glowworm Glow Worm 18sx User guide

Flexicom

Installation and Servicing

18sx

G.C. No. 41-315-72

30sx

G.C. No. 41-047-76

High Efficiency

Condensing System

Boiler

www.glow-worm.co.uk

Guarantee Registration

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

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

our customers a Comprehensive Guarantee.

This product is guaranteed for 24 months from the date of installation or 30 months from the date

of manufacture, whichever is the shorter, for parts and labour.

The second year of the parts guarantee, from the beginning of the 13th month onwards after

installation or manufacture, is conditional upon the boiler having been serviced by a competent

person approved at the time by the Health and Safety Executive in accordance with the

manufacturer’s recommendations. We strongly recommend regular servicing of your gas

appliance, but where the condition is not met, any chargeable spare parts or components issued

within the applicable guarantee period still benet from a 12 month warranty from the date of issue

by the manufacturer.

We recommend you complete and return as soon as possible your guarantee registration card.

If your guarantee registration card is missing you can obtain a copy or record your registration by

telephoning the Glow-worm Customer Service number 01773 828100.

Customer Service:

01773 828100

Technical Helpline:

01773 828300

General and Sales enquiries:

Tel. [phone]

Fax: [phone]

To register your Glow-worm appliance call:

0800 0732142

Benchmark places responsibilities on both manufacturers and installers. The purpose is to ensure that customers are provided
with the correct equipment for their needs, that it is installed, commissioned and serviced in accordance with the manufacturer’s
instructions by competent persons and that it meets the requirements of the appropriate Building Regulations. The Benchmark
Checklist can be used to demonstrate compliance with Building Regulations and should be provided to the customer for future
reference.
Installers are required to carry out installation, commissioning and servicing work in accordance with the Benchmark Code of
Practice which is available from the Heating and Hotwater Industry Council who manage and promote the Scheme.
Visit www.centralheating.co.uk for more information.

2

These instructions consist of, Installation, Servicing, Fault Finding, Replacement of Parts

and Spares. The instructions are an integral part of the appliance and must, to comply

with the current issue of the Gas Safety (Installation and Use) Regulations, be handed to

the user on completion of the installation.

CONTENTS DESCRIPTION SECTION PAGE

Warnings 4
Important Information 4

INTRODUCTION

Statutory Requirements 5
Boiler Design 6
Safety Devices 6
Servicing, Maintenance and Spare Parts 6

Boiler Specication 1 7
Boiler Dimensions & Hydraulic Schematic 2 8
Boiler Location, Clearances
and Ventilation 3 9
Flue Options and Terminal Clearances 4 10
Water System 5 12
Installation Preparation 6 15

INSTALLATION

Gas/Water Connections 7 17
Boiler Fixing 8 18
Safety Discharge Valve and
Condensate Connections 9 19
Flue Length Preparation and Installation 10 21
Electrical Connection 11 38
Commissioning 12 40

MAINTENANCE

Servicing 13 43
Fault Finding 14 48
Replacement of Parts 15 54
Spare Parts 16 61
Manual Handling 17 62

Declaration of Conformity 18 63

3

WARNINGS

Gas Leak or Fault

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

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

ventilate the area.

Metal Parts

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

with particular regard to edges.

Sealed Components

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

Important Information

Gas Category

This boiler is for use only on G20 natural gas.

Gas Safety (Installation and Use)
Regulations

In your own interests and that of safety, it is the Law that
ALL gas appliances are installed by a competent person
approved at the time by the Health and Safety Executive in
accordance with the current issue of these regulations.

Control of Substances Hazardous to Health

Under Section 6 of The Health and Safety at Work Act
1974, we are required to provide information on substances
hazardous to health.
The adhesives and sealants used in this appliance are cured
and give no known hazard in this state.

Manual Handling

With regards to the “Manual Handling Operations, 1992
Regulations”, the appliance exceeds the recommended
weight for a one man lift, refer to section 17 for more
information.
The handling of the boiler may involve lifting, pushing and
pulling, the use of a sack truck may be required.
The following handling techniques and precautions should be
considered:

- Grip the boiler at its base

- Be physically capable

- Use safety clothing where appropriate, e.g. gloves, safety
footwear.
Ensure safe lifting techniques are used

- Keep back straight.

