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GlowWorm Flexicom CX HE Combi 24 & 30 Installation ... - BHL.co.uk

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2000225263-03 01.06INSTALLATION AND SERVICING<strong>Flexi<strong>co</strong>m</strong><strong>24</strong>cxG.C. No. 47-047-33<strong>30</strong>cxG.C. No. 47-047-34High EfficiencyCondensing <strong>Combi</strong>nationBoilersGlow-worm, Nottingham Road, Belper, Derbyshire. DE56 1JTwww.glow-worm.<strong>co</strong>.<strong>uk</strong>1


Guarantee RegistrationThank 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 offerour customers a Comprehensive Guarantee.This product is guaranteed for <strong>24</strong> months from the date of installation or <strong>30</strong> months from the dateof manufacture, whichever is the shorter, for parts. In addition this product is guaranteed for 12months from the date of installation or 18 months from the date of manufacture, whichever is theshorter, for labour.The se<strong>co</strong>nd year of the parts guarantee, from the beginning of the 13th month onwards afterinstallation or manufacture, is <strong>co</strong>nditional upon the boiler having been serviced by a CORGI registeredgas installer,in ac<strong>co</strong>rdance with the manufacturer’s re<strong>co</strong>mmendations. We strongly re<strong>co</strong>mmend regular servicingof your gas appliance, but where the <strong>co</strong>ndition is not met, any chargeable spare parts or <strong>co</strong>mponentsissued within the applicable guarantee period still benefit from a 12 month warranty fromthe date of issue by the manufacturer.We re<strong>co</strong>mmend you <strong>co</strong>mplete and return as soon as possible your guarantee registration card.If your guarantee registration card is missing you can obtain a <strong>co</strong>py or re<strong>co</strong>rd your registration bytelephoning the Glow-worm Customer Service number 01773 828100.Customer Service:01773 828100Technical Helpline:01773 828<strong>30</strong>0General and Sales enquiries:Tel. 01773 8<strong>24</strong>639Fax: 01773 820569To register your Glow-worm appliancecall:0800 07321422


The instructions <strong>co</strong>nsist of two parts, <strong>Installation</strong> and Servicing Instructions. The instructionsare an integral part of the appliance and must, to <strong>co</strong>mply with the current issue ofthe Gas Safety (<strong>Installation</strong> and Use) Regulations, be handed to the user on <strong>co</strong>mpletion ofthe installation.CONTENTS DESCRIPTION SECTION PAGEINTRODUCTIONWarnings 4Important Information 4General Information 5Appliance Safety Devices 6Maintenance and Servicing 6INSTALLATIONINSTRUCTIONSTechnical Information 1 7Boiler Location and Ventilation 2 10Flue Options and Terminal Clearances 3 11Heating System 4 13Domestic Hot Water System 5 15<strong>Installation</strong> Preparation 6 15Gas/Water & Appliance Connection 7 18Safety Discharge Valve andCondensate Connection 8 20Flue Preparation and <strong>Installation</strong> 9 22Electrical Connection 10 35Commissioning 11 37Servicing 12 40Fault Finding 13 44Replacement of Parts 14 50Spare Parts 15 58Manual Handling 16 593


General InformationGeneral NoteThis boiler is designed for use as part of a sealed watercentral heating system with fully pumped circulation. Thepump, expansion vessel and associated safety devices are allfitted within the boiler.Once the <strong>co</strong>ntrols are set the boiler operates automatically.Please read these instructions and follow them carefully forthe <strong>co</strong>rrect installation and e<strong>co</strong>nomical use of your boiler.Water TreatmentIn the case of an existing system, it is ESSENTIAL that priorto installing the new boiler the system is thoroughly flushed.For optimum performance after installation of a new system,the boiler and its associated central heating system shouldalso be flushed. Flushing should be carried out in ac<strong>co</strong>rdancewith BS7593: 1992 using a cleanser such as Sentinel X<strong>30</strong>0or X400, Fernox Restorer or Salamander <strong>co</strong>rrosion guardcleaner.For long-term <strong>co</strong>rrosion protection, after flushing, a suitableinhibitor should be used, refer to the current issue of BS5449 and BS 7593 on the use of inhibitors in central heatingsystems. Examples are Sentinel X100 Fernox Protector orSalamander <strong>co</strong>rrosion guard inhibitor.Compartment or Cupboard <strong>Installation</strong>sIf the boiler is fitted into a <strong>co</strong>mpartment or cupboard it doesnot require ventilation openings.Do not use the <strong>co</strong>mpartment or cupboard for storage.Condensate DrainThe <strong>co</strong>ndensate drain, see diagram 8.2, must not be modifiedor blocked.Pluming from flue terminalLike all <strong>co</strong>ndensing boilers this appliance will produce a plumeof <strong>co</strong>ndensation from the flue terminal in <strong>co</strong>ol weather. This isdue to the high efficiency and hence low flue gas temperatureof the boiler. It is normal and not a fault indication.Electrical SupplyIf the mains electricity and gas are to be turned off for anylong periods during severe weather, it is re<strong>co</strong>mmended thatthe whole system, including the boiler, should be drained toavoid the risk of freezing.NOTE: Contact your installation/servicing <strong>co</strong>mpany asdraining, refilling and pressurising MUST be carried out by a<strong>co</strong>mpetent person.Manual HandlingIMPORTANT: With regards to the “Manual HandlingOperations, 1992 Regulations”, the appliance exceeds there<strong>co</strong>mmended weight for a one man lift.ClearancesIf fixtures are positioned close to the boiler, space must beleft as shown in diagram 2.1.5


1 Technical Information872802539012651C LFLUE7647BOILERC L700FlexibleCondensateConnection19 (Gas & Domestic Water)22.5 (Central Heating)FLOW60100167.560100RETURNDiagram 1.11.1 IMPORTANTThe boiler is supplied in one carton, which includes theappliance packs, see diagram 6.1.The flue is supplied separately.This boiler is for use only on G20 natural gas.Where no British Standards exists, materials and equipmentshould be fit for their purpose and of suitable quality andworkmanship.The installation of this boiler must be carried out by a <strong>co</strong>mpetentperson in ac<strong>co</strong>rdance the rules in force in the <strong>co</strong>untries ofdestination.Manufacturer’s instructions must not be taken as overridingstatutory requirements.1.2 Statutory RequirementsIn GB the installation of the boiler must be carried out by a<strong>co</strong>mpetent person as described in the following regulations:The manufacturer’s instructions supplied.The Gas Safety (<strong>Installation</strong> and Use) Regulations.The appropriate Buildings Regulations either The BuildingRegulations, The Building Regulations (S<strong>co</strong>tland),The BuildingRegulations (Northern Ireland).The Water Fittings Regulations or Water byelaws in S<strong>co</strong>tland.The Health and Safety at Work Act, Control of SubstancesHazardous to Health (COSHH).The Current I.E.E. Wiring Regulations.Where no specific instructions are given, reference should bemade to the relevant British Standard Code of Practice.In IE, the installation must be carried out by a <strong>co</strong>mpetentperson and installed in ac<strong>co</strong>rdance with the current editionof I.S.813 “Domestic Gas <strong>Installation</strong>s”, the current BuildingRegulations and reference should be made to the current ETCIrules for Electrical <strong>Installation</strong>.In 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.In IE: I.S.813, BS5546, BS 5449, BS 7074, BS 7593.Manufacturer’s instructions must not be taken as overridingstatutory requirements.NOTE: For further information, see the current issue of theBuilding Regulations, approved document L1 ( in the UK) andthe following current issues of:1) Central heating system specification (CheSS)and2) Controls for domestic central heating system and hot water.BRECSU.7


1 Technical Information1.3 Technical DataAll dimensions are given in millimetres (except as noted).See diagrams 1.1 and Boiler Specification table.The data label is positioned on the base of the boiler.BOILER SPECIFICATION <strong>24</strong>cx <strong>30</strong>cxLift weight 36kg (79Ib) 36kg (79Ib)Total weight (installed) 41kg (90Ib) 41kg (90IbGas <strong>co</strong>nnection Ø O.D. 15mm. <strong>co</strong>pper 15mm. <strong>co</strong>pperHeating and return <strong>co</strong>nnection Ø O.D. 22mm. <strong>co</strong>pper 22mm. <strong>co</strong>pperDomestic hot water <strong>co</strong>nnection Ø O.D. 15mm. <strong>co</strong>pper 15mm. <strong>co</strong>pperCondensate <strong>co</strong>nnection Ø I.D. 21.5mm. plastic 21.5mm. plasticSafety valve discharge <strong>co</strong>nnection Ø O.D. 15mm. <strong>co</strong>pper 15mm. <strong>co</strong>pperHeating circuit PMS safety valve (preset) 3 bar (43/5Ibf/in2) 3 bar (43/5Ibf/in2)Heating system minimum pressure 0.7bar (10.1Ibf/in 2 ) 0.7bar (10.1Ibf/in 2 )Domestic water circuit PMW 10bar (145Ibf/in2) 10bar (145Ibf/in2)Minimum working pressure for 0.2bar (2.9Ibf/in 2 ) 0.2bar (2.9Ibf/in 2 )maximum domestic flow rateSpecific water rate at 35° rise 9.85L/min. 12.3L/min.Minimum domestic hot water 776L/hr. 1032L/hr.flow rate at 35° riseMaximum domestic hot water temperature 63° 63°Expansion vessel capacity 8 litres (1.76 gallons) 8 litres (1.76 gallons)Expansion vessel charge pressure 0.5bar (7,3Ibf/in 2 ) 0.5bar (7,3Ibf/in 2 )Electrical supply 2<strong>30</strong>V~50Hz fused 3A 2<strong>30</strong>V~50Hz fused 3AElectrical rating 180W fused 3A 180W fused 3AEN437 IP clasification X4D X4DInternal fuse rating on main PCB 2A 2AGas supply (governed metre only) I2H G20 natural gas I2H G20 natural gasInlet gas working pressure 20mbar 20mbarBurner % CO 2 case on 9.3 nominal 9.3 nominalBurner % CO 2 case off 9.3 nominal 9.3 nominalApproximate max. gas rateafter 10 mins. from <strong>co</strong>ldApproximate min. gas rateafter 10 mins. from <strong>co</strong>ld1.93 m 3 /h 2.59 m 3 /h68.1 ft3/h 91.5 ft3/h0.99 m3/h 0.99 m3/h35.1 ft3/h 35.1 ft3/h12994Flue type C13, C33, C53 C13, C33, C53NOx Class 5 Class 5Heat output <strong>co</strong>ndensing mode 18.8kW <strong>24</strong>.9kWHeat input Nett Q = kW DHW max. 25.5 min. 9.4 DHW max. <strong>30</strong>.8 min. 9.4CH max. 18.3 min. 9.4 CH max. <strong>24</strong>.5 min. 9.4Heat output P = kW DHW max. 25.1 min. 9.3 DHW max. <strong>30</strong>.0 min. 9.3CH max. 18.0 min. 9.3 CH max. <strong>24</strong>.0 min. 9.38


1 Technical Information1.4 Gas Supply1<strong>30</strong>89The gas installation must be in ac<strong>co</strong>rdance with the relevantstandards.In GB this is BS6891.In IE this is the current edition of I.S.813 “Domestic Gas<strong>Installation</strong>s”.The supply from the governed meter must be of adequate sizeto provide a steady inlet working pressure of 20mbar (8in wg)at the boiler.On <strong>co</strong>mpletion, test the gas installation for soundness using thepressure drop method and suitable leak detection fluid, purgein ac<strong>co</strong>rdance with the above standard.1.5 Condensate DrainA plastic drain pipe must be fitted to allow discharge of<strong>co</strong>ndensate to a drain.Condensate should, if possible, be discharged into the internalhousehold draining system. If this is not practical, dischargecan be made externally into the household drainage system ora purpose designed soak away, see section 8 for more details.1.6 Upward Piping FrameShould any <strong>co</strong>mbination of the domestic hot water, heating flowor return pipes <strong>co</strong>me from above the boiler, an Upward PipingFrame is available to facilitate, part No. A2041500.Contact Glow-worm for further details.Diagram 1.29


2 Boiler Location and Ventilation2.1 LocationThis boiler is not suitable for outdoor installation.This boiler may be installed in any room, although particularattention is drawn to the installation of a boiler in a room<strong>co</strong>ntaining a bath or shower where reference must be made tothe relevant requirements.This boiler is suitable for installation in bathroom zones 2 and3.In GB this is the current I.E.E. WIRING REGULATIONS andBUILDING REGULATIONS.In IE reference should be made to the current edition of I.S.813“Domestic Gas <strong>Installation</strong>s” and the current ETCI rules.5600+5131272.2 ClearancesThe boiler should be positioned so that at least the minimumoperational and servicing clearances are provided, see diagram2.1.Additional clearances may be beneficial around the boiler forinstallation and servicing.For flue installations where external access is not practicable,<strong>co</strong>nsideration should be given for the space required to insertthe flue internally, which may necessitate clearance larger thanthose specified in diagram 2.1.150 5552.3 Timber Frame BuildingsIf the boiler is to be installed in a timber frame building it shouldbe fitted in ac<strong>co</strong>rdance with the Institute of Gas Engineersdocument IGE/UP/7/1998. If in doubt seek advice from localgas undertaking or Glow-worm.1502.4 Room VentilationThe boiler is room sealed so a permanent air vent is notrequired.2.5 Cupboard or Compartment VentilationDue to the high efficiency and hence low casing temperatureof this boiler, cupboard or <strong>co</strong>mpartment ventilation is notnecessary.Leave existing air vents.+A removable <strong>co</strong>mpartment door can be placeda minimum of 5mmThis can be reduced to 20mm for a direct rear flueDiagram 2.110


3 Flue Options and Terminal ClearancesTop horizontal teles<strong>co</strong>pic flue Ø60/100Part No. A2043600Top horizontal standard flue Ø60/100Part No. A2043400Rear teles<strong>co</strong>pic flue Ø60/100Part No. A2043500Flue AccessoriesBlack Horizontal Terminal Kit, for use withA2043500; A2043600; A2043400Black Horizontal Terminal Kit,<strong>co</strong>ncentric flue Ø60/100 - Part No. A2043700Plume Management Kit, for use withA2043500; A2043600; A2043400Plume Management Kit, basic set, white,<strong>co</strong>ncentric flue Ø60/100 - Part No. A20441001m extension, white - Part No. A2044<strong>30</strong>087 o elbow, white - Part No. A204470045 o bend (2), white - Part No. A2044500Plume Management Kit, basic set, black,<strong>co</strong>ncentric flue Ø60/100 - Part No. A20440001m extension, black - Part No. A204420087 o elbow, black - Part No. A204460045 o bend (2), black - Part No. A2044400Twin FlueTwin Flue Adapter, <strong>co</strong>ncentric flue Ø80Part No. A2011000Vertical FlueVertical Flue Adapter, <strong>co</strong>ncentric flue Ø60/100Part. No. A20<strong>24</strong>600Vertical flue terminal kit, <strong>co</strong>ncentric flue Ø60/100Part. No. 2000460480Concentric Flue Ø60/100 accessories:2 metre extension kit, <strong>co</strong>ncentric flueØ60/100 - Part No. 20004604831 metre extension kit, <strong>co</strong>ncentric flueØ60/100 - Part No. 20004604820.5 metre extension kit, <strong>co</strong>ncentric flueØ60/100 - Part No. 2000460481Adjustable flue pipe 0-50mm kit,<strong>co</strong>ncentric flue Ø60/100 - Part No. 200046048790 o flue elbow pack,<strong>co</strong>ncentric flue Ø60/100 - Part No. 200046048445 o flue bend pack,<strong>co</strong>ncentric flue Ø60/100 - Part No. 2000460485Flue support clips (3),<strong>co</strong>ncentric flue Ø60/100- Part No. A2043900Additional accessories are available.See Glow-worm “<strong>Flexi<strong>co</strong>m</strong> Range Guide” for<strong>co</strong>nfigurations available.Diagram 3.111


3 Flue Options and Terminal Clearances3.1 Flue OptionsThere are various flue options to choose from as illustrated indiagram 3.1. The flue lengths and installation are described insection 9.3.2 Flue Terminal PositionHORIZONTAL FLUESA DIRECTLY BELOW AN OPENING, AIR BRICK,OPENING WINDOWS <strong>30</strong>0B ABOVE AN OPENING, AIR BRICK,OPENING WINDOWS <strong>30</strong>0C HORIZONTALLY TO AN OPENING,AIR BRICK, OPENING WINDOWS <strong>30</strong>0D BELOW GUTTER, DRAIN/SOIL PIPE 25E BELOW EAVES 25F BELOW A BALCONY OR CAR PORT 25G FROM VERTICAL DRAIN PIPES ANDSOIL PIPES 25H FROM INTERNAL/EXTERNAL CORNERS 25H* TO A BOUNDARY ALONGSIDE T<strong>HE</strong>TERMINAL <strong>30</strong>0IABOVE ADJACENT GROUND ORBALCONY LEVEL <strong>30</strong>0J* FROM SURFACE OR A BOUNDARYFACING T<strong>HE</strong> TERMINAL 600K FACING TERMINALS 1200LFROM OPENING (DOOR/WINDOW)IN CAR PORT INTO DWELLING 1200M VERTICAL FROM A TERMINAL 1500N HORIZONTALLY FROM A TERMINAL <strong>30</strong>0VERTICAL FLUESP FROM ANOT<strong>HE</strong>R TERMINAL 600Q ABOVE ROOF LEVEL <strong>30</strong>0R FROM ADJACENT OPENING WINDOW 1000S FROM ADJACENT WALL TO FLUE <strong>30</strong>0The minimum acceptable siting dimensions for the terminalfrom obstructions, other terminals and ventilation openings areshown in diagram 3.2. For Ireland the minimum distances forflue terminal positioning must be those detailed in I.S.813 “DomesticGas <strong>Installation</strong>s”.The terminal must be exposed to the external air, allowing freepassage of air across it at all times.Being a <strong>co</strong>ndensing boiler some pluming may occur from theflue outlet. This should be taken into <strong>co</strong>nsideration when selectingthe position for the terminal.NOTE: If necessary it is permitted to increase the terminal protrusionthrough the outside wall to greater than the minimum dimensionof 87mm but no more than 600mm, see diagram 1.1.Carports or similar extensions of a roof only, or a roof and onewall, require special <strong>co</strong>nsideration with respect to any openings,doors, vents or windows under the roof. Care is requiredto protect the roof if made of plastic sheeting. If the carport<strong>co</strong>mprises of a roof and two or more walls, seek advice fromthe local gas supply <strong>co</strong>mpany before installing the boiler.H* and J* See diagram 3.2 . These dimensions <strong>co</strong>mply withthe building regulations, but they may need to be increased toavoid wall staining and nuisance from pluming depending onsite <strong>co</strong>nditions.Plume Management Kit: Part No.A2044100 (white) orA2044000 (black) can be used to over<strong>co</strong>me many site issues.3.3 Terminal GuardA terminal guard is required if persons <strong>co</strong>uld <strong>co</strong>me into <strong>co</strong>ntactwith the terminal or the terminal <strong>co</strong>uld be subject to damage.If a terminal guard is required, it must be positioned to provideminimum of 50mm clearance from any part of the terminal andbe central over the terminal.The guard should be similar to that shown in diagram 3.3.A suitable guard is manufactured by: -Tower Flue ComponentsMorley Rd.TonbridgeKentTN9 1RA.Size: 280mm x 280mm x 270mm.12325Diagram 3.2Diagram 3.312


4 Heating System4.1 GeneralThe boiler is for use only with sealed central heating systems.The safety valve is an integral part of the boiler and it cannotbe adjusted.The digital readout on the <strong>co</strong>ntrols fascia indicates the systempressure when there is no demand.The circulation pump is integral with the boiler.4.2 Expansion VesselThe boiler has an integral expansion vessel with a capacity of8 litres (1.76 gallons), with a charge pressure of 0.5bar.NOTE: The expansion vessel volume depends on the totalwater system volume and the initial system design pressure.Guidance on vessel sizing is also given in the current issue ofBS5449 and BS7074 Part 1, for IE refer to the current editionof I.S.813 “Domestic Gas <strong>Installation</strong>s”.128004.3 Flow RateIf it is necessary to alter the flow rate, the system can befitted with a lockable balancing valve in the main flow orreturn pipes shown as valve “A” in diagram 4.1. The flow ratethrough the boiler must not be allowed to fall below that givenin diagram 1.2.4.4 BypassThe boiler is fitted with an automatic bypass.Diagram 4.2 shows the pump head remaining for the heatingsystem depending on the bypass setting and the speedsetting of the pump, see section 11 Commisioning.Ensure that under no circumstances does the flow rate dropbelow the figure specified, refer to diagram 1.2 and section11.6.The installation of the boiler must <strong>co</strong>mply with therequirements of the current issue of BS6798, in Ireland,refer also to the current edition of I.S.813 “Domestic Gas<strong>Installation</strong>s”.In GB it is necessary to <strong>co</strong>mply with the Water Supply (WaterFittings) Regulations 1999 (for S<strong>co</strong>tland, the Water Byelaws2000, S<strong>co</strong>tland).To <strong>co</strong>mply with the Water regulations your attention is drawnto: The Water Regulations guide published by the WaterRegulations Advisory Service (WRAS) gives full details of therequirements.In IE the requirements given in the current edition of I.S.813“Domestic Gas <strong>Installation</strong>s” and the current BuildingRegulations must be followed.4.5 Filling the Sealed SystemNOTE: The water pressure at the boiler must be at least1.2bar to enable filling the boiler to a minimum pressure. Theboiler is supplied with a filling device, see diagrams 4.1 and4.3.This filling device is designed to enable the filling andpressurisation of the system in the event of loss of pressure.Diagram 4.113


4 Heating System51310<strong>24</strong>.5Remaining Conveyancing Capacity (mH2O)43.532.521.510.5automatic bypass - fully closedautomatic bypass - factory settingautomatic bypass - fully openpump speed 1pump speed 20-100 100 <strong>30</strong>0 500 700 900 1100 1<strong>30</strong>0 1500Litres/hrDiagram 4.<strong>24</strong>.6 Water TreatmentIn the case of an existing system, it is ESSENTIAL that priorto installing the new boiler the system is thoroughly flushed.For optimum performance after installation of a new system,the boiler and its associated central heating system shouldalso be flushed. Flushing should be carried out in ac<strong>co</strong>rdancewith BS7593: 1992 using a cleanser such as Sentinel X<strong>30</strong>0or X400, Fernox Restorer or Salamander <strong>co</strong>rrosion guardcleaner.For long-term <strong>co</strong>rrosion protection, after flushing, a suitableinhibitor should be used, refer to the current issue of BS5449 and BS 7593 on the use of inhibitors in central heatingsystems. Examples are Sentinel X100 Fernox Protector orSalamander <strong>co</strong>rrosion guard inhibitor.126574.7 Draining PointsDraining taps must be provided at the lowest points of thesystem, which will allow the entire system to be drained.Drain points for the appliance are provided at the positionsshown in diagram 4.3.FILLING LOOPDRAIN POINTSDiagram 4.314


5 Domestic Hot Water SystemGeneral - All domestic hot water circuits, <strong>co</strong>nnections, fittingsmust be in ac<strong>co</strong>rdance with the relevant standards and watersupply regulations.For GB: Guidance G17 to G<strong>24</strong> and re<strong>co</strong>mmendation R17 toR<strong>24</strong> of the Water Regulations Guide.For IE: The current edition of I.S.813 “Domestic Gas<strong>Installation</strong>s”.5.1 Water PressureThe maximum working pressure of the domestic hot watercircuit is 10 bar. If the <strong>co</strong>ld water supply pressure exceedsthis, then a pressure-reducing valve must be fitted in thesupply to the boiler.5.2 ‘Hard’ Water AreasThe temperatures within the heat exchanger are limited bythe boiler <strong>co</strong>ntrol system to minimise scale formation withinthe hot water pipework. However, in areas where the water is‘hard’ (i.e. more than 200mg/litre), it is re<strong>co</strong>mmended that thehot water setting is reduced and that a scale reducer is fitted.Refer to the manufacturer’s instructions or <strong>co</strong>nsult the localwater <strong>co</strong>mpany for additional advice.5.3 Domestic Water Flow RateThe water flow rate is restricted to a maximum 9.4 l/min for<strong>24</strong>cx and 11.7 l/min for <strong>30</strong>cx, by a restrictor factory fittedwithin the boiler.6 <strong>Installation</strong> Preparation6.1 Appliance PackIMPORTANT: With regards to the Health and Safety ManualHandling requirements, two persons shall be required to liftthe appliance, refer to section 16 Manual Handling.Please check the <strong>co</strong>ntents of packs as shown in diagram 6.1.NOTE: The packs are located in the top polystyrene packing.The wall hanging bracket is located at the rear of the boiler,slide upwards to remove.6.2 Wall TemplateTake the wall template from the document pack located withinthe top polystyrene packing and place in the desired positionon a flat wall, giving due <strong>co</strong>nsideration to the required boilerclearances, see section 2, and the flue you are fitting.6.3 Flue Hole CuttingExternal access flue installation can use a 105mm diameter<strong>co</strong>re drill.Internal access only flue installation will need a 125mm diameter<strong>co</strong>re drill.If flue extension pipes are to be used then a <strong>co</strong>re drill sizeof 125mm is required. This will allow the extension pieces toslope at 44mm/metre (2.5°) towards the boiler.Top horizontal flue - (standard andteles<strong>co</strong>pic)The standard horizontal flue is designed with an internal fall of44mm/metre (2.5°) towards the boiler for disposal of <strong>co</strong>ndensatetherefore the hole can be drilled horizontally. If thestandard flue length alone is being used then the flue hole ofdiameter 105mm can be cut in the position marked on the walltemplate.For standard side flues the horizontal flue centre line on thewall template should be extended to the side wall, and thevertical centre of the flue hole marked at 176mm from theback wall.For extended side flues, the flue hole centre should bedetermined by extending the dashed inclined line on thetemplate to the side wall. This dashed line is drawn at 44mm/metre (2.5°) rise from the boiler. Where this line reaches theside wall, a horizontal line should be marked. The verticalcentre line of the flue should then be marked at 176mm fromthe back wall.To allow for the flue passing through the wall at this anglea 125mm hole should be drilled irrespective of internal orexternal installation.Remove the wall template whilst drilling the flue hole.6.4 Rear flue - teles<strong>co</strong>picThe rear flue is designed with an internal fall of 44mm/metretowards the boiler for disposal of <strong>co</strong>ndensate therefore thehole can be drilled horizontally. For installations with externalaccess, a 105mm diameter <strong>co</strong>re drill can be used.15


6 <strong>Installation</strong> Preparation12778Central Heating x 2Domestic Water flowGasDomestic Water returnSafety Discharge ValveDiagram 6.116


6 <strong>Installation</strong> Preparation6.5 Wall Hanging Bracket AssemblyThe Wall Hanging Bracket is supplied in the main boilerpackaging at the rear of the boiler.1<strong>30</strong><strong>24</strong>Reposition the wall template over the flue hole and markthe position of the fixing holes for the hanging bracket, seediagram 6.2.NOTE: Due to the varied site <strong>co</strong>nditions we do not supplyfixings and advise that the installer should supply those whichare suitable.Drill fixing holes and insert suitable wall plugs.Rear Flue only - If external access is not available the flueto be used should be assembled as described in section 9and inserted through the hole in the wall before fitting the wallhanging bracket.Fit the fixing jig support plate to the bottom of the wall hangingbracket, push down to locate.Mark, drill and plug at fixing points and secure the jig supportplate, see diagram 6.3.Rear Flue only - The flue can now be pulled back through thehanging bracket and secured as shown in diagram 6.2.HANGINGBRACKETFIXINGSDiagram 6.21<strong>30</strong>25JIG SUPPORTPLATE FIXINGSDiagram 6.317


7 Gas / Water & Appliance Connection7.1 Systems ConnectionThe Gas and Water systems can be <strong>co</strong>nnected and filled priorto installation of boiler.All water and gas <strong>co</strong>nnections are on the fixing jig with theexception of the <strong>co</strong>ndense drain and safety discharge, thepositions of these are shown on the wall template.An Upward Piping Frame, part no. A2041500 should be usedif the supplies <strong>co</strong>me from above the boiler otherwise the pipeswill have to be chased into the wall.Assemble the pipes to the jig as shown in diagram 7.1.Fit ‘O’ ring seal to the Double Check Valve assembly.Fit the Central Heating Isolation Valve handles and securewith screws provided.Fit the assembled Jig Plate to the Support Plate as shown indiagram 7.2.Assemble the Gas Service Cock and position onto the plasticplug.NOTE: Make sure the drain points are accessible, referdiagram 4.3.Plumb system pipe work to the <strong>co</strong>pper tails. Do not subjectservice <strong>co</strong>cks to heat.There are flats on the body of the valves for locating aspanner to aid tightening to <strong>co</strong>pper tails using the tighteningsequence shown in diagram 7.4.Fit Double Check Valve into Isolation Valve and secure withthe wire retaining clip.NOTE: At this stage alternative filling and pre-filling methodscan be used, refer to section 11 Commissioning.Prior to filling the water system ensure that the blanking plugsand isolation valves are secured.Flush out the domestic hot water and the heating systems.The whole of the gas installation, including the meter, shouldbe inspected, tested for soundness and purged in ac<strong>co</strong>rdancewith the current issue of BS6891 and in IE the current editionof I.S.813 “Domestic Gas <strong>Installation</strong>s”.'O' RING SEAL13101DOUBLE C<strong>HE</strong>CKINLET VALVEJIG SUPPORTPLATEJIG PLATE12957LOCATIONSLOTSJIG SUPPORTPLATEJIG PLATEWIRERETAININGCLIPISOLATION VALVEHANDLEAND SCREWDiagram 7.1UNIONCONNECTIONSDiscardDiagram 7.218


7 Gas / Water & Appliance Connection7.2 Appliance ConnectionIMPORTANT: With regards to the Manual HandlingOperations, 1992 Regulations, the following lift operationexceeds the re<strong>co</strong>mmended weight for a one man lift, refer tosection 16 Manual Handling.12955Rear Flue onlyThis must be fitted before hanging the boiler, refer to Section 9.NOTE: The appliance and jig (pre-filled) may <strong>co</strong>ntain a smallamount of water, place a water <strong>co</strong>ntainer beneath the boiler<strong>co</strong>nnections.Make sure the isolation valves are closed before dis<strong>co</strong>nnectingthe 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 slightlyto the wall and position just above the hanging bracket. Lowerthe boiler slowly push back and engage onto the hangingbracket making sure the boiler is located over the retainingbosses, see diagram 7.3.Remove the protective caps.Engage the fixing jig <strong>co</strong>nnections, ensuring that the previouslypositioned washers have not been disturbed.Make good the final <strong>co</strong>nnections.Diagram 7.312777BFAGC D AH1 2 3 4 5A - Central Heating Isolation ValveB - Domestic Hot WaterC - Gas Service CockD - Domestic Cold WaterE - Washers (not shown)F - Condensate ConnectionG - Double check inlet valveH - Safety Discharge ValveNumbers 1 - 5show the sequence to be usedwhen tightening to <strong>co</strong>pper tails.Diagram 7.419


8 Safety Discharge Valve & Condensate Connections8.1 Safety Discharge ValveThe pipe from the safety discharge valve must not dischargeabove an entrance, window or any type of public access area.Take the safety discharge pipe, supplied in the pipe pack andthe union nut and seal, supplied in the loose items pack andfit as shown in diagram 8.1.This must be extended, using not less than 15mm o.d. pipe,to discharge, in a visible position, outside the building, facingdownwards, preferably over a drain.The pipe must have a <strong>co</strong>ntinuous fall and be routed to aposition so that any discharge of water, possibly boiling,or steam cannot create any danger to persons, damage toproperty or external electrical <strong>co</strong>mponents and wiring.To ease future servicing it is advisable to use a <strong>co</strong>mpressiontype fitting to extend the safety discharge valve tube.SECURINGCLIP126678.2 Condensate Drain ConnectionThe <strong>co</strong>ndensate drain <strong>co</strong>nnection is at the rear of the boiler,see diagram 7.4. A flexible <strong>co</strong>ndensate outlet pipe is suppliedfitted to the boiler and should be used to fit onto the drain<strong>co</strong>nnection, to discharge <strong>co</strong>ndensate to a drain. The drainpipe 22mm to 25mm OD. non <strong>co</strong>rrosive plastic pipe shouldhave a fall of at least 2.5 0 away from the boiler.Condensate should, if possible be discharged into thehousehold internal drainage system. If this is not practicable,discharge can be allowed into the external household drainsor a purpose designed soak away, refer to diagram 8.2.It is re<strong>co</strong>mmended that any external <strong>co</strong>ndensate drain pipe isinsulated and also preferably of 32mm diameter, to preventfreezing in adverse weather <strong>co</strong>nditions.The <strong>co</strong>ndensate is discharged periodically in ‘slugs’ bysiphonic action.It is not necessary to provide air breaks or extra traps in thedischarge pipe as there is already a trap inside the boiler.Fitting an extra trap may cause the boiler siphon to workin<strong>co</strong>rrectly.Refer to BS5546 or BS6798 for advice on disposal of boiler<strong>co</strong>ndensate.SAFETYDISCHARGEVALVEUNION NUTAND SEALVIEW ON UNDERSIDE OF BOILERDiagram 8.120


9 Flue Preparation and <strong>Installation</strong>The cut ducts must be de-burred and all filings and debrisremoved.Insert the flue duct into the air duct terminal assembly,remembering to engage the catch within the terminal.NOTE: If you require to lubricate the seals to ease installation,do not use mineral oils or grease, sili<strong>co</strong>n grease or water isre<strong>co</strong>mmended.Fit the sealing <strong>co</strong>llar onto the locating ring on the flue terminal,see diagram 9.6.Push the flue assembly into the wall, externally or internally,initially until the end of the assembly protrudes a short wayfrom the inside face of the wall. This will enable the internaltrim ring (if required) to be positioned and allow the flueassembly to be drawn back into the flue elbow.Secure the flue elbow in position on top of the boiler with fourtorque headed screws supplied.Draw the flue assembly from wall and engage the flue ductinto the elbow and butt fit between the air duct and flue elbow.Ensuring the <strong>co</strong>rrect alignment of the terminal.Fit the securing <strong>co</strong>llar into position, mark through two of thepre drilled holes in the securing <strong>co</strong>llar. Remove securing<strong>co</strong>llar and drill two 3mm diameter holes one in the elbow andone in the air duct, take care not to pierce the inner flue duct.Fit the securing <strong>co</strong>llar and secure with screws provided, seediagram 9.10.Slide the internal trim ring back against the wall, securing inplace with a small amount of sealant if required.NOTE: If the air and flue ducts have been <strong>co</strong>rrectly cut to theinstructions given, the sealing <strong>co</strong>llar should fit flush with theoutside wall, check this.13mmAIR DUCTLLTERMINALCATCHDiagram 9.81296712847FLUE DUCTL + 11mmDiagram 9.91<strong>30</strong>19Diagram 9.10<strong>24</strong>


9 Flue Preparation and <strong>Installation</strong>9.8 Top Horizontal Side flue - Teles<strong>co</strong>picPart No. A2043600. Refer to diagram 9.1 forkit <strong>co</strong>ntents.128049.9 Flue LengthThe maximum permissable horizontal flue length is 8 metresplus the Top horizontal side flue - teles<strong>co</strong>pic. This can beachieved by the use of extensions, however, for every 90 o or45 o elbows used the flue length MUST be reduced by 1 metre.When extension pipes are used the flue system must bedesigned to have a <strong>co</strong>ntinuous fall to the boiler of at least44mm/metre (2.5°) to allow <strong>co</strong>ndensate to run back into theboiler and out via the drain.9.10 PreparationRemove the top flue outlet <strong>co</strong>ver secured with four screws,see diagram 9.2.Temporarily fit the flue elbow, measure the distance from theoutside wall to flue elbow. If the measurement ‘Y’ exceeds525mm, see diagram 9.11 then the appropriate length ofextension pipe is required. If the dimension is less than320mm DO NOT cut the flue, it can project beyond theoutside wall face, see diagrams 9.4. If this is not desirablethen a Top horizontal side flue - standard MUST be used andcut to length.Left Hand illustratedDiagram 9.111<strong>30</strong>209.11 Flue FittingSet the flue to the required length ‘Y’, ensure the air ductseams line up.Remove the flue elbow.Mark the securing hole position in the air duct. Drill a 3mmdiameter hole at this position, take care not to pierce theinner flue duct. Secure with screw provided and tape the joint,see diagram 9.5.Fit the sealing <strong>co</strong>llar onto the locating ring on the flue terminal,see diagram 9.6.Push the flue assembly into the wall, externally or internally,until the end of the assembly protrudes a short way from theinside face of the wall. This will enable the internal trim ring (ifrequired) to be positioned and allow the flue assembly to bedrawn back up to the flue elbow.Secure the flue elbow in position on top of the boiler with fourtorque headed screws supplied.Draw the flue assembly from wall and engage the flue ductinto the elbow and butt fit between the air duct and flue elbow.Ensure the <strong>co</strong>rrect alignment of the flue.Fit the securing <strong>co</strong>llar in position, mark through two of the predrilled holes in the securing <strong>co</strong>llar. Remove securing <strong>co</strong>llarand drill two 3mm diameter holes one in the elbow and one inthe air duct, take care not to pierce the inner flue duct. Fit thesecuring <strong>co</strong>llar and secure with screws provided, see diagram9.12.Slide the internal trim ring back against the wall, securing inplace with a small amount of sealant if required.Diagram 9.1225


9 Flue Preparation and <strong>Installation</strong>9.12 Top Horizontal Side flue - StandardPart No. A2043400. Refer to diagram 9.8 forkit <strong>co</strong>ntents.1<strong>30</strong>229.13 Flue LengthRemove the top flue outlet <strong>co</strong>ver secured with four screws,see diagram 9.2.Temporarily fit the flue elbow, measure the distance from theoutside wall to flue elbow. If the measurement ‘Y’ exceeds652mm, then the appropriate length of extension pipe isrequired. The minimum dimension for LH is 270 and RH <strong>24</strong>2to suit a minimum wall thickness of 75mm, see diagram 9.11.9.14 Flue FittingRemove the flue elbow.Separate the flue duct from the terminal by twisting to releasethe terminal catch, then pull out of the retaining seal, refer todiagram 9.9.The flue duct cutting length (L + 11mm.) is shown in diagram9.9.The air duct should be cut at the opposite end to the terminalThe plastic flue duct MUST be cut at the opposite end to theterminal catch.The plastic flue duct extensions MUST be cut at the oppositeend to seal.The cut ducts must be de-burred and all filings and debrisremoved.Insert the flue duct into the air duct terminal assembly,remembering to engage the catch within the terminal.NOTE: If you require to lubricate the seals to ease installation,do not use mineral oils or grease, sili<strong>co</strong>n grease or water isre<strong>co</strong>mmended.Fit the sealing <strong>co</strong>llar behind the locating lugs on the flueterminal, see diagram 9.6.Push the flue assembly into the wall, externally or internally,initially until the end of the assembly protrudes a short wayfrom the inside face of the wall. This will enable the internaltrim ring (if required) to be positioned and allow the flueassembly to be drawn back into the flue elbow.Secure the flue elbow in position on top of the boiler with fourtorque headed screws supplied.Draw the flue assembly from wall and engage the flue ductinto the elbow and butt fit between the air duct and flue elbow.Ensuring the <strong>co</strong>rrect alignment of the terminal.Fit the securing <strong>co</strong>llar into position, mark through two of thepre drilled holes in the securing <strong>co</strong>llar. Remove securing<strong>co</strong>llar and drill two 3mm diameter holes one in the elbow andone in the air duct, take care not to pierce the inner flue duct.Fit the securing <strong>co</strong>llar and secure with screws provided, seediagram 9.13.Slide the internal trim ring back against the wall, securing inplace with a small amount of sealant if required.NOTE: If the air and flue ducts have been <strong>co</strong>rrectly cut to theinstructions the sealing <strong>co</strong>llar should fit flush with the outsidewall, check this.Diagram 9.1326


9 Flue Preparation and <strong>Installation</strong>9.15 Rear flue - Teles<strong>co</strong>pic Part No.A2043500. Refer to diagram 9.14 for kit<strong>co</strong>ntents.<strong>24</strong> to 28129669.16 Flue LengthMeasure the distance from the outside wall to the inside wallface. This measurement must not exceed 512mm (465mmif the upward piping kit is used). If the dimension is less than291mm DO NOT cut the flue, it can project to its maximum.9.17 Flue FittingSet the flue to the required length ‘Y’ plus <strong>24</strong>mm min to 28mmmax, see diagram 9.16, ensure the air duct seams line up.Mark the securing hole position in the air duct. Drill a 3mmdiameter hole at this position, take care not to pierce theinner flue duct. Secure with screw provided and tape the joint,see diagrams 9.14 and 9.15.Fit the sealing <strong>co</strong>llar onto the locating ring on the flue terminal,see diagram 9.6.Push the teles<strong>co</strong>pic terminal assembly into the wall, externallyor internally, initially.Draw the teles<strong>co</strong>pic flue through the wall and engage theteles<strong>co</strong>pic terminal assembly into the clamping band grips.The teles<strong>co</strong>pic terminal assembly must be pulled forward ofthe clamping band grips by the dimension shown in diagram9.16 to ensure a good seal when the boiler is located onto thefixing plate.Ensuring the <strong>co</strong>rrect alignment of the terminal.Secure the teles<strong>co</strong>pic terminal assembly using the clampingband supplied. The position of the clamping band securingscrew is important, refer to label and wall template.IMPORTANT: C<strong>HE</strong>CK T<strong>HE</strong> CLAMPING BAND ISSUFFICIENTLY TIGHTENED TO AVOID ANY MOVEMENTOF T<strong>HE</strong> FLUE W<strong>HE</strong>N FITTING T<strong>HE</strong> BOILER.Remove the rear flue outlet <strong>co</strong>ver secured with four screws.Fix the boiler to the wall, refer to Section 6 Boiler Fixing.13203Diagram 9.1528mm MAX<strong>24</strong>mm MIN12958Diagram 9.14Diagram 9.1627


9 Flue Preparation and <strong>Installation</strong>9.18 Vertical flueThe vertical flue system is available as an option where theboiler position does not permit the use of the top horizontal orrear flue system.The system is made up of accessories. The accessoriesinclude terminal assembly, bends 45º and 90º, flueextensions, fixing bracket and appropriate weather <strong>co</strong>llar, seediagram 9.17.The maximum permitted straight flue length is 8 metres plusthe terminal. for each 90 o or 2x45 o bends fitted, the maximumlength must be reduced by 1 metre, see diagram 9.22.NOTE: 2x45º bends can replace 1x90º bend if necessary.When using 90º bends any horizontal extension pipe shouldbe inclined by a minimum of 44mm/metre (2.5°) towards theboiler to facilitate <strong>co</strong>ndense removal, see (a) in diagram 9.22.Alternatively use 45º bends to avoid horizontal runs, see (b) indiagram 9.22.The terminal should be positioned at least 600mm from anyopening into the building, refer to diagram 3.2.Measure the distance of flue length required for theinstallation.The flue must be designed with a <strong>co</strong>ntinuous fall towards theboiler.Remove the top flue outlet <strong>co</strong>ver secured with four screws,see diagram 9.2.Refer to diagram 9.18. Secure the flue adapter in positionon top of the boiler with four torx headed screws supplied,making sure the nib fits into the locating slot in the boilercasing to ensure <strong>co</strong>rrect orientation.The rubber ‘O’ rings of each section should be lubricated priorto assembly.NOTE: Do not use mineral oils or grease, sili<strong>co</strong>n grease orwater is re<strong>co</strong>mmended.Secure the first extension pipe to the flue adapter with thesecuring <strong>co</strong>llar supplied by positioning the <strong>co</strong>llar centrally overthe joint, then tighten the two screws on the securing <strong>co</strong>llar,see diagram 9.19.Fit more extension pipes as required using the <strong>co</strong>llar andscrews supplied with each extension pipe. To fit position the<strong>co</strong>llar centrally over the joint, tighten the two screws on thesecuring <strong>co</strong>llar. Using the holes provided in the securing<strong>co</strong>llar drill and insert the two self tapping srews supplied, seediagram 9.20.The rubber ‘O’ rings of each section should be lubricated priorto assembly.NOTE: Do not use mineral oils or grease, sili<strong>co</strong>n grease orwater is re<strong>co</strong>mmended.When building the flue up it is re<strong>co</strong>mmended that it issupported every 2 metres and at every bend by a fixingbracket.Project the rise of the flue pipe to roof level and cut a 150mmhole in the roof.12969Diagram 9.1728


9 Flue Preparation and <strong>Installation</strong>Flue Terminal <strong>Installation</strong>(a) Pitched RoofFit the required pitched roof weather <strong>co</strong>llar over the 150mmhole in the roof. Make good the tiling or slating around the<strong>co</strong>llar in<strong>co</strong>rporating the flashing of the weather <strong>co</strong>llar. Positionthe angle cap over the weather <strong>co</strong>llar in the <strong>co</strong>rrect orientationto attain the <strong>co</strong>rrect angle for your roof.(b) Flat RoofFit the aluminium weather <strong>co</strong>llar over the 150mm hole in theroof ensuring a weather tight seal.From above carefully place the flue terminal through theweather <strong>co</strong>llar.Completion of <strong>Installation</strong>With the flue terminal positioned in the roof the length of thefinal pipe can be determined. If a teles<strong>co</strong>pic length cannotbe used, then a standard flue length can be cut to make the<strong>co</strong>rrect length. Cut the flue to the desired length measuringfrom the ‘O’ ring end and discard the plain end of the tube.The cuts must be square and made free of burrs to allow<strong>co</strong>rrect assembly. (NOTE: The flue pipe is 10mm longer thanthe air pipe), see diagram 9.21. Carefully push the terminalassembly upwards to allow room for fitting the final flue piece.Fit a fixing bracket to the terminal assembly. Pull the terminalassembly down and join to the flue system. Ensure that theterminal is making a weather tight seal on the weather <strong>co</strong>llar.Secure the fixing bracket fitted to the terminal to the roofingstruts or a purpose made batton.1<strong>30</strong>23Diagram 9.18Diagram 9.191298212981Diagram 9.2029


9 Flue Preparation and <strong>Installation</strong>1298412983Diagram 9.21Diagram 9.22<strong>30</strong>


9 Flue Preparation and <strong>Installation</strong>129709.19 Twin flueThe twin flue system is available as an option when the tophorizontal, rear or vertical flue system is not appropriate.The system can provide an independent horizontal air inletand flue outlet, horizontal air inlet and vertical flue outlet orvertical air inlet and flue outlet via a <strong>co</strong>ncentric terminal.NOTE: The air and flue outlets do not have to be equallengths. 2x45° bends can replace 1x90° bend if necessary.The maximum permitted straight pipe length is 20 metres plusterminal assemblies, for each 90° or 45° x 2 bends fitted, themaximum length must be reduced by 1 metre.NOTE: When using 90° bends any horizontal run should beinclined by a minimum of 44mm/metre (2.5°) towards theboiler to facilitate <strong>co</strong>ndense removal.Alternatively use 45° bends to avoid horizontal runs in the fluepipe.Terminal PositionThe clearances for a flue outlet are given in the "Flue Locationand Ventilation" section.In addition the horizontal air inlet must not be closer than <strong>30</strong>0mm from a flue outlet on the same wall or 1200mm from anopposing flue outlet.<strong>Installation</strong> DetailsThe parts available for a twin flue system installation areshown in diagram 9.23.Boiler ConnectionRemove the top flue outlet <strong>co</strong>ver secured with four screws,see diagram 9.2Push the twin flue adaptor onto the outlet of the boiler with theair inlet to the left hand side. Secure the adaptor to the toppanel with the screws provided. Care should be taken wheninserting the screw through the hole in adaptor top.To facilitate engagement, it is re<strong>co</strong>mmended that the rubber‘O’ rings are lubricated with sili<strong>co</strong>ne grease or water prior toassembly.See diagram 9.<strong>24</strong> new adaptor in position.Air and Flue Pipe <strong>Installation</strong>The air and flue pipes can now be built up from the boiler.The flue must be designed with a <strong>co</strong>ntinuous fall towards theboiler. If using the horizontal flue pipe or 90° bends the pipemust be inclined at 44mm/metre (2.5°) minimum, see diagram9.25.Alternatively if space allows, use 45° bends in place of 90ºbends.The rubber ‘O’ rings of each section should be lubricated priorto assembly with sili<strong>co</strong>ne grease.When building the flue up it is re<strong>co</strong>mmended that it is supportedevery 2 metres and at every bend by a fixing bracket.Diagram 9.2331


9 Flue Preparation and <strong>Installation</strong>Horizontal Terminal <strong>Installation</strong>With due <strong>co</strong>nsideration to terminal clearances mentioned inSection 3.2 drill the one or two holes as required with a 90mm<strong>co</strong>re drill.Push the horizontal terminal through the wall allowing approx.100mm to protrude outside.Push a grey rubber wall seal onto either side of the wall ensuringthat both wall seals are pushed up to the wall surface,see examples (b) and (c) diagram 9.25.Vertical Terminal <strong>Installation</strong>With due <strong>co</strong>nsideration to terminal clearances mentioned inSection 3.2, project the rise of the flue pipe to roof level andcut 150mm hole in the roof.(a) Pitched RoofFit the required pitched roof weather <strong>co</strong>llar over the 150mmhole in the roof. Make good the tiling or slating around the<strong>co</strong>llar in<strong>co</strong>rporating the flashing of the weather <strong>co</strong>llar. Positionthe angle cap over the weather <strong>co</strong>llar in the <strong>co</strong>rrect orientationto attain the <strong>co</strong>rrect angle for your roof. One way round givesa pitch of 25°-38° and the other gives 37°- 50°.(b) Flat RoofFit the aluminium weather <strong>co</strong>llar over the 150mm hole in theroof ensuring a weather tight seal.12985Diagram 9.<strong>24</strong>Horizontal Pipes-Completion of <strong>Installation</strong>Having built the pipe(s) from the boiler to the terminal(s), thelength of the final pipe piece can be determined. Cut pipes atthe opposite end to the ‘O’ ring seal making square and freefrom burrs. Push the horizontal terminal through the wall toengage the final pipe piece and pull back ensuring the greywall seals are fully pulled up to the outside and inside wallfaces.Vertical Pipes-Completion of <strong>Installation</strong>Refer to diagram 9.25.For installation of (a), attach the twin pipe to <strong>co</strong>ncentric flueadaptor, part number A2011600, to the base of vertical terminalassembly. For installation of (b), attach the single pipeto <strong>co</strong>ncentric adaptor, part number A2011500, to the base ofvertical terminal assembly.With the vertical terminal assembly positioned in the roof,the length of the final pipe can be determined. Cut the flueto the desired length measuring from the ‘O’ ring seal endand discard the plain end of the tube. The cut end should besquare and free from burrs. Carefully push the terminal assemblyupwards to allow room for fitting the final flue piece(s).Fit a 100mm fixing bracket to the terminal assembly PartNo2000460486. Pull the terminal assembly down and join tothe flue system. Ensure that the terminal is making a weathertight seal on the weather <strong>co</strong>llar. Secure the fixing bracketfitted to the terminal to the roofing struts or a purpose madebatton.32


9 Flue Preparation and <strong>Installation</strong>12987Diagram 9.2533


9 Flue Preparation and <strong>Installation</strong>IMPORTANT: The flue outlet mustnot be positioned within <strong>30</strong>0mmfrom an opening, air brick oropening windows.FLUEOUTLETFLUEPRODUCTS12997PLUMEMANAGEMENTKIT9.20 Plume Management KitThe Plume Management Kit: Part No. A2044100 (white) orA2044000 (black) can be used to over<strong>co</strong>me many site issues.The Plume Management Kit will fit to the Top Horizontal Teles<strong>co</strong>pic,Rear Horizontal Teles<strong>co</strong>pic and Standard HorizontalFlue. This enables the flue products to exhaust further awayfrom the boiler, thereby reducing the impact of pluming. Theflue air inlet can be sited closer to doors, opening windowsand air bricks, see diagram 9.26.The maximum length of the Plume Management Kit must NOTexceed 6m with a horizontal <strong>co</strong>ncentric flue length of 2m max.For each 90 o bend or 2 x 45 o bends the maximum length of thePlume Management Kit must be reduced by 1m.For more information <strong>co</strong>ntact Glow-worm, refer to page 2.The Plume Management Kit is supplied with installationinstructions.AIR BRICKOPENINGWINDOWOR DOOR75mm. MIN.100mm.MIN.AIR INLETDiagram 9.2634


10 Electrical ConnectionWARNING: This appliance must be earthed.This appliance must be wired in ac<strong>co</strong>rdance with theseinstructions. Any fault arising from in<strong>co</strong>rrect wiring cannot beput right under the terms of the Glow-worm guarantee.All system <strong>co</strong>mponents must be of an approved type.Electrical <strong>co</strong>mponents have been tested to meet theequivalent requirements of the BEAB.Do not interrupt the mains supply with a time switch orprogrammer.Connection of the whole electrical system and any heatingsystem <strong>co</strong>ntrols to the electrical supply must be through a<strong>co</strong>mmon isolator.Isolation should preferably be by a double pole switchedfused spur box having a minimum <strong>co</strong>ntact separation of3mm on each pole. The fused spur box should be readilyaccessible and preferably adjacent to the boiler. It should beidentified as to its use.A fused three pin plug and shuttered socket outlet may beused instead of a fused spur box provided that:a) They are not used in a room <strong>co</strong>ntaining a fixed bath orshower.b) Both the plug and socket <strong>co</strong>mply with the current issue ofBS1363.10.3 Mains Voltage System ControlsWARNING: UNDER NO CIRCUMSTANCES MUSTANY MAINS VOLTAGE BE APPLIED TO ANY OF T<strong>HE</strong>TERMINALS ON T<strong>HE</strong> <strong>24</strong>V CONNECTION PLUG.Connect mains supply and system <strong>co</strong>ntrols as diagram 10.4.External <strong>co</strong>ntrols should be fitted in ac<strong>co</strong>rdance with the rulesin force.10.4 Electrical Connections - TestingCarry out preliminary electrical system checks as below:1. Test insulation resistance to earth of mains cables.2. Test the earth <strong>co</strong>ntinuity and short circuit of cables.3. Test the polarity of the mains.10.1 Installer InterfaceGain access to the Installer Interface by removing thesecuring screw, see diagram 10.1.Remove the cable securing clip which will release the InstallerInterface cap, see diagram 10.1.Release the cable gland, see diagram 10.2, then removethe test cables from the terminal strip and discard. Route themains supply and system cables through the strain relief and<strong>co</strong>nnect to the relevant plug dependant upon your choice ofsystem <strong>co</strong>ntrols.Initially if system <strong>co</strong>ntrols are not fitted then leave the wire linkin place between “L” and “R”, this will allow the appliance torun <strong>co</strong>ntinuously on heating.10.2 System Controls <strong>24</strong>VWARNING: UNDER NO CIRCUMSTANCES MUSTANY MAINS VOLTAGE BE APPLIED TO ANY OF T<strong>HE</strong>TERMINALS ON T<strong>HE</strong> <strong>24</strong>V CONNECTION PLUG.Connect the mains supply and system heating <strong>co</strong>ntrols e.g.room thermostat as diagram 10.3. External <strong>co</strong>ntrols should befitted in ac<strong>co</strong>rdance with the rules in force.IMPORTANT NOTEALL electrical <strong>co</strong>nnections to the boilermust be permanently fixed to a wall or asturdy support feature in a tidy manner.35


10 Electrical ConnectionREMOVAL AND REPLACEMENT OFINSTALLER INTERFACE AND CAP13201FLEXICOM COMBI <strong>24</strong>VROOM T<strong>HE</strong>RMOSTAT12611VIEW ON UNDERSIDE OF BOILERSECURINGSCREWDiagram 10.312612CABLESECURINGCLIPSECURINGSCREWDiagram 10.113137INSTALLERINTERFACECAPINSTALLERINTERFACEELECTRICALCONNECTIONTERMINALPLUGSSTRAINRELIEFCABLE GLANDDiagram 10.2Diagram 10.436


11 Commissioning11.1 Pre-filling the Heating CircuitRefer to diagram 11.11. Ensure that the flexible hose is <strong>co</strong>nnected to the doublecheck valve by tightening the knurled nut marked ‘E’.2. Ensure that the water <strong>co</strong>cks are securely tightened onto thejig blanking plugs.3. Open the Central Heating Flow and Return <strong>co</strong>cks marked‘A’ using a screwdriver or a 4mm allen key - slot in line withthe axis of the <strong>co</strong>ck (shown closed in diagram).4. Open the Domestic Cold Water <strong>co</strong>ck marked ‘B’ using ascrewdriver or a 3mm allen key - slot in line with the axis ofthe <strong>co</strong>ck (shown closed in diagram).NOTE: A manometer kit accessory, part no. 0020016995 isavailable to monitor system pressure during filling, this shouldbe attached to the drain point <strong>co</strong>nnection marked ‘C’ and thedrain point opened to enable a reading of the system pressureto be taken. If the manometer kit is not used caution shouldbe taken not to overpressurise the system.5. Open the two filling taps marked ‘D’ by rotating themthrough 90 o to fill the heating system to a pressure of1.0bar. Close the two filling taps marked ‘D’.6. Vent all air from the system - repeat step 5 as neccessaryuntil the system is full and all the air has been removed.7. Close the Domestic Cold Water <strong>co</strong>ck marked ‘B’ using ascrewdriver or a 3mm allen key (shown closed in diagram).8. Close the Central Heating Flow and Return <strong>co</strong>cks marked‘A’ using a screwdriver or a 4mm allen key (shown closedin diagram). If the manometer kit was used, close drainpoint marked ‘C’ and remove the manometer.9. To <strong>co</strong>mply with the water regulations the flexible hose mustbe dis<strong>co</strong>nnected from the double check valve - undo theknurled nut marked ‘E’ and pull the flexible hose from thedouble check valve.11.2 Filling the SystemWith the boiler in place:1. Ensure that the flexible hose is <strong>co</strong>nnected to the doublecheck valve by tightening the knurled nut marked ‘E’.2. Open the Central Heating Flow and Return <strong>co</strong>cks marked‘B’ using a screwdriver or a 4mm allen key - slot in line withthe axis of the <strong>co</strong>ck (shown closed in diagram).3. Open the Domestic Cold Water <strong>co</strong>ck marked ‘B’ using ascrewdriver or a 3mm allen key - slot in line with the axis ofthe <strong>co</strong>ck (shown closed in diagram).4. Switch on the appliance.Set the Central Heating temperature and the Domestic HotWater temperature to OFF by pressing the MODE buttonon the User Interface until it shows the appropriate symbolor and then pressing the - (minus) SELECTOR°C button.bar °CThe display bar will now permanently show system pressure.5. Open the two filling taps marked ‘D’ by rotating themthrough 90 o to fill the heating system to a pressure of1.0bar. Close the two filling taps marked ‘D’.6. Vent all air from the system - repeat step 5 as neccessaryuntil the system is full and all the air has been removed.7. After filling is <strong>co</strong>mplete set the Central Heating temperatureand the Domestic Hot Water temperature to the desiredlevel using the MODE and + (plus) SELECTOR buttons asdescribed above.8. To <strong>co</strong>mply with the water regulations the flexible hose mustbe dis<strong>co</strong>nnected from the double check valve - undo theknurled nut marked ‘E’ and pull the flexible hose from thedouble check valve.11.3 Filling Domestic Water CircuitFully open any valves in the domestic water supply to theboiler.Open the domestic water isolation valve, slot in line with thelength of the valve (shown closed in diagram).Open all hot water taps in turn and close them when waterflows. Check for water soundness of the <strong>co</strong>mplete domesticwater system.The water flow rate is restricted by a restrictor factory fitted tothe boiler.11.4 Re-pressurising System1. Ensure that the flexible hose is <strong>co</strong>nnected to the doublecheck valve by tightening the knurled nut marked ‘E’.2. Open the two filling taps marked ‘D’ by rotating themthrough 90 o to fill the heating system to a pressure of1.0bar. Close the two filling taps marked ‘D’.3. Vent all air from the system - repeat step 2 as neccessaryuntil the system is full and all the air has been removed.4. To <strong>co</strong>mply with the water regulations the flexible hose mustbe dis<strong>co</strong>nnected from the double check valve - undo theknurled nut marked ‘E’ and pull the flexible hose from thedouble check valve.ADBC13133DAGAS INLETPRESSURETEST POINTEDiagram 11.137


11 Commissioning11.5 Initial LightingThe lighting procedure of the boiler is fully automated.Check that all external <strong>co</strong>ntrols are calling for heat.The digital display will show water temperature in centralheating demand. The appliance will enter a self checkingroutine then the fan should start and the ignition will<strong>co</strong>mmence.If the burner fails to light the fan will stop. Initially this may bedue to air in the gas supply line. The boiler will automaticallyhave five attempts at ignition.If the burner fails to ignite the display will show F1.Depress the ‘reset’ button on the fascia to clear the displayand repeat the ignition sequence.Once the system has been purged of air set the hot waterto the desired temperature by using the MODE and + (plus)SELECTOR buttons.Open a hot water tap, the diverter valve motor will move tohot water supply and the display will read domestic hot watertemperature.Check that hot water is available and then close the hot watertap.Set the Central heating water temperature to the desiredtemperature by using the MODE and + (plus) SELECTORbuttons.The appliance will then <strong>co</strong>ntinue to fire in central heating untilthe user <strong>co</strong>ntrols are satisfied or there is another demandmade for hot water.NOTE: After ignition in central heating demand the boiler willramp slowly to full rate rather than going immediately to fullrate. This is an adaptive feature to <strong>co</strong>pe with small systemrequirements.11.6 TestingShould any doubt exist about the gas rate, check it usingthe gas meter test dial and stop watch at least 10 minutesafter the burner has lit, making sure that all other gas burningappliances and pilot lights are off.It should be noted that this appliance will modulate the heatinput ac<strong>co</strong>rding to demand. This may affect the gas ratesmeasured if the appliance reaches its operating temperatureduring the measurement.The approximate gas rates:<strong>24</strong>cx : 1.9m3/h (68ft3/h)<strong>30</strong>cx : 2.6m3/h (92ft3/h)The gas valve is factory set for natural gas (G20) and shouldneed no adjustment. It should be checked that the supplypressure is 20mbar when the boiler is firing at full rate. Thiscan be achieved by turning on several hot water taps andchecking the inlet pressure at the pressure test point on thegas inlet <strong>co</strong>ck, see diagram 11.1. Turn taps off and dis<strong>co</strong>nnectpressure gauge.In the unlikely event that the gas valve needs adjusting,refer to section 12.6. Re-setting of the gas valve requiresa <strong>co</strong>mbustion analyser and any adjustment should only becarried out by a <strong>co</strong>mpetent person.NOTE: The burner pressure cannot be measured at the gasvalve as it is altered by the suction of the fan and modulatedac<strong>co</strong>rding to demand.11.7 Testing - Heating SystemCheck that all external <strong>co</strong>ntrols are calling for heat. The boilerwill fire automatically. Fully open all radiator valves, flow<strong>co</strong>ntrol valve, if fitted, see diagram 4.1.Balance the radiators as required and if fitted adjust valve togive the required system differential. Turn off all radiators thatcan be shut off by the user and check to see if less than themaximum differential allowed of 20 o C can be achieved acrossflow and return.The pump has two speeds and can be adjusted depending onthe requirements of the central heating system, see diagram4.2.The appliances have an inbuilt automatic adjustable bypassvalve. The pressure can be adjusted between approx 1.5and 3.5mH2O but is factory pre-set to approx 2.5mH2O.The pressure changes by approx 0.1mH2O for each full turnof the bypass screw, see diagram 11.2. Turning clockwiseincreases the pressure and turning anti-clockwise decreasesthe pressure.Allow the system to reach maximum temperature then switchoff the boiler by isolating from the electrical supply.Drain the entire system rapidly whilst hot, using the drain tapat the lowest part of the system. Fill and vent the system asdescribed previously in section 11.2.Lock or remove the handle from <strong>co</strong>ntrol valve, if fitted.11.8 CompletionAdjust the boiler temperature <strong>co</strong>ntrol and any system <strong>co</strong>ntrolsto their required settings. In addition it is necessary to<strong>co</strong>mplete the “Benchmark” logbook.For IE, it is necessary to <strong>co</strong>mplete a “Declaration ofConformity” to indicate <strong>co</strong>mpliance to I.S.813. An example ofthis is given in the current edition of I.S.813.Testing Flue Gases: If any doubt exists that the flueproducts are not exhausting <strong>co</strong>rrectly, investigate by use of agas analyser (FGA).AUTOMATICBYPASS VALVEBYPASS SCREW1<strong>30</strong>72Diagram 11.238


11 Commissioning11.9 Instruct the UserInstruct and demonstrate the lighting procedure and advisethe user on the safe and efficient operation of the boiler.Instruct on and demonstrate the operation of any heatingsystem <strong>co</strong>ntrols.Advise the user on the use and maintenance of any scalereducer and pass on any relevant instructional documents.Advise that to ensure the <strong>co</strong>ntinued efficient and safeoperation of the boiler it is re<strong>co</strong>mmended that it is checkedand serviced at regular intervals. The frequency of servicingwill depend upon the installation <strong>co</strong>nditions and usage, but ingeneral, once a year should be enough.Draw attention, if applicable, to the current issue of the GasSafety (<strong>Installation</strong> and Use) Regulations, Section 35, whichimposes a duty of care on all persons who let out any property<strong>co</strong>ntaining a gas appliance in the UK.The user shall not interfere with or adjust sealed <strong>co</strong>mponents.It is the Law that any servicing is carried out by a <strong>co</strong>mpetentperson.Advise the user that, like all <strong>co</strong>ndensing boilers this appliancewill produce a plume of <strong>co</strong>ndensation from the flue terminal in<strong>co</strong>ol weather. This is due to the high efficiency and hence lowflue gas temperature of the boiler.Advise the user of the precautions necessary to preventdamage to the system, boiler and the building, in the event ofthe heating system being out of use during frost or freezing<strong>co</strong>nditions.Advise the user that the permanent mains electrical supplySHOULD NOT be switched off, as the built in frost protectionand pump/valve saver program would not be operable.Reminder, leave these instructions and the ‘Benchmark’logbook with the user.39


12 ServicingImportant NotesTo ensure the <strong>co</strong>ntinued efficient and safe operation of theboiler it is re<strong>co</strong>mmended that it is checked and serviced atregular intervals. The frequency of servicing will depend uponthe particular installation and usage, but in general once ayear should be enough.It is the Law that any servicing is carried out by a <strong>co</strong>mpetentperson.When replacing a part on this appliance, use only spare partsthat you can be assured <strong>co</strong>nform to the safety and performancespecification that we require. Do not use re<strong>co</strong>nditionedor <strong>co</strong>py parts that have not been clearly authorised by Glowworm.Before <strong>co</strong>mmencing with a service or replacement of partsthe boiler should be isolated from the electrical supply and thegas supply should be turned off at the gas service <strong>co</strong>ck, seediagram 12.1.Testing Flue Gases: If any doubt exists that the flue productsare not exhausting <strong>co</strong>rrectly, investigate by use of a gasanalyser (FGA).Measurement of the products of <strong>co</strong>mbustion can be achievedby removing the front panel as described in section 12.1 andthen <strong>co</strong>nnecting a probe to the <strong>co</strong>mbustion analyser test pointon the flue elbow, refer Combustion Check.GAS SERVICE COCK1<strong>30</strong>14PRESSURETEST POINTDiagram 12.11<strong>30</strong>28IMPORTANT NOTE: Products of <strong>co</strong>mbustion will be dischargedwhen the cap is removed. It is important to replacethe cap immediately.Combustion CheckA <strong>co</strong>mbustion check should not be necessary unless a gascarrying <strong>co</strong>mponent has been replaced or the <strong>co</strong>mbustionsetting is suspect.Connect a CO 2<strong>co</strong>mbustion analyser to the test point, seediagram 12.2.Turn on the gas service <strong>co</strong>ck, see diagram 12.1.Turn on the electrical supply, the appliance will begin the ignitionsequence.A <strong>co</strong>mpetent person only should carry out any adjustmentto the gas valve, refer to diagram 12.3.Monitor the <strong>co</strong>mbustion reading and at max rate the readingshould be 9.3% ± 0.5.COMBUSTION ANALYSERTEST POINTDiagram 12.212776If adjustment proves necessary then proceed as follows:Press the “reset” button on the <strong>co</strong>ntrols fascia, release andimmediately press and hold in the “+” button. After approximately5 se<strong>co</strong>nds “Hi” will be displayed. Pressing the modebutton when “Hi” is selected will force the boiler to maximumrate, the display will flash between “Hi” and the “default display”this will indicate the boiler has been forced to maximum.Adjust the maximum rate CO 2with the throttle to 9.3%. (Rotateanti-clockwise to increase).To exit the check sequences press the “mode” and “+” buttonssimultaneously, this will reset the boiler to the default display.OFFSETOFFSETPRESSURETHROTTLEDiagram 12.340


12 ServicingMonitor the <strong>co</strong>mbustion reading and at min rate the readingshould be 9.3% ± 0.5.If adjustment proves necessary then proceed as follows:Press the “reset” button on the <strong>co</strong>ntrols fascia, release andimmediately press and hold in the “+” button. After approximately5 se<strong>co</strong>nds “Hi” will be displayed. Pressing the “+” or “-”buttons will cycle between “Hi” and “Lo”. Pressing the modebutton when “Lo” is selected will force the boiler to minimumrate, the display will flash between “Lo” and the “default display”this will indicate the boiler has been forced to minimum.Refer to diagram 12.3, remove the offset screw <strong>co</strong>ver.Adjustment of the CO 2at minimum rate is very <strong>co</strong>arse socarefully adjust the CO 2with the offset adjustment to 9.3%.(Rotate clockwise to increase).Refit the offset <strong>co</strong>ver and the cap on the test point.To exit the check sequences press the “mode” and “+” buttonssimultaneously, this will reset the boiler to the default display.12.1 GeneralFRONTPANELSECURINGSREWSDiagram 12.41<strong>30</strong>93 12672Removal of the front panel is required for all routine servicing.Remove the two screws on the underside of the front panel,see diagram 12.4 and lift off the retaining pins.For access inside the appliance a Torx T20 drive is requiredor alternatively a flat blade screwdriver can be used.Unless stated otherwise any part removed during servicingshould be replaced in the reverse order to removal.Servicing should always include the removal of any debrisfrom the <strong>co</strong>ndensate pipe and siphon.After <strong>co</strong>mpleting any servicing of gas carrying <strong>co</strong>mponents,ALWAYS test for gas soundness and carry out a functionaltest of the <strong>co</strong>ntrols.12.2 Flue HoodEase the securing clips away from the sump to release theretaining catch then push the flue hood up to disengage fromthe sump, see diagram 12.5.12673To remove, swivel flue hood 90 0 and pull down and out, seediagram 12.5.Check seal for wear or damage and replace if necessary.IMPORTANT: Do not allow fixings, nuts, screws, etc. to fallinto the open flue hood sump, use a temporary <strong>co</strong>ver whilstremoving any parts.Diagram 12.541


12 Servicing12.3 BurnerDis<strong>co</strong>nnect the gas supply at the gas valve and electrical<strong>co</strong>nnections, see diagram 12.6.The Silencer (front) is a push fit, so there is no need for toolsto remove or fit, see diagram 12.7.Release the igniter unit support bracket, see diagram 12.8.Remove the fan retaining bracket.To ease removal of the securing nut from the fan retainingbracket, a flat bladed screwdriver can be used in the positionshown and gently levered down as indicated, see diagram12.9.Remove the fan and gas valve assembly.The silencer (rear) is a push fit so no tools are required for itsremoval or fitting, see diagram 12.10.ELECTRICALCONNECTIONSIGNITERUNITIGNITIONLEADSPADECONNECTORSECURINGSCREWS (2)12662Diagram 12.8SECURINGSCREW (3)1266412814FANFANRETAININGBRACKETGASVALVETUBINGNUTELECTRICALCONNECTION(removed)GASPIPEDiagram 12.6SECURINGNUTDiagram 12.9SILENCERFRONT13128SILENCERREARFAN/GAS VALVEASSEMBLY1<strong>30</strong>07Diagram 12.7Diagram 12.1042


12 ServicingCheck the spark electrode gap is 4mm. Clean and adjust asnecessary, diagram 12.11.It should not be necessary to remove the spark electrode fromthe burner during servicing.Remove the flanged nuts and studs that secure the burner,note that two studs at the rear also hold the fan clampingbracket, see diagram 12.12.SECURINGNUTS (6)FAN CLAMPINGBRACKET12815Clean the burner with a soft brush taking great care not todamage the surface of the burner. DO NOT use wire or sharpinstruments to clean the mesh of the burner.NOTE: The burner gasket should be inspected but will notneed replacing unless there are signs of wear or damage.Follow the tightening sequence when re-fitting the burner, seediagram 12.12.12.4. Heat ExchangerBURNERRemove loose debris from inside the heat exchanger using asoft brush and vacuum cleaner.1<strong>30</strong>06Carefully flush by spraying water into the heat exchanger, anyremaining debris should pass through the <strong>co</strong>ndensate trap(Ensure the water is kept away from electrical <strong>co</strong>mponents).12.5 Condensate TrapThe <strong>co</strong>ndensate trap does not normally need removing duringservicing unless the service fill level is at full, see diagram12.13.Diagram 12.12To flush the <strong>co</strong>ndense drain carefully pour water into the heatexchanger and check that water flows freely to drain.12.6 Casing panel seal checkCheck the <strong>co</strong>ndition of the seal and replace if worn ordamaged.12810SPARKELECTRODE12813SECURINGSCREWSECURINGNUTSEARTH TAG4mm<strong>HE</strong>ATEXCHANGERSPARK GAPCONDENSATETRAPSERVICEFILL LEVELDiagram 12.11Diagram 12.1343


13 Fault FindingNOTE:Before trying to operate the boiler make sure that :• All gas supply <strong>co</strong>cks are open and that the gas supply hasbeen purged of air.• There is a permanent mains supply to the boiler.• There is a heating demand from the external <strong>co</strong>ntrols.WARNINGAlways isolate the boiler from the electrical supply before carryingout any electrical replacement work.Always check for gas soundness after any service work.Electrical TestingShould there be any doubt about the voltage supply to any ofthe <strong>co</strong>mponents, it is possible to carry out a simple electricaltest.Important: On <strong>co</strong>mpletion of the Service/Fault Finding taskswhich have required the breaking and remaking of the electrical<strong>co</strong>nnections the earth <strong>co</strong>ntinuity, polarity, short circuit andresistance to earth checks must be repeated using a suitablemultimeter.To carry out the electrical test, gain access, as follows:Hinge down the <strong>co</strong>ntrol box and unclip the rear <strong>co</strong>ver to gainaccess. Refer to the wiring diagram 13.1 and fault findingcharts, diagrams 13.2 to 13.6.44


13 Fault Finding12716<strong>HE</strong>ATING FLOWT<strong>HE</strong>RMISTORGASCONTROLVALVEFANWATERPRESSURESENSORIGNITERUNIT<strong>HE</strong>ATINGRETURNT<strong>HE</strong>RMISTORIGNITIONELECTRODEPUMPD.H.W.FLOWT<strong>HE</strong>RMISTORTHREEWAYVALVEFLOWSENSORN L R F2<strong>30</strong>V~50HzMAINSSUPPLYEXTERNALCONTROLSMAIN CONTROLBOARDAPPLIANCEINTERFACEBOARDCOMBI <strong>CX</strong>Diagram 13.145


13 Fault FindingSTARTCENTRAL <strong>HE</strong>ATING1<strong>30</strong>12Is there anything displayedon the LCD?NoIs the power switched on?NoSwitch the power onYesYesIs the display flashing 'F'?YesConsult the Fault TableCheck wires betweenmain PCB and displayPCBNoYesInitiate a CH demand.Does the boiler light?YesNoAdjust CH setpoint to 82 0 Cand make sure external<strong>co</strong>ntrol is calling for ademand. Does the boilerlight?YesSuccessful ignitionNoYesDoes the display flash 'F'during or after a CHdemand?NoNoNoConsult the State TableNormal operationSTARTDHW1<strong>30</strong>15Is there anything displayedon the LCD?NoIs the power switched on?NoSwitch the power onYesYesIs the display flashing 'F'?YesConsult the Fault TableCheck wires betweenmain PCB and displayPCBNoYesInitiate a DHW demand.Does the boiler light?YesNoAdjust DHW setpoint to60 0 C and turn on a hotwater tap.Does the boiler light?YesSuccessful ignitionNoYesDoes the display flash 'F'during or after a CHdemand?NoNoNoConsult the State TableNormal operationDiagram 13.<strong>24</strong>6


13 Fault Finding1<strong>30</strong>10Diagram 13.347


13 Fault FindingState list - To access the state lists the ‘-’ button must be pressed for longer than 5 se<strong>co</strong>nds until itbegins to flash ‘S’ and then a number to indicate the state. The state numbers are given below.STATE LISTS1<strong>30</strong>11Central heating mode (Priority 3)S.00 no heating requiredS.01 fan pre-runS.02 pump pre-runS.03 ignitionS.04 burner onS.05 pump / fan overrunS.06 fan overrunS.07 pump overrunS.08 Anti cycling periodDomestic hot water mode (Priority 2)S.10 domestic hot water demandS.11 fan pre-runS.13 ignitionS.14 burner onS.15 pump / fan overrunS.16 fan overrunS.17 pump overrunPossible CausesCycling / preheat mode (Priority 1)S.20 domestic hot water cycling mode activeS.21 fan pre-runS.22 Pump pre runS.23 ignitionS.<strong>24</strong> burner onS.25 pump / fan overrunS.26 fan overrunS.27 pump overrunS.28 Anticycling periodSpecial cases of status messagesS.<strong>30</strong> No Heating demand from external <strong>co</strong>ntrols 2<strong>30</strong>V Check wiring in external <strong>co</strong>ntroller.Check wiring at Installer Interface.S.31 summer mode Check CH setpoint / Check external <strong>co</strong>ntrolsS.32 Antifreeze active – fan speed variation too high Check fan <strong>co</strong>nnection.– waiting during blocking functionS.34 frost protection active (Priority 4) Temperature below 8 O C - check thermistor<strong>co</strong>nnection if this is not true.S.36 No Heating demand from external <strong>co</strong>ntrols <strong>24</strong>V Check wiring in external <strong>co</strong>ntroller.Check wiring at Installer Interface.S.42 Accesory Module is blocking burner operation Check accessory module.S.53 waiting time: temperature difference flow- return sensor too high (Check thermistor fit)S.54 waiting time: no water in system, temperature(gradient error) rise flow / return sensor too highCheck flow & return thermistor <strong>co</strong>nnections to pipes.Check harness <strong>co</strong>nnection to thermistor.Check harness wires are not trapped between anyinternal <strong>co</strong>mponents.Check flow & return thermistor <strong>co</strong>nnections to pipes.Check harness <strong>co</strong>nnection to thermistor.Check harness wires are not trapped between anyinternal <strong>co</strong>mponents.S.76 Waiting period – pressure sensor Check system pressure - default display.S.96 Return-Sensor check is running, demand Check return thermistor <strong>co</strong>nnection to pipe.(DHW or heating) is blockedCheck harness <strong>co</strong>nnection to thermistor.S.97 Water pressure sensor check is running, Check <strong>co</strong>nnection to pressure sensor.demand (DHW or heating) is blockedCheck pump has not seized.S.98 Flow / Return - sensor check is running, demand(DHW or heating) is blockedCheck flow & return thermistor <strong>co</strong>nnections to pipes.Check harness <strong>co</strong>nnection to thermistor.Check harness wires are not trapped between anyinternal <strong>co</strong>mponents.Diagram 13.448


