 Gas control assembly 334 702
2 205701 Injector - 60F 313 393
3 230357 Air pressure switch 313 604
4 230209 Pilot burner/electrode assembly 387 980
5 WW4607 Ignition lead 136 824
6 800271 Thermostat - control 313 605
7 800272 Thermostat - overheat cutoff 313 606
8 800276 Fan assembly 313 612
9 800275 Thermostat knob assembly 313 609

15.2 Ordering

When ordering any spare part please quote the part number
and description from the list together with the model name and
serial number of the appliance, located on the “Data label” refer
Section 1.5.

If ordering from British Gas also quote the GC number of the
appliance and part.

10 202015 Fuse 334 750
11 208302 Sight glass 312 419
12 900817 Control board (PCB) 313 301

35

221504A

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

11

15 Spare Parts

3337

1

8

3

6

4

9

5

2

10

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

221504A

36

7

12

Diagram 15.1