- Avoid twisting at the waist.

- Avoid upper body/top heavy bending.

- Always grip using the palm of the hand.

- Use designated hand holds.

- Keep load as close to body as possible.

- Always use assistance if required.

Electrical Supply

The boiler MUST be earthed.

All system components shall be of an approved type and all
wiring to current I.E.E. wiring regulations.
External wiring must be correctly earthed, polarised and in
accordance with the relevant standards.

In GB, this is BS 7671.
In IE, this is the current edition of ETCI rules.

The boiler MUST be connected to a permanent 230V ac,
50Hz supply.
Connection of the whole electrical system of the boiler,
including any heating controls, to the electrical supply MUST
be through one common isolator and must be fused 3 Amp
maximum.
Isolation should be by a double pole switched fused spur box,
with a minimum gap of 3mm for both poles. The fused spur
box should be readily accessible and preferably adjacent to
the appliance. It should be identied as to its use.
Alternatively connection can be made through an unswitched
shuttered socket and 3A fused 3-pin plug both to the current
issue of BS 1363, provided they are not used in a room
containing a bath or shower.
Wiring to the boiler must be PVC 85OC insulated cable, not
less than 0.75mm2 (24/0.20mm).

Testing and Certication

This boiler is tested and certicated for safety and
performance. It is, therefore, important that no alteration is
made to the boiler, without permission, in writing, by Glow­worm.
Any alteration not approved by Glow-worm, could invalidate
the certication, boiler warranty and may also infringe the
current issue of the statutory requirements.

4

Statutory Requirements

CE Mark

This boiler meets the requirements of Statutory Instrument,
No. 3083 The Boiler (Efciency) Regulations, and therefore is
deemed to meet the requirements of Directive 92/42/EEC on
the efciency requirements for new hot water boilers red with
liquid or gaseous fuels.
Type test for purposes of Regulation 5 certied by: Notied
body 0087.
Product/production certied by: Notied body 0086.
The CE mark on this appliance shows compliance with:

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

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

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

IMPORTANT

Where no British Standards exists, materials and equipment
should be t for their purpose and of suitable quality and
workmanship.
The installation of this boiler must be carried out by a
competent person approved at the time by the Health and

Safety Executive in accordance the rules in force in the

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

Statutory Requirements

In GB, the installation of the boiler must comply with the

requirements of the current issue of BS6798 and be carried
out by a competent person, approved at the time by the

Health and Safety Executive, as described in the following

regulations:
The manufacturer’s instructions supplied.
The Gas Safety (Installation and Use) Regulations.
The appropriate Buildings Regulations either The Building
Regulations, The Building Regulations (Scotland),The
Building Regulations (Northern Ireland).
The Water Supply (water ttings) Regulations 1999 and water
byelaws 2000, Scotland.
The Health and Safety at Work Act, Control of Substances
Hazardous to Health (COSHH).
The Current I.E.E. Wiring Regulations.
Where no specic instructions are given, reference should be
made to the relevant British Standard Code of Practice.

In IE, the installation must be carried out by a competent
person approved at the time by the Health and Safety

Executive and installed in accordance with the current edition

of I.S.813 “Domestic Gas Installations”, the current Building
Regulations and reference should be made to the current
ETCI rules for Electrical Installation.
GB: the following Codes of Practice apply:
BS4814, BS6798, BS5440 Part 1 and 2, BS5546 Part 1,
BS5449, BS6891, BS6700, BS7074 Part 1 and 2, BS7593,
BS7671.

IE: I.S.813, BS5546, BS 5449, BS 7074, BS 7593.
NOTE: For further information, see the current issue of the

Building Regulations, approved document L1 ( in the UK) and
the following current issues of:

1) Central heating system specication (CheSS)
and

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

Gas Supply

The gas installation must be in accordance with the relevant
standards.

In GB, this is BS6891.
In IE, this is the current edition of I.S.813 “Domestic Gas

Installations”.
The 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 tightness using the
pressure drop method and suitable leak detection uid, purge
in accordance with the above standard.

Domestic Hot Water

All domestic hot water circuits, connections, ttings must be
in accordance with the relevant standards and water supply
regulations.
GB: Guidance G17 to G24 and recommendation R17 to R24
of the Water Regulations Guide.

IE: The current edition of I.S.813 “Domestic Gas Installations”.

Heating System

In GB, it is necessary to comply with the Water Supply (Water

Fittings) Regulations 1999 (for Scotland, the Water Byelaws
2000, Scotland).
To comply with the Water regulations your attention is drawn
to: The Water Regulations guide published by the Water
Regulations Advisory Service (WRAS) gives full details of the
requirements.
In IE, the requirements given in the current edition of I.S.813
“Domestic Gas Installations” and the current Building
Regulations must be followed.

5

Boiler Design

Boiler Design

These boilers are designed for use as part of a sealed water
central heating system with fully pumped circulation. The
pump, expansion vessel and associated safety devices are all
tted within the boiler. The daily pump exercise programme
combined with the built-in frost protection will help to maintain
and protect the boiler. Once the controls are set the boiler

operates automatically.

Range Rating

The boilers are fully modulating, it is therefore not necessary
to range rate them. However, if desired, it is possible to range
rate the boiler between 10 and Max. output (according to the
model), in 1kW increments, refer to section 12.

Safety Devices

Electrical Supply Failure

The boiler will not work without an electrical supply.
Normal operation of the boiler should resume when the
electrical supply is restored. Reset any external controls, to
resume normal operation of the central heating. If the boiler
does not resume normal operation press the reset button. If
the boiler does not resume normal operation after this call
your Installation/Servicing company or Glow-worm service.

Overheating Safety

The boiler software is designed to recognise the potential
for an overheat lockout and will shutdown before this
happens. To restart the boiler, press the reset button on the
controls fascia. If the boiler fails to resume normal operation
and all external controls are calling for heat, then call your
Installation/Servicing company or Glow-worm service.

Safety Discharge Valve

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

Condensate Drain

A plastic drain pipe must be tted to allow discharge of
condensate to a drain. Condensate should, if possible, be
discharged into the internal household draining system. If
this is not practical, discharge can be made externally into
the household drainage system or a purpose designed soak
away, see section 8 for more details.

Pluming from ue terminal

Like all condensing boilers this appliance will produce a plume
of condensation from the ue terminal in cool weather. This is
due to the high efciency and hence low ue gas temperature
of the boiler. This is normal and not an indication of a fault.

Frost protection

The appliance has a built in frost protection device that
protects the boiler from freezing. With the gas and electric
supplies ON and irrespective of any room thermostat setting,
the frost protection device will operate the pump when the
temperature of the boiler water falls below 8°C.
A timer is used so that the temperature can be checked
periodically. After 10 minutes the pump will be stopped if the
temperature is higher than 10°C or has already reached 35°C.
The burner will activate if the boiler temperature does not
reach 10°C after 30 minutes or at any time if the temperature
drops to 5°C.
The burner will switch off when the temperature reaches 35°C.

Condensate Drain Blockage

As a safety feature the boiler will stop working if the
condensate drain becomes blocked. During freezing
conditions an ice blockage in the condense drain, external to
the house would also activate the safety feature. Use warm
cloths on the pipe to release an ice blockage.
Once the blockage is removed the boiler should then restart.

Servicing, Maintenance and Spare Parts

Servicing and Maintenance

To ensure the continued efcient 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.
If this applaince is installed in a rented property there is a duty
of care imposed on the owner of the property by the current
issue of the Gas Safety (Installation and Use) Regulations,
Section 35.
Servicing/maintenance should be carried out by a competent
person approved at the time by the Health and Safety
Executive in accordance with the rules in force in the
countries of destination.
To obtain service, please call your installer or Glow-worm’s
own service organisation using the telephone number on the
inside front cover of this literature.

6

Spare Parts

We only use parts that you can be assured conform to
the safety and performance specication. DO NOT use
reconditioned or copy parts that have not been clearly
authorised by Glow-worm.
If a part is required contact Glow-worm’s own service
organisation using the telephone number on the inside front
cover of this booklet.
Please quote the name of the appliance, this information will
be on the name badge on the front of the appliance.
If in doubt seek advice from the local gas company or Glow­worm’s own service organisation using the telephone number
on the inside front cover of this booklet.

1 Boiler Specication

14733

Approximate gas rate at part load.

PLEASE REFER TO COMMISSIONING

13, C33, C43, C53C13, C33, C43, C53

C

7

2 Boiler Dimensions and Hydraulic Schematic

87

280

149

19

(Gas and

Domestic Water)

22.5

(Central

Heating)

624

C

L

FLUE

C

L

FLUE

13899

2.1 Boiler Dimensions and Hydraulic
Schematic

All dimensions are given in millimetres (except as noted).
The general arrangement of the boiler is shown in diagram

2.1. and the hydraulic and gas schematic, diagram 2.2.
The data label is positioned on the front of the inner casing
panel.

14022

C

L

FLUE

76

C

L

FLUE

Flexible
Condensate
Connection

FLOW

25

100

167.5

390

47

BOILER

C

L

100

700

RETURN

Diagram 2.1

Diagram 2.2

8

3 Boiler Location, Clearances and Ventilation

3.1 Location

This boiler is not suitable for outdoor installation.
This boiler may be installed in any room, although particular
attention is drawn to the installation of a boiler in a room
containing a bath or shower where reference must be made to
the relevant requirements.
This boiler is suitable for installation in bathroom zones 2 and

3.
In GB this is the current I.E.E. WIRING REGULATIONS and
BUILDING REGULATIONS.
In IE reference should be made to the current edition of
I.S.813 “Domestic Gas Installations” and the current ETCI

rules.

3.2 Clearances

The boiler should be positioned so that at least the minimum
operational and servicing clearances are provided, see
diagram 3.1.
Additional clearances may be benecial around the boiler for
installation and servicing.
For ue installations where external access is not practicable,
consideration should be given for the space required to insert
the ue internally, which may necessitate clearance larger
than those specied in diagram 3.1.

13127

3.3 Timber Frame Buildings

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

3.4 Combustible Material

The boiler and ue are suitable for installation onto and
through combustible materials provided that:-

1) Minimum 5mm clearance is maintained around the
circumference of the ue (air intake).

2) The combustible surface and xings are suitable for
supporting the load.

3) The minimum clearances from the boiler case are
maintained.

3.5 Room Ventilation

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

3.6 Cupboard or Compartment Ventilation

Due to the high efciency and hence low casing temperature
of this boiler, cupboard or compartment ventilation is not
necessary.
Leave existing air vents.

Diagram 3.1

9

4 Flue Options and Terminal Clearances

Ridge Tile Terminal

Part No. A2043800 ­Section 10, page 32

Plume Management
Kit basic set, white,

concentric ue (Ø60/100)

- Part No. A2044100
for use with Part No.
A2043400 and Part No.
A2043600 - Section 10,
page 37

Top horizontal telescopic ue (Ø60/100)
Part No. A2043600 - Section 10, page 21

Twin Flue
Twin Flue Adapter, concentric
ue (Ø80) Part No. A2011000

- Section 10, page 34

Top horizontal standard ue (Ø60/100)
Part No. A2043400 - Section 10, page 25

Vertical Flue
Vertical Flue Adapter, concentric
ue (Ø60/100) Part. No. A2024600
Section 10, page 31

Vertical ue terminal kit, concentric
ue (Ø60/100) Part. No.
2000460480 - Section 10, page 30

Direct rear telescopic ue (Ø60/100)
Part No. A2043500 - Section 10,
page 29

10

Multiple Boiler Chimney Flue
Vertical concentric stack ue
suitable for use with:-

Top horizontal telescopic ue,
Top standard horizontal ue,
Twin Flue, as specied by the
manufacturer.

Diagram 4.1

4 Flue Options and Terminal Clearances

HORIZONTAL FLUES

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

* TO A BOUNDARY ALONGSIDE THE

H
TERMINAL 300
I ABOVE ADJACENT GROUND OR
BALCONY LEVEL 300

J

* FROM SURFACE OR A BOUNDARY

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

4.1 Flue Options

There are various ue options to choose from as illustrated in
diagram 4.1. The ue lengths and installation are described in
section 10.

4.2 Flue Terminal Position

In GB the minimum acceptable siting dimensions for the

terminal from obstructions, other terminals and ventilation
openings are shown in diagram 4.2.
In IE the minimum distances for ue terminal positioning must
be those detailed in I.S.813 “Domestic Gas Installations”.
The terminal must be exposed to the external air, allowing free
passage of air across it at all times.
Being a condensing boiler some pluming may occur from
the ue outlet. This should be taken into consideration when
selecting the position for the terminal.
Carports or similar extensions of a roof only, or a roof and
one wall, require special consideration with respect to any
openings, doors, vents or windows under the roof. Care is
required to protect the roof if made of plastic sheeting. If
the carport comprises of a roof and two or more walls, seek
advice from the local gas supply company before installing the
boiler.
H* and J* See diagram 4.2. These dimensions comply with
the building regulations, but they may need to be increased to
avoid wall staining and nuisance from pluming depending on
site conditions.
NOTE: If the ue terminal is positioned near a light source
insects may enter the ue system. Where safe and practical
to do so, advise the homeowner to check the ue outlet and
clear visible insects from the terminal end.

4.3 Terminal Guard

A terminal guard is required if persons could come into contact
with the terminal or the terminal could be subject to damage.
If a terminal guard is required, it must be positioned to provide
minimum of 50mm clearance from any part of the terminal and
be central over the terminal.
The guard should be similar to that shown in diagram 4.3.
A suitable guard is manufactured by: ­Tower Flue Components
Morley Rd.
Tonbridge
Kent TN9 1RA.
Size: 280mm x 165mm. Part No. CGDK3

15583

VERTICAL FLUES

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

Diagram 4.2

Diagram 4.3

11

5 Water System - Heating

5.1 General

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

5.2 Safety Valve

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

not discharge above an entrance, window or any type of
public access area.

5.3 Expansion Vessel

The boiler has an integral expansion vessel with a capacity of
8 litres (1.76 gallons), with a charge pressure of 0.5bar.
NOTE: The expansion vessel volume depends on the total
water system volume and the initial system design pressure.
In GB, Guidance on vessel sizing is also given in the current
issue of BS5449 and BS7074 Part 1.

In IE, current edition of I.S.813 “Domestic Gas Installations”

5.4 Flow Rate

If it is necessary to alter the ow rate, the system can be
tted with a lockable balancing valve in the main ow or
return pipes shown as valve “A” in diagram 5.1. The ow rate
through the boiler must not be allowed to fall below that given
in section 1 - Specication Table.

5.5 Bypass

The boiler is tted with an automatic bypass, see diagram 5.2.
and section 12 Commissioning. The pump remaining
conveying capacity is shown in diagram 5.3
Ensure that under no circumstances does the ow rate drop
below the gure specied, refer to section 1 - Specication
Table.

5.6 Filling the Sealed System

Provision for lling the system at low level must be made, see
diagram 5.4. There must be no permanent connection to the
mains water supply, even through a non-return valve.
NOTE: It is important that ttings used for connection
to potable water comply with the water undertakings
requirements.

5.7 Draining Points

Draining taps must be provided at all low points of the system,
which will allow the entire system to be drained.
Draining taps shall be to the current issue of BS2879.
Drain points for the appliance are provided at the positions
shown in diagram 5.5.

ADDITIONAL
EXPANSION
VESSEL
(if required)

HEATING
CIRCUIT

RETURN

'A'

BOILER

14023

13073

12

FLOW CONTROL
VALVE

DRAIN
POINT

Diagram 5.1

Diagram 5.2

5 Water System - Heating

5.8 Water Treatment

Existing system- It is ESSENTIAL that prior to installing the

new boiler the system is thoroughly ushed.
New system- For optimum performance after installation, the
boiler and its associated central heating system should also
be ushed.
Flushing should be carried out in accordance with BS7593:
2006 using a cleanser such as Sentinel X300 or X400, Fernox
Restorer or Salamander corrosion guard cleaner.

IMPORTANT: Ensure all cleanser is removed from the whole
system before adding an inhibitor.
For long-term corrosion protection, after ushing, an inhibitor
should be used, refer to the current issue of BS 5449 and
BS 7593 on the use of inhibitors in central heating systems.
Examples are Sentinel X100 Fernox Protector or Salamander
corrosion guard inhibitor.

13102

Diagram 5.3

Diagram 5.4

14024

13

5 Water System - Domestic Hot Water

DRAIN POINTS

5.9 Unvented DHW System

General - All domestic hot water circuits, connections, ttings

must be in accordance with the relevant standards and water
supply regulations.
For GB: Guidance G17 to G24 and recommendation R17 to
R24 of the Water Regulations Guide.
For IE: The current edition of I.S.813 “Domestic Gas
Installations”.
Where a storage system will not have a vent to atmosphere
the installation must comply with the building regulations and

the Water Supply (water ttings) Regulations 1999 and water
byelaws 2000, Scotland, see also the current issue of BS5546

and BS6700.
If tting to an existing system the local authority should be
informed.

5.10 Domestic Water Cylinder

SINGLE FEED INDIRECT CYLINDERS ARE NOT SUITABLE
AND SHOULD NOT BE USED.
The domestic hot water cylinder must be of the double feed
indirect coil type. It must be suitable for working at a gauge
pressure of 0.35bar above the safety valve setting.

13942

Diagram 5.5

14

6 Installation Preparation

E

E - Boiler Securing Screw

13900

Diagram 6.1

15

6 Installation Preparation

6.1 Appliance Pack

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

The packs are located in the top polystyrene packing.

Remove the carton sleeve and top pack then lift the boiler and
its polystyrene base support out of the lower pack.

6.2 Site Requirements

The boiler mounting wall should be suitable for the weight of
the appliance and be true and at.

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

6.3 Wall Template

Take the wall template from the document pack located within
the top polystyrene packing and place in the desired position

on the wall, giving due consideration to the required boiler
clearances, see section 3, and the ue you are tting.
Mark the position of the ue centre, if tting a side ue, extend
the ue centre line into the corner then 149mm along the
adjacent wall, see diagram 6.2.
For extended side ues, the ue hole centre should be
determined by extending the dashed inclined line on the
template to the side wall. This dashed line is drawn at 44mm/
metre (2.5°) rise from the boiler. Where this line reaches the
side wall, a horizontal line should be marked. The vertical
centre line of the ue should then be marked at 176mm from
the back wall.
To allow for the ue passing through the wall at this angle
a 125mm hole should be drilled irrespective of internal or
external installation.
Remove the wall template whilst drilling the ue hole.

WALL
TEMPLATE

o

2.5

44mm/metre
inclined extended
flue length

Standard
flue length
Horizontal

HANGING
BRACKET
FIXINGS

149

o

90

Diagram 6.2

13941

14810

6.4 Flue Hole Cutting

External access ue installation can use a 105mm diameter
core drill.
Internal access only ue installation will need a 125mm
diameter core drill.
NOTE: The ue is designed with an internal fall of 44mm/
metre (2.5°), therefore the hole can be drilled horizontally.

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

6.5 Wall Hanging Bracket Assembly

The Wall Hanging Bracket is supplied in the main boiler
packaging at the rear of the boiler.
Reposition the wall template over the ue hole and mark
the position of the xing holes for the hanging bracket, see
diagram 6.3.
NOTE: Due to the varied site conditions we do not supply
xings and advise that the installer should supply those which
are suitable.
Drill xing holes and insert suitable wall plugs.
Direct Rear Flue only - If external access is not available the
ue to be used should be assembled as described in sections

10.11 to 10.13 and inserted through the hole in the wall before
tting the wall hanging bracket.
Fit the xing jig support plate to the bottom of the wall hanging
bracket, push down to locate.
Mark, drill and plug at xing points and secure the jig support
plate, see diagram 6.3.
Direct Rear Flue only - The ue can now be pulled back
through the hanging bracket and secured as shown in
diagram 6.3.