13 Fault FindingTo enter the diagnostics menu follow the procedure below:-Press and hold the ‘ ’ and ‘+’ buttons for approx 5 se<strong>co</strong>nds until the screen changes. Use the ‘+’ or ‘-’ buttonto select the number 96, this is the password. Hold the ‘ ’ for approx 5 se<strong>co</strong>nds when 96 is selected, when thescreen changes release the button. The screen will flash between ‘L1’ and a number. ‘L1’ indicates you have level1 access, the number indicates the diagnostic number below. Use the ‘+’ and ‘-’ to cycle through the selectionsbelow. To select a diagnostic number press the ‘ ’ button when the <strong>co</strong>rrect number is selected. The display willshow the parameter value of the diagnostic number selected. To return to the diagnostic number selector simplypress the ‘ ’ button. To change the parameter use the + or - buttons. Once the value has been changed it mustbe saved by holding the ‘ ’ button for approximately 5 se<strong>co</strong>nds. This will return to the diagnostic number selector.DIAGNOSTIC CODES - LEVEL 1Installer Access1<strong>30</strong>75Domestic hot water flow temperature reading(<strong>co</strong>mbination boiler only)N/AFlow temperature setpointDomestic hot water setpointN/AN/AN/ADomestic hot water demandN/AN/ADiagram 13.549


14 Replacement of Parts14.1 GeneralReplacement of parts must be carried out by a <strong>co</strong>mpetentperson.Before replacing any parts the boiler should be isolated fromthe mains electric supply and the gas should be turned off atthe service <strong>co</strong>ck on the boiler, see diagram 14.1.Ensure that <strong>co</strong>mponents with electrical <strong>co</strong>nnections aredis<strong>co</strong>nnected before removal.Unless stated otherwise parts are replaced in the reverseorder to removal.After replacing any parts always test for gas soundness and ifnecessary carry out functional test of the <strong>co</strong>ntrols.For replacement of parts the front casing of the boiler willneed to be removed. To remove undo the two screws on theunderside of the front casing and lift off.The side panels can be removed to aid replacement of parts.To hinge a side panel undo and remove the four screwssecuring each side panel to the boiler, two below and two atthe top.14.2 Draining of Boiler Heating CircuitDrain down the Heating Circuit of the boiler only, by closingthe heating flow and return isolating valves on the wallmounting jig. Attach a length of hose to the drain point andopen the drain valve, see diagram 14.1.After replacing parts, close the drain valve and remove thehose. Open the heating flow and return isolating valves andrefill, vent and pressurise the heating circuit, refer to section11.DRAINPOINTCH FLOW & RETURNISOLATING VALVESDRAINVALVEGASISOLATIONVALVEDRAINVALVE1<strong>30</strong>26DRAINCOLD POINTWATERISOLATIONVALVEDiagram 14.112665Check for leaks.14.3 Draining of Boiler Hot Water CircuitDrain the Domestic Hot Water circuit by closing the <strong>co</strong>ld-waterisolation valve on the wall mounting jig, see diagram 14.1.SPACERLOCKINGSCREWOpen one or more hot water taps to drain the hot water circuit.After replacing parts open the <strong>co</strong>ld-water isolation valve andslowly open a hot water tap to remove air. Close the hot watertap and check for any leaks.EXPANSION VESSELRETAINING BRACKET14.4 Igniter UnitFor access, refer to section 14.1.EXPANSION VESSELRemove ignition lead and electrical <strong>co</strong>nnections then removeigniter unit by removing two securing screws, see diagram12.8.14.5 Ignition LeadFor access, refer to section 14.1.Pull the spark plug style <strong>co</strong>nnector off the spark electrodeand the spade <strong>co</strong>nnector <strong>co</strong>nnected to the igniter unit, seediagram 12.11.14.6 Silencer Assembly (front)For access, refer to section 14.1.COUPLINGDiagram 14.2Pull forwards to remove.The silencer is a push fit so no tools or fixings are required forits removal or fitting, see diagram 12.7.50


14 Replacement of Parts14.7 Gas ValveRemove the three securing screws, holding the gas valve tothe fan, see diagram 12.6.Remove the gas valve.After re-fitting check the <strong>co</strong>mbustion CO 2and adjust ifnecessary, refer to section 12, Combustion Check.After assembly test for gas soundness and purge inac<strong>co</strong>rdance with the current issue of BS6891or in IE, thecurrent edition of I.S.813 “Domestic Gas <strong>Installation</strong>s”.14.8 Flue HoodFor access, refer to section 14.1.Pull the flue hood securing clips away from the flue hoodsump and push flue hood up slightly towards flue hood top,see diagram 12.5.To remove swivel flue hood 90 0 and pull down and outtowards front of boiler.14.9 FanFor access, refer to section 14.1.Remove the gas valve as described in the relevant parts ofsection 14.7.Remove the securing nut holding the fan retaining bracket,lift front of bracket away from stud and pull forward to releasethe fan, see diagram 12.9, check and replace any seals orgaskets if necessary.14.10 Expansion VesselFor access, refer to section 14.1.Drain the boiler heating circuit, refer to section 14.2.Undo the <strong>co</strong>upling at the base of the vessel, see diagram14.2.Remove the locking screw and spacer from the retainingbracket at the top of the expansion vessel. Whilst holdingand also pushing down slightly on the vessel, remove theexpansion vessel retaining bracket by unhooking and slidingforward.The expansion vessel can now be removed by sliding itforward clear of its support guides.When re-fitting a new gasket will be required between theexpansion vessel and <strong>co</strong>upling.Refill, vent and pressurise the boiler.Check for leaks.14.11 Fan/Gas valve assemblyFor access, refer to section 14.1.Undo the tubing nut to remove the gas valve from the gas pipeand any electrical <strong>co</strong>nnections, see diagram 12.6.Remove the securing nut holding the fan retaining bracket,press down on burner to ease removal of securing nut. Slideout the fan retaining bracket.Lift front of bracket away from stud and pull forward to releasethe fan, see diagram 12.9.Lift fan/gas valve assembly up and forward away from locatingstuds.Remove fan gasket and replace if necessary.To replace the fan and retaining bracket <strong>co</strong>rrectly, insert intoslots on fan clamping bracket, see diagram 12.12 and locateonto lugs on the burner.14.12 Silencer assembly (rear)For access, refer to section 14.1.Remove the fan/gas valve assembly, see relevant sections.Pull Silencer rear away from fan/gas valve assembly.The rear silencer is a push fit so no tools or fixings arerequired for its removal or fitting, see diagram 12.10.14.13 Spark ElectrodeFor access, refer to section 14.1.Remove the spark plug lead and earth lead.Remove the two securing nuts, see diagram 12.11.Withdraw the spark electrode by slowly pulling up and leaningit forward towards the centre of the heat exchanger to ensurethat the electrode does not foul on the hole in the burnercasing.Check spark gap.14.14 BurnerFor access, refer to section 14.1.Remove igniter unit, flue hood, fan and gas valve assemblyand spark electrode lead, refer to relevant sections.Remove the flanged nuts and studs that secure the burner,note that two studs at the rear also hold the fan clampingbracket, see diagram 12.12.NOTE: The burner gasket should be inspected but will notneed replacing unless there are signs of wear or damage.IMPORTANT: Do not allow fixings, nuts, screws, etc. to fallinto the open flue hood sump, use a temporary <strong>co</strong>ver whilstremoving any parts.51


14 Replacement of Parts14.15 Condensate TrapFor access, refer to section 14.1.1<strong>30</strong>27Remove the drain outlet pipe from the base of the trap. Removethe <strong>co</strong>ndensate drain securing screw and carefully pullthe trap forward, see diagram 12.13.On the <strong>co</strong>ndensate trap there is a key symbol that should bein line with the locked padlock symbol on the <strong>co</strong>ndense drain.To remove the trap turn in the direction indicated, see diagram12.13, toward the unlock symbol and carefully pull down clearof the <strong>co</strong>ndense drain.Remove any solids found in the <strong>co</strong>ndense trap.Flush water through the trap to remove any remaining solids.Check for any debris in the outlet pipe of the <strong>co</strong>ndensate drainand clean as necessary.Reassemble and refit the <strong>co</strong>ndense trap.14.16 Heating Flow ThermistorFor access refer to section 14.1.Remove the silencer front, fan/gas valve assembly and fluehood for access. See relevant sections.Refer to diagram 14.3.Remove the electrical <strong>co</strong>nnections from the thermistor.Remove the retaining clip from the flow pipe.Remove the thermistor from the retaining clip.Note that the polarity of the wiring to thermistors is unimportant.FLOW PIPE<strong>HE</strong>ATING FLOWT<strong>HE</strong>RMISTORDiagram 14.31<strong>30</strong>60<strong>HE</strong>AT RETURNT<strong>HE</strong>RMISTOR14.17 Heating Return ThermistorFor access, refer to section 14.1.Refer to diagram 14.4.Remove the electrical <strong>co</strong>nnections from the thermistor.Remove the retaining clip from the return pipe.Remove the thermistor from the retaining clip.Note that the polarity of the wiring to thermistor is unimportant.Diagram 14.452


14 Replacement of Parts14.18 Domestic Hot Water ThermistorFor access, refer to section 14.1.Refer to diagram 14.5.Remove the electrical <strong>co</strong>nnections from the thermistor.Remove the retaining clip from the DHW pipe.Remove the thermistor from the retaining clip.Note that the polarity of the wiring to thermistor is unimportant.DHW T<strong>HE</strong>RMISTOR1<strong>30</strong>6314.19 Plate-to-Plate Heat ExchangerFor access, refer to section 14.1.Drain the boiler heating circuit, refer to section 14.2.Refer to section 14.3 and drain the boiler hot water circuit.Refer to diagram 14.6.Remove the gas supply pipe from the gas service <strong>co</strong>ck andthe gas valve, refer to relevant parts of section 14.7.Diagram 14.5Remove the <strong>co</strong>ndensate trap as described in section 14.15.Remove the four screws securing the plate-to-plate heatexchanger to the hydroblock, see diagram 14.6.SECURINGSCREWS (4)SEALINGWAS<strong>HE</strong>RS (4)12820Remove the plate-to-plate heat exchanger.When replacing the plate-to-plate heat exchanger ensure thatthe four rubber sealing washers are fitted into the hydroblock.NOTE: The plate-to-plate heat exchanger only fits one wayround.Refill, vent and pressurise the boiler.Open the <strong>co</strong>ld-water isolation valve and slowly open a hotwater tap to remove air.Close the hot water tap and check for any leaks.Open the heating circuit isolation valves, re-pressurise thesystem as necessary, refer to diagram 14.1.PLATE TO PLATE<strong>HE</strong>AT EXCHANGERYDiagram 14.653


14 Replacement of Parts14.20 Pump (head only)For access, refer to section 14.1.12666Refer to section 14.2 and drain the boiler heating circuit.Refer to diagram 14.7.Remove the four cap head screws.Carefully remove the pump head together with cable. Do notstrain cable.Support the pump head, unscrew cable <strong>co</strong>ver at the side ofpump head and remove.Dis<strong>co</strong>nnect wiring from pump head.Re<strong>co</strong>nnect wiring to new pump head and fit <strong>co</strong>ver.Fit the new pump head with ‘O’ ring.Refill, vent and pressurise the boiler and check for leaks.PUMP<strong>HE</strong>ADCAP <strong>HE</strong>ADSCREW (4)CABLECOVERDiagram 14.7SECURINGCLIP1266714.21 Safety Discharge ValveFor access, refer to section 14.1.Refer to section 14.2 and drain the boiler heating circuit.Refer to diagram 14.8.Undo the safety discharge valve union and remove from thepipework.Remove the retaining clip and withdraw the safety dischargevalve.Fit new ‘O’ ring.Refill, vent and pressurise the boiler and check for leaks.SAFETYDISCHARGEVALVE14.22 Automatic Air VentFor access, refer to section 14.1.Refer to section 14.2 and drain the boiler heating circuit.Refer to diagram 14.9.Remove the retaining clip to release the automatic air vent.Fit the new automatic air vent and ‘O’ ring ensuring the ventcap is left loose.Refill, vent and pressurise the boiler and check for leaks.AUTOMATICAIR VENTRETAININGCLIPDiagram 14.812669Diagram 14.954


