221899A.03.01
Instructions for Use
Installation and Servicing
To be l ef t wi t h t he user
Micron
40FF
G.C. No. 41-047-17
Fanned Flue Boiler
This is a Cat I2H Appliance
Reference in these instructions to British Standards and Statutory
Regulations/Requirements apply only to the United Kingdom.
For Ireland the rules in force must be used.
The instructions consist of three parts, User, Installation and Servicing Instructions, which includes the Guarantee Registration
Card. The instructions are an integral part of the appliance and must, to comply with the current issue of the Gas Safety
(Installation and Use) Regulations, be handed to the user on completion of the installation.
Guarantee Registration
Thank you for installing a new Glow-worm appliance in your home.
Glow-worm appliances' are manufactured to the very highest standard so we are pleased
to offer our customers' a Comprehensive First Year Guarantee.
In the centre pages are to be found your Guarantee Registration Card, which we recommend you complete and
return as soon as possible.
If this card is missing you can obtain a copy or record your registration by telephoning the Heatcall Customer
Service number 01773 828100.
Our Guarantee gives you peace of mind plus valuable protection against breakdown by covering the cost of:
' REGISTER YOUR GLOW-WORM APPLIANCE
All replacement parts
O'
FOR 1ST YEAR GUARANTEE PROTECTION
' All labour charges
O'
' All call-out charges
O'
CALL 0208 247 9857
Hepworth Heating Ltd.,
Customer Services:
Nottingham Road, Belper, Derbyshire. DE56 1JT
Tel: (01773) 828100
General/Sales enquiries:
Tel: (01773) 824141 Fax: (01773) 820569
One Contact Local Service Fax: (01773) 828070
7319
Important Information
TESTING AND CERTIFICATION
This boiler is tested and certificated to EN483 for safety and performance. It is therefore important that no alteration is made to the
boiler, without permission, in writing, from Hepworth Heating Ltd.
Any alteration not approved by Hepworth Heating Ltd., could invalidate the certification, boiler warranty and may also infringe the
current issue of the Statutory Requirements.
CE MARK
This boiler meets the requirements of Statutory Instrument No. 3083 The boiler (Efficiency) Regulations, and therefore is deemed
to meet the requirements of Directive 92/42/EEC on the efficiency requirements for new hot water boilers fired with liquid or gaseous
fuels.
Type test for purposes of Regulation 5 certified by: Notified body 0086.
Product/productioncertifiedby: Notified body 0086.
The CE mark on this appliance shows compliance with:
1. Directive 90/396/EEC on the approximation of the Laws of the Member States relating to appliances burning gaseous fuels.
2. Directive 73/23/EEC on the harmonization of the Laws of the Member States relating to the electrical equipment designed
for use within certain voltage limits.
3. Directive 89/336/EEC on the approximation of the Laws of the Member States relating to electromagnetic compatibility.
INFORMATION FOR THE INSTALLER AND SERVICE ENGINEER.
Under Section 6 of The Health and Safety at Work Act 1974, we are required to provide information on substances hazardous to
health.
Insulation pads and Glass yarn.
These can cause irritation to skin, eyes and the respiratory tract. If you have a history of skin complaint you may be susceptible to
irritation. High dust levels are usual only if the material is broken. Normal handling should not cause discomfort, but follow normal
good hygiene and wash your hands before eating, drinking or going to the lavatory. If you do suffer irritation of the eyes or severe
irritation to the skin seek medical attention.
SPARE PARTS
REMEMBER, When replacing a part on this appliance, use only spare parts that you can be assured conform to the safety and
performance specification that we require. Do not use reconditioned or copy parts that have not been clearly authorised by Hepworth
Heating Ltd.
CONTENTS DESCRIPTION SECTION PAGE No.
General Information 3
INSTRUCTIONS
Lighting the Boiler 3
FOR USE
General Data 1 4
INSTALLATION
Flue and Ventilation 2 6
INSTRUCTIONS Water Systems 3 7
Flue and Appliance Preparation 4 9
Boiler Installation 5 12
Commissioning 6 16
Instructions to the User 7 17
Servicing 8 18
SERVICING
Fault Finding 9 19
INSTRUCTIONS
Replacement Parts 10 22
Spare Parts 11 24
221899A 2
Instructions for Use
Introduction
All CORGI Registered Installers carry a CORGI ID card, and
have a registration number. Both should be recorded in your
Please read these instructions and follow them carefully for the
boiler Logbook. You can check your installer is CORGI registered
safe and economical use of your boiler.
by calling CORGI direct on :- 01256 372300.
The Micron series are fanned flue boilers designed to provide
central heating and indirect domestic hot water.
Cleaning
The boiler is fully automatic in operation having only one user
WARNING. This appliance contains metal parts (components)
control, the temperature control.
and care should be taken when handling and cleaning, with
WARNING. It is important that the case is not disturbed or
particular regard to edges.
removed other than for servicing by a competent person.
Clean the casing occasionally by wiping it over with a damp
cloth or dry polishing duster.
Gas Leak or Fault
Do not use an abrasive cleaner.
If a gas leak or fault exists or is suspected, the boiler must be
turned off, including the electrical supply and must not be used
To Light the Boiler
until the fault has been put right.
WARNING. Sealed Systems
Advice/help should be obtained from your installation/servicing
company or the local gas undertaking. A sealed water system must be filled and pressurised by a
competent person.
Electrical Supply Failure
Only light the boiler when you are sure that the system has been
filled and pressurised.
Failure of the electrical supply will cause the burner to go out.
Should this occur, operation of the appliance will normally
The pressure gauge should show at least 0.7bar, anything less
resume after the electrical supply is restored.
than this figure could indicate a leak and you MUST contact your
installation/servicing company.
Note: If the boiler is switched OFF, manually, wait at least 30
seconds before switching on again.
If there is any doubt about the boiler being full of water consult
your installation/servicing company.
Safety Temperature Limiter
ALL SYSTEMS.
If the overheat Safety Temperature Limiter operates as indicated
Turn the electrical supply on to the boiler and check that all
by illuminated reset light, open the controls cover and turn
remote controls are calling for heat. Check also that the
temperature control to  0 (anticlockwise) and then back to
programmer (if fitted) is in the  ON mode.
original position, refer to diagram 9.1. If the overheat operates
again, turn the appliance off and contact your installation/
To Turn the Boiler On
servicing company.
Open the controls cover, see diagram 9.1.
Protection Against Freezing.
Turn the control knob clockwise to any position between  0 and
If the boiler is to be out of use for any long period of time during MAX. The maximum temperature setting is about 82oC (180oF),
severe weather conditions we recommend that the whole of the see diagram 9.1.
system, including the boiler, be drained off to avoid the risk of
The boiler lighting operