Glow-worm EnergySaver 60 User Manual

Instructions for Use

Installation and Servicing

T o be left with the user

Energysaver

60

G.C. No. 41 319 71

221836B.11.00

4040/S

High Efficiency Boiler

PAS010

This is a Cat II

Reference in these instructions to British Standards and Statutory

Regulations/Requirements apply only to the United Kingdom.

For Ireland the rules in force must be used.

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

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.

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

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

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

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

Appliance

2H3P

Guarantee Registration

to offer our customers' a Comprehensive First Year Guarantee.

return as soon as possible.

Service number 01773 828100.

✔

All replacement parts

❏

✔

All labour charges

❏

All call-out charges

✔

❏

One Contact Local Service

REGISTER YOUR GLOW-WORM APPLIANCE

FOR 1ST YEAR GUARANTEE PROTECTION

CALL 0208 247 9857

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

Nottingham Road, Belper, Derbyshire. DE56 1JT

Tel: [phone] Fax: [phone]

Hepworth Heating Ltd.,

General/Sales enquiries:

Important Information

TESTING AND CERTIFICATION

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

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

1.2.

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

Cut off devices with copper phial/bulb only.
Bulb contains activated charcoal and very small amounts of

chloroddifludromethane 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.

FLUE SEALANT

This contains cyclohexylaminosilane.
It may cause irritation of skin of sensitive persons. Wash contact

area with soap and water, if irritation occurs, seek medical
advice.

It will cause irritation on contact with eyes. If so, wash eye with
large amounts of fresh water for at least 15 minutes. If irritation
occurs, seek medical advice.

If swallowed drink plenty of milk and seek medical advice.

CONTENTS DESCRIPTION SECTION PAGE No.

INSTRUCTIONS

FOR USE

Introduction 3
Lighting the Boiler 5

General Data 1 6
Water System 2 8

INSTALLATION

INSTRUCTIONS

Boiler Location 3 11
Flue 4 12
Preparation 5 14
Water and Condensate Connections 6 16
Flue Installation 7 17
Gas Connection 8 20
Electrical Connection 9 20
Commissioning 10 22
User Information 11 23

Servicing 12 24

SERVICING

INSTRUCTIONS

Fault Finding 13 26
Replacement Parts 14 33
Spare Parts 15 39

221836B

2

Instructions for Use

GREEN

HIGH/LOW CONTROL KNOB
LIGHT
FOR HIGH
FLAME

GREEN
LIGHT
FOR LOW
FLAME

ORANGE DEMAND LIGHT

Introduction

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

This boiler is designed to provide central heating from a fully
pumped open vented or sealed water system with a fully indirect
cylinder.

The boiler is fully automatic in operation, having two user
controls, high/low control on the left and the control thermostat
on the right, see diagram 1.

The “high/low” control can set to “Low” during the summer
months.

Important Notice

This boiler is for use on natural gas (G20) as distributed in the
United Kingdom and Ireland, but may be converted for use on
L.P.G. Propane (G31) with the use of a conversion kit, i.e.

Energysaver 60, Kit No.444509.
If your boiler has been converted to use L.P.G. Propane the

following note applys:
Propane cylinders are under pressure and should never be

stored or used indoors residentially.
They should only be kept outside.
Under no circumstances should LPG Propane cylinders be

fitted or stored in basement areas or boiler house.

CONTROL
THERMOSTAT

0163M

KNOB

n

i

m

0

m

a

x

p

m

e

t

Diagram 1

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.

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 information plate, see diagram 2.

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

All CORGI Registered Installers carry a CORGI ID card, and
have a registration number. Both should be recorded in your
boiler Logbook. You can check your installer is CORGI registered
by calling CORGI direct on :- 01256 372300.

7891

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.

RESET BUTTON

INSTRUCTION LABEL

3

Diagram 2

221836B

Instructions for Use

150

Boiler Clearances

If fixtures are positioned close to the boiler, space must be left
as shown in diagram 3. 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.

55

5

*

5

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.

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.

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

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

.

100

INCREASE THIS DIMENSION TO

*

25mm FROM COMBUSTIBLE MATERIAL

5

*

5

*

500

PERMANENT
SURFACE

CLEARANCE OPPOSITE TO FLUE EXIT
MUST BE ADEQUATE FOR THE
INTERNAL INSTALLATION

Diagram 3

Electrical Supply Failure

Failure of the electrical supply will cause the burner to go out.
Should this happen, operation of the boiler 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, press the reset button on
the underside of the boiler, see diagram 2.

221836B

4

Instructions for Use

Overheat Safety Cutoff

If the cutoff operates on any other occasion than an electrical
failure, press the reset button as stated in “Electrical Supply
Failure”.

If the boiler fails to relight contact your installation/servicing
company.

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 and system 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).

On demand, the orange light will come on.
Turn the left hand switch to “high” flame.
Turn the control thermostat knob, at the right, clockwise to any

position between “MIN” and “MAX., see diagram 1. The
maximum setting is about 82

The boiler will not light between “O” and “MIN”.
The boiler lighting operation is now automatic as follows:
The fan operates, followed by an ignition spark until the burner

lights on low flame after a short period it will go to high flame and
the green light will come on.

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

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

When the boiler thermostat is satisfied the burner and green
light will go out.

When the system controls are satisfied the burner, orange and
green lights will go out.

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

The “high/low” switch should be set to “high” for winter use, but
when domestic hot water only is required in the summer it can
be turned to “low”.

If no light comes on you should contact your installation/
servicing company, to check the controls, although the system
may be working.

o

C (180oF).

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 and switch off the
electrical supply to the boiler.

To relight follow the sequence given above.
Note: If the burner goes out for any reason, wait 30 seconds

before relighting.

Condensation Pluming

Like all condensing boilers this appliance will produce a plume
of condensation from the flue terminal in cool weather. This is
due to the high efficiency and hence low flue gas temperature
of the boiler.

5

221836B

1 General

119

640

460
360

50

25

65

710

42

300

124

70

32

CAPPED OFF

FLUE
TERMINAL
DETAIL

63

Ensure flue slopes 2˚ down
towards the boiler
i.e. 35mm fall per metre
of flue length (2

CONDENSATE DRAIN
WATER CONNECTIONS

GAS CONNECTION

32

)

˚

0156M

102

DRAIN
CONNECTION

Important Notice

This boiler is for use only on G20 gas, but may be converted for
use on G31 gas (L.P.G.) with an available conversion kit.

Energysaver 60, Kit No. 444509.
The boiler is delivered in one pack.
Wherever possible, all materials 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 water systems.

This boiler is not suitable for outdoor locations.

1.1 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.

1.2 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 Bylaws, The
Health and Safety at Work Act, Control of Substances Hazardous
to Health, The Electricity at Work Regulations and any applicable
local regulations.

Diagram 1.1

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 and BS7074 Part 1 and 2, BS7478, BS7593, BS7671.

We also suggest that you have to hand a copy of the British Gas
publication, “Guidance Notes for the Installation of Domestic
Condensing Boilers”.

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

BSI Certification

This boiler certificated to the current issue of P.A.S. 010 for
performance and safety.

It is 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 warranty and could also infringe the current
issue of the Statutory Requirements.

1.3 Range Rating

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

1.4 General Data

The data label is positioned on the inner case, visible when the
outer case is removed.

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

221836B

6

1 General

The Seasonal Efficiency Domestic Boilers UK (SEDBUK)
is 86.9%.

The value is used in the UK Government’s Standard Assessment
Procedure (SAP) for energy rating of dwellings. The test data
from which it has been calculated have been certified by B.S.I.

1.5 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 a suitable leak detection fluid, purge
in accordance with the above standard.

1.6 Electrical Supply

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

wired and 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 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.

1.7 Condensate

The boiler condensate should, if possible, be discharged into
the household internal draining system, that is, sink or washing
machine drain. If this is not practicable, discharge can be
external, into the household drainage system or a purpose
designed soakaway

The boiler is fitted with a safety device to prevent the boiler from
working if the condensate pipe gets blocked by either ice or
debris.

It is, therefore, recommended that any external condensate
drain pipe is insulated to prevent it freezing up.

Alternatively, a larger diameter pipe can be used and insulated.
The condensate drain pipe should be checked during any

servicing and any debris found removed.
Refer to the British Gas publication “Guidance Note for the

Installation of Domestic Condensing Boilers” for further
information.

DATA TABLE 1.

MODEL

TOTAL
WEIGHT

LIFT
WEIGHT

WATER
CONTENT

GAS
CONNECTION

WATER
CONNECTION

ELECTRICITY
SUPPLY

TABLE 2.

RANGE RATING

NOMINAL kW
HEAT INPUT
(GROSS) Btu/h

NOMINAL kW

28mm copper flow

at right return at left

240V ~ 50HZ, fused 3A.

Energysaver 60

LOW MIN MID MAX

10.16 16.94 18.64 20.33

34,680 57,800 63,584 69,350

8.79 14.65 16.12 17.58

60

48.0 kg
(106 lb)

31.5 kg

(69.5 lb)

1.6 Litre

(0.35 gal)

Rc 1/2 in.

HEAT
OUTPUT Btu/h

NOMINAL kW
HEAT
OUTPUT Btu/h

30,000 50,000 55,000 60,000

9.40 15.67 17.24 18.81

32,100 53,500 58,800 64.150

CONDENSING
BURNER m bar

SETTING (HOT)
PRESSURE in.w.g

APPROX m3h
GAS
RATE ft3h

4.5 11.8 14.3 17.0

1.8 4.7 5.7 6.8

0.96 1.6 1.77 1.9
34 57 62.5 68

BURNER INJECTOR MARKING: 60N

1.9 Anti-theft Kits

Anti-theft kits are available for these appliances, contact
Hepworth Heating Ltd. for further information.

1.8 Heating System Controls

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

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

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

7

221836B

(

)

2 Water System

Note.

The boiler has 28mm copper connections which must be used
for the Energysaver 60.

4042

2.1 Draining Tap

The boiler is provided with a draining point at the lower left hand
side of the burner manifold, to be used for draining the boiler,
see diagram 2.1.

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 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
a design flow rate as shown in Table 3.

See chart for pressure drop of the boiler, diagram 2.2.
High resistance microbore systems may require a higher duty

pump.

o

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

o

C (180oF), to give

2.4 Bypass

A BYPASS MUST BE FITTED, see diagram 2.3 for a suitable
position.

The flow rate through the boiler must not be allowed to fall below
that given in Table 3.

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

1.5m away from the boiler.

must be placed at least

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 an inhibitor manufacturer for
their recommendations as to the best product to use.

Note: This boiler has a totally copper water system and does
not require a special inhibitor normally associated with other
types of high efficiency (“condensing”) boilers.

If an existing system is to be reused take special care to drain
the entire system, including the radiators, then thoroughly
cleaning out before fitting the boiler whether or not adding an
inhibitor.

2.6 Open (Vented) Water System

The boiler must be supplied from an unrestricted water supply
taken from a feed and expansion cistern situated at a maximum
height of 27metres (90ft) above the boiler.

The cold feed 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 2.3.

BOILER
DRAIN
POINT

Diagram 2.1

Flow rate (gallons/minute)

0123

2.0

1.5

1.0

0.5

Water pressure loss

(metres head of water)

0

5

0

10 15

Flow rate

4

20 25 30

litres/minute

56

78

35 40

0164M

70
60
50
40
30
20

Water pressure loss

10
0

(inches head of water)

Diagram 2.2

TABLE 3

Design Minimum

Flow Rate Flow Rate

Energysaver 60

23L/min 17L/m

2.7 Domestic Hot Water Cylinder

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

2.8 Domestic Hot Water System - Unvented

Where a storage system will not have a vent to atmosphere the
installation must comply with the Building Regulations and local
Water Company bylaws, see also the current issue of BS5546
and BS6700.

If fitting to an existing system the local authority should be
informed.

2.9 Sealed Water Systems

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

See diagram 2.4 for a suggested layout.

221836B

8

2 Water System

2.10 Safety Valve

A safety valve must be fitted to a sealed 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.

2.11 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 2.4 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.

450mm
MIN.
HEIGHT

1150mm
MIN.

BOILER

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

22mm (MIN) VENT

FEED AND
EXPANSION
CISTERN

15mm (MINIMUM)
COLD FEED

15mm (MINIMUM)
BY-PASS WITH
LOCKSHIELD VALVE

PUMP

150 mm
MAX

RET.

Diagram 2.3

FLOW

RET.

CYLINDER

HEATING

FLOW

4357A

(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

40/50-15mm (min)

22mm (min)

60-15mm (min)

BY-PASS WITH
LOCKSHIELD
VALVE

SAFETY
VALVE

AIR
RELEASE
POINT

FILLING POINT

CIRCULATING
PUMP

PRESSURE
GAUGE

EXPANSION
VESSEL

5609

Diagram 2.4

9

221836B

M

2 Water Sytem

2.12 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 is
a position where it can be seen when filling the system.

2.13 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.

2.14 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.

2.15 Filling a Sealed Water System

Provision for filling the system at low level must be made. Three
methods are shown in diagram 2.5. There must be no permanent
connection to the mains water supply, even through a non­return valve.

METHOD 1

TEMPORARY
HOSE

SUPPLY
PIPE

METHOD 2

TEMPORARY
HOSE

SUPPLY
PIPE

METHOD 3

CISTERN

HOSE
UNIONS

SUPPLY STOP
VALVE

DOUBLE CHECK
VALVE ASSEMBLY

HOSE
UNIONS

SUPPLY STOP
VALVE

OVERFLOW

SERVICING
VALVE

COMBINED
CHECK VALVE
AND VACUUM
BREAKER

SERVICING
VALVE

SERVICING
VALVE

PRESSURE
REDUCING
VALVE

0051

HEATING
SYSTEM

HEATING
SYSTEM

HEATING
SYSTEM

SUPPLY
STOP VALVE

SUPPLY
PIPE

HOSE
UNIONS

DOUBLE CHECK
VALVE ASSEMBLY

Diagram 2.5

221836B

10

3 Boiler Location

NOTE:

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)
Regulations 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.

3.1 Boiler Clearances

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

3.1.
Additional clearances may be required around the boiler for

installation purposes, dependent upon site conditions.

3.2 Timber Frame Buildings

If the boiler is to be installed in a timber frame building it should
be fitted in accordance with the Institute of Gas Engineers
document IGE/UP/7/1998. If in doubt seek advice from the local
gas undertaking or Hepworth Heating Ltd.

150

55

100

INCREASE THIS DIMENSION TO

*

25mm FROM COMBUSTIBLE MATERIAL

5

*

5

0157M

3.3 Room Ventilation

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

3.4 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 4.

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.

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

5

*

5

*

500

PERMANENT
SURFACE

CLEARANCE OPPOSITE TO FLUE EXIT
MUST BE ADEQUATE FOR THE
INTERNAL INSTALLATION

Diagram 3.1

TABLE 4

Ventilation high level low level
From Room cms in

Energysaver 60

190 29.5 190 29.5

2

cms in

2

Ventilation
From Outside

Energysaver 60

11

92 14.3 92 14.3

221836B

4 Flue

NOTE:

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

Important. The flue must be installed with a fall of 35mm per
metre (2

It is of no advantage to exceed this angle (2
the fan to flue elbow may become more difficult as the angle is
increased.

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

The rear and side flue assemblies are designed for internal
installation, but if necessary, due to insufficient clearances
(boiler/flue terminal location) they can be installed from the
outside.

For a wall thickness up to 300mm the flue can be fully installed
from the inside.

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

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

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

o

) towards the boiler, see diagram 4.1.

o

) indeed sealing of

'R'

REAR FLUE LENGTHS

R = Wall Thickness

STD Flue pack

1m Flue pack 75mm to 953mm
2m Flue pack 75mm to 1953mm
3m Flue pack 75mm to 2933mm

75mm to 442mm

6860

Make sure flue slopes
2

down towards

˚

the boiler
that is 35mm fall
per metre
of flue
length (2

)

˚

300mm

2

˚

REAR FLUE

SIDE VIEW

Make sure flue slopes
2˚ down
towards the boiler
that is 35mm fall per metre
of flue length (2

)

˚

35mm

10.5mm

0158M

Diagram 4.2

'S'

SIDE FLUE LENGTHS

S = "External wall face" to "boiler casing"

STD Flue pack 80mm to 331mm

1m Flue pack 80mm to 841mm

2m Flue pack 80mm to 1841mm

3m Flue pack 80mm to 2821mm

Diagram 4.3

6861

221836B

SIDE FLUE

FRONT VIEW

2

˚

1metre

Diagram 4.1

12