14 Replacement of Parts14.23 Flow SensorFor access, refer to section 14.1.1<strong>30</strong>64Refer to section 14.3 and drain the boiler hot water circuit.Refer to diagram 14.10.Undo the brass securing nut on the domestic <strong>co</strong>ld waterreturn pipe.Remove the securing clip between the hydroblock and theflow sensor.FLOWSENSORRETAININGCLIPSRemove the electrical <strong>co</strong>nnection to the flow sensor.Remove the securing clip holding the brass elbow to the flowsensor.Partially withdraw the flow sensor to allow removal of the electrical<strong>co</strong>nnection before full removal of the sensor.Remove flow sensor.Fit new ‘O’ rings.After replacing the flow sensor, open the <strong>co</strong>ld-water isolationvalve and slowly open a hot water tap to remove air.DOMESTICCOLD WATERRETURNDiagram 14.10Close the hot water tap and check for any leaks.1266814.<strong>24</strong> Three Way ValveFor access, refer to section 14.1.Refer to section 14.2 and drain the boiler heating circuit.Refer to section 14.3 and drain the boiler hot water circuit.Refer to diagram 14.11.Undo the nut retaining the heating return isolation valve to thefixing jig. Be careful not to lose the sealing washer.Undo the securing nut on the underside of the fixing jig andpull the pipe away from the three-way valve assembly.Fully remove the three securing screws and pull the three-wayvalve assembly towards the left to disengage from the hydroblock.(Ensure that the original o-ring has not been retained inthe hydroblock.)Fit the new three-way valve assembly.SECURINGSCREW (3)RETAININGCLIPTHREE WAYVALVEVIEW SHOWINGUNDERSIDE OFFIXING JIGRETAININGCLIPReassemble, refill, vent and pressurise the boiler and checkfor leaks.ISOLATION VALVERETAINING NUTPIPE SECURING NUTDiagram 14.1155


14 Replacement of Parts14.25 Heat ExchangerFor access, refer to section 14.1.SECURING SCREW12812Remove silencer front, flue hood, gas valve / burner assembly,spark electrode lead, burner and <strong>co</strong>ndense trap.Refer to section 14.2 and drain the boiler heating circuit.Refer to section 14.3 and drain the boiler hot water circuit.Remove the retaining clip from the flexible hose <strong>co</strong>nnectioninto the brass elbow on the lower left hand side of the heatexchanger. Detach the flexible hose.Remove screws securing the heat exchanger, one on top andone underneath the heat exchanger, see diagram 14.12.Undo the knurled nut at the right hand side of the hydroblock.Remove the retaining clip from the flanged elbow at the righthand bottom of the heat exchanger.Remove the flow pipe.Lift up heat exchanger slightly to disengage it from its hangingbracket.Remove the heat exchanger by pulling forward and tiltingbackwards to ease removal <strong>co</strong>mplete with sump, return pipeand flanged elbows.14.26 Access to User interface and MainPCBFor access, refer to section 14.1.Hinge down the <strong>co</strong>ntrol box and unclip the rear <strong>co</strong>ver to gainaccess.Remove electrical <strong>co</strong>nnections from main PCB noting theirpositions for replacement.Unclip main PCB and remove, see diagram 14.13.Unclip user interface and remove.For replacement, see diagram 14.14 and ensure that the userinterface <strong>co</strong>nnection cable is refitted.NOTE: When re-fitting any of the <strong>co</strong>ntrol boards make sureyou support the <strong>co</strong>ntrol box to avoid straining hinges as youpush down and clip back into place.Z<strong>HE</strong>ATEXCHANGERFUSESECURINGSCREW Diagram 14.12RETAINING CLIPS1<strong>30</strong>03MAIN PCBRETAININGCLIPSDiagram 14.1356


14 Replacement of Parts14.27 Control BoxFor access, refer to section 14.1.Hinge down the <strong>co</strong>ntrol box and unclip the rear <strong>co</strong>ver to gainaccess.1<strong>30</strong>01USER INTERFACECONNECTION CABLERemove relevant electrical <strong>co</strong>nnections from main PCB andgrommets from the <strong>co</strong>ntrol box.IMPORTANT: Support the <strong>co</strong>ntrol box whilst undoing thehinges.Remove the hinge securing screws accessed from beneaththe boiler and remove the <strong>co</strong>ntrol box, see diagram 14.15.14.28 Fuse - Main PCB - Control BoxFor access, refer to section 14.26.The fuse is located at the top left hand <strong>co</strong>rner of the mainPCB, see diagram 14.13.14.29 Installer InterfaceRemove the Installer Interface securing screw accessed frombeneath the boiler.Carefully pull down the Installer Interface to remove, seediagrams 10.1 and 10.2.CONTROL BOXREAR COVERUSERINTERFACESECURINGSCREWDiagram 14.141<strong>30</strong>04HINGESECURINGSCREWCONTROLBOXHINGEDiagram 14.1557


15 Spare Parts15.1 Spare PartsWhen ordering spare parts, <strong>co</strong>ntact Glow-worm’s own service organisation using the telephone number on the inside front <strong>co</strong>ver ofthis booklet. Please quote the name of the appliance and serial number, to be found on the data label. If ordering from British Gasalso quote the G.C. number of the part.Key No. Part No. Description GC No1 0020020734 Fan XXXXXX2 0020020763 Igniter unit XXXXXX3 0020020781 Heating flow & return thermistor (2) XXXXXX4 0020014160 DHW thermistor XXXXXX5 0020020735 Gas valve XXXXXX6 0020020731 Electrode XXXXXX7 0020020728 Burner XXXXXX8 0020023826 User interface XXXXXX9 0020014402 Plate to plate heat exchanger <strong>24</strong>/<strong>30</strong>cx XXXXXX10 0020014180 Pump (head only) XXXXXX11 0020014174 Flow sensor XXXXXX12 0020023825 Main PCB XXXXXX13 0020014190 Water pressure sensor XXXXXX1251<strong>30</strong>3134678131211 109Diagram 15.158


16 Manual HandlingIMPORTANT. With regards to the Manual Handling Operations,1992 Regulations, the following lift operation exceeds there<strong>co</strong>mmended weight for a one man lift.General re<strong>co</strong>mmendations when handlingClear the route before attempting the lift.Ensure safe lifting techniques are used – keep back straight – bend usinglegs. Keep load as close to body as possible. Do not twist – repositionfeet instead. If 2 persons performing lift, ensure <strong>co</strong>-ordinatedmovements during lift. Avoid upper body/top heavy bending - do notlean forward/sideways. Re<strong>co</strong>mmend wear suitable cut resistant gloveswith good grip to protect against sharp edges and ensure good grip.Always use assistance if required.Removal of carton from delivery vanRe<strong>co</strong>mmend 2 person lift or 1 person with use of sack truck. If 1person is performing lift, straddle the load, tilt and place carton into positionon truck. Re<strong>co</strong>mmend secure appliance onto truck with suitablestraps. Ensure safe lifting techniques are used – keep back straight– bend using legs. Keep load as close to body as possible. If 2 personsperforming lift, ensure <strong>co</strong>-ordinated movements during lift. Always useassistance if required.Carriage of carton from point of delivery to pointof installation – ground floor.Re<strong>co</strong>mmend 2 person lift or 1 person with use of sack truck. If 1 personis performing lift, straddle the load, tilt and place carton into position ontruck. Re<strong>co</strong>mmend secure appliance onto truck with suitable straps.Ensure safe lifting techniques are used – keep back straight – bendusing legs. Keep load as close to body as possible. If 2 persons performinglift, ensure <strong>co</strong>-ordinated movements during lift. Clear the routebefore attempting the lift. If removing boiler from truck straddle the loadand tilt forwards to facilitate secure grip. Ensure safe lifting techniquesare used – keep back straight – bend using legs. Do not twist – repositionfeet instead. Take care to avoid trip hazards, slippery or wetsurfaces and when climbing steps and stairs. Always use assistance ifrequired.Carriage of carton from point of delivery to pointof installation – first or higher floor, cellar.Re<strong>co</strong>mmend 2-person lift or 1 person with use of sack truck. If 1 personis performing lift, straddle the load, tilt and place carton into position ontruck. Re<strong>co</strong>mmend secure appliance onto truck with suitable straps.Ensure safe lifting techniques are used – keep back straight – bend usinglegs. Keep load as close to body as possible. If 2 persons performinglift, ensure <strong>co</strong>-ordinated movements during lift. Avoid upper body/topheavy bending - do not lean forward/sideways. Clear the route beforeattempting the lift. If removing boiler from truck straddle the load andtilt forwards to facilitate secure grip. Ensure safe lifting techniques areused – keep back straight – bend using legs. Do not twist – repositionfeet instead. Take care to avoid trip hazards, slippery or wet surfacesand when climbing steps and stairs. Always use assistance if required.Carriage of carton from point of delivery to pointof installation – roofspace.Re<strong>co</strong>mmend 2-person lift. Ensure <strong>co</strong>-ordinated movements duringlift. Avoid upper body/top heavy bending - do not lean forward/sideways.Clear the route before attempting the lift. Take care to avoid triphazards, slippery or wet surfaces and when climbing steps and stairs.When transferring appliance into roofspace, re<strong>co</strong>mmend 1 person to bein roofspace to receive the appliance and other person to be below topass up and support appliance. Ensure safe lifting techniques are used– keep back straight – bend using legs. Keep load as close to body aspossible. Always use assistance if required. It is assumed safe access,flooring and adequate lighting are provided in the roof space. It isre<strong>co</strong>mmended a risk assessment of the roof space area be carried outbefore moving the appliance into the area to take into ac<strong>co</strong>unt access,stability of flooring, lighting and other factors, and appropriate measurestaken.Unpacking of appliance from carton.Re<strong>co</strong>mmend 2 persons unpack appliance from carton. Always keepworking area clear. Re<strong>co</strong>mmend cut base end of carton and opencarton flaps, then tilt boiler forwards from its side onto its base and removecarton by sliding up over the boiler. Ensure safe lifting techniquesare used – keep back straight – bend using legs. Keep load as closeto body as possible. Always use assistance if required. Dispose ofpackaging in a responsible manner. Re<strong>co</strong>mmend wear suitable cutresistant gloves with good grip to protect against sharp edges andensure good grip when handling appliance outside packaging.Positioning of Appliance for Final <strong>Installation</strong>– no obstructions.Re<strong>co</strong>mmend 2 persons lift appliance to position into place. Fit bracketsecurely onto wall before lifting appliance into position. Obtain firmgrip on front and sides of appliance, lift upwards, ensure stable balanceachieved and lift upwards to position in place on bracket. Ensuresafe lifting techniques are used – keep back straight – bend usinglegs - when lifting load from floor level. Do not twist – reposition feetinstead. Keep boiler as close as possible to body throughout lift tominimise strain on back. Ensure <strong>co</strong>-ordinated movements to ensureequal spread of weight of load. Always use assistance if required.Re<strong>co</strong>mmend wear suitable cut resistant gloves with good grip toprotect against sharp edges and ensure good grip when handlingappliance.Positioning of Appliance for Final <strong>Installation</strong>– above worktop, foreseeable obstructions etc.Re<strong>co</strong>mmend 2 persons lift appliance to position into place. Fit bracketsecurely onto wall before lifting appliance into position. Obtain firm gripon front and sides of appliance, lift upwards, onto worktop if practicable.Ensure stable balance achieved and lift upwards to position in place onbracket. If 2 persons positioning onto bracket obtain firm grip at frontand sides/base of boiler. Ensure <strong>co</strong>-ordinated movements during 2person lifts to ensure equal spread of weight of load. Ensure safe liftingtechniques are used – keep back straight – bend using legs - when liftingload from floor level. Do not twist – reposition feet instead. Keepboiler as close as possible to body throughout lift to minimise strain onback. Avoid upper body/top heavy bending - do not lean forward/sideways.Always use assistance if required. Re<strong>co</strong>mmend wear suitablecut resistant gloves with good grip to protect against sharp edges andensure good grip when handling appliance.Positioning of Appliance for Final <strong>Installation</strong> –within <strong>co</strong>mpartment etc. restricting installation.Re<strong>co</strong>mmend 2 persons lift appliance to position into place, space permitting.Fit bracket securely onto wall before lifting appliance into position.Obtain firm grip on front and sides of appliance, lift upwards,onto worktop if practicable. Ensure stable balance achieved and liftupwards to drop into place onto bracket. If 2 persons positioning ontobracket obtain firm grip at front and sides/base of boiler. Ensure <strong>co</strong>ordinatedmovements during 2 person lifts to ensure equal spread ofweight of load. If 1 person positioning onto bracket re<strong>co</strong>mmend obtainfirm grip supporting base of boiler. Ensure safe lifting techniques areused – keep back straight – bend using legs - when lifting load fromfloor level. Do not twist – reposition feet instead. Keep boiler as closeas possible to body throughout lift to minimise strain on back. Alwaysuse assistance if required. Re<strong>co</strong>mmend wear suitable cut resistantgloves with good grip to protect against sharp edges and ensure goodgrip when handling appliance.Positioning of Appliance for Final <strong>Installation</strong>– in roof space restricting installation.Re<strong>co</strong>mmend 2 persons lift appliance to position into place, space permitting.Fit bracket securely onto wall before lifting appliance into position.Obtain firm grip on front and sides of appliance, lift upwards,ensure stable balance achieved and lift upwards to drop into placeonto bracket. If 2 persons positioning onto bracket obtain firm grip atfront and sides/base of boiler. Ensure <strong>co</strong>-ordinated movements during2 person lifts to ensure equal spread of weight of load. If 1 personpositioning onto bracket re<strong>co</strong>mmend obtain firm grip supportingbase of boiler. Ensure safe lifting techniques are used - keep backstraight – bend using legs - when lifting load from floor level. Do nottwist – reposition feet instead. Keep boiler as close as possible to bodythroughout lift to minimise strain on back. Always use assistance if required.Re<strong>co</strong>mmend wear suitable cut resistant gloves with good gripto protect against sharp edges and ensure good grip when handlingappliance. It is re<strong>co</strong>mmended a risk assessment of the roof spacearea be carried out before moving the appliance into the area to takeinto ac<strong>co</strong>unt access, stability of flooring, lighting and other factors, andappropriate measures taken.59


Because of our <strong>co</strong>nstant endeavour for improvement, details may vary slightly from those shown in these instructions.60

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