JIG SUPPORT
PLATE FIXINGS

Diagram 6.3

16

JIG SUPPORT

7 Gas / Water Connections

7.1 System connection

NOTE: The Gas and Water systems can be connected

and lled prior to installation of boiler, refer to section 12
Commissioning. Make sure the drain points are accessible,
refer diagram 5.5.
All water and gas connections are on the xing jig with the
exception of the condense drain and safety discharge, the
positions of these are shown on the wall template.
An Upward Piping Frame, part no. A2041500 should be used
if the supplies come from above the boiler otherwise the pipes
will have to be chased into the wall.
Assemble the pipes to the jig as shown in diagram 7.1.
Fit the Central Heating Isolation Valve handles and secure
with screws provided.
Fit the assembled Jig Plate to the Support Plate as shown in
diagram 7.2.
Assemble the Gas service isolation valve and position onto
the plastic plug.
Plumb system pipe work to the copper tails. Do not subject
isolation valves to heat.
Prior to lling the water system ensure that the blanking plugs
and isolation valves are secured.
Flush out the domestic hot water and the heating systems.
The whole of the gas installation, including the meter, should
be inspected, tested for soundness and purged in accordance
with the current issue of BS6891 and in IE the current edition
of I.S.813 “Domestic Gas Installations”.

14025

Diagram 7.1

13039

PLATE

JIG PLATE

JIG SUPPORT
PLATE

JIG PLATE

Diagram 7.2

17

8 Boiler Fixing

1

2

3

5

8.1 Boiler Hanging

IMPORTANT: With regards to the Manual Handling

Operations, 1992 Regulations, the following lift operation
exceeds the recommended weight for a one man lift, refer to
section 17 Manual Handling.
IMPORTANT: Direct Rear Flue only - The direct rear ue
must be tted before hanging the boiler, refer to sections 10.11
to 10.13, and the rear outlet cover plate should be removed.
The appliance and jig (pre-lled) may contain a small amount of
water, place a water container beneath the boiler connections.
Make sure the isolation valves are closed before disconnecting
the blanking plugs and discarding the jig plate.
Position the sealing washers supplied in the Loose Items pack,
as shown in diagram 6.1.
Lifting the boiler into position, lean the top of the boiler slightly
to the wall and position just above the hanging bracket. Lower
the boiler slowly, push back and engage onto the hanging
bracket making sure the boiler is located over the retaining
bosses, secure with screw provided, see diagram 8.1.
Remove the protective caps.
Engage the xing jig connections, ensuring that the previously
positioned washers have not been disturbed.
There are ats on the body of the valves for locating a spanner
to aid tightening to copper tails using the tightening sequence
shown in diagram 8.2.
Make good the nal connections.

14812

SECURING
SCREW

D

A

B

Diagram 8.1

13943

4

E

A

A - Central Heating Isolation Valve
B - Gas Service Isolation Valve
C - Washers (not shown)
D - Condensate Connection
E - Safety Discharge Pipe

18

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

Diagram 8.2

9 Safety Discharge Valve and Condensate Connections

9.1 Safety Discharge Valve

Take the safety discharge pipe, supplied in the pipe pack and
the union nut and seal, supplied in the loose items pack and
t as shown in diagram 9.1.
This must be extended, using not less than 15mm o.d. pipe,
to discharge, in a visible position, outside the building, facing
downwards, preferably over a drain.
To ease future servicing it is advisable to use a compression
type tting to extend the safety discharge valve tube.
The pipe must have a continuous fall and be routed to a
position so that any discharge of water, possibly boiling,
or steam cannot create any danger to persons, damage to
property or external electrical components and wiring.

9.2 Condensate Trap and Siphonic Drain
Connection

A exible condensate outlet pipe is tted and should be used
to couple the condensate trap and siphonic drain to a 22mm
to 25mm O.D. non corrosive plastic pipe (overow pipe), see
diagram 8.2.
IMPORTANT: Please remove the bung from the exible pipe
before tting to a drain outlet pipe.

NOTE: the pipe should have a fall of a least 2.5
away from the boiler.
Condensate should, if possible be discharged into the
household internal drainage system. If this is not practicable,
discharge can be allowed into the external household drains
or a purpose designed soak away, refer to diagram 9.2.
It is recommended that any external condensate drain pipe is
protected and also preferably of 32mm diameter, to prevent
freezing in adverse weather conditions.
The condensate is discharged periodically in ‘slugs’ by
siphonic action.
It is not necessary to provide air breaks or extra traps in the
discharge pipe as there is already a 75mm high trap inside
the boiler. Fitting an extra trap may cause the boiler siphon to
work incorrectly.
Refer to BS5546 or BS6798 for advice on disposal of boiler
condensate.

°

44mm/metre

12667

Diagram 9.1

19

9 Safety Discharge Valve and Condensate Connections

13000

20

Diagram 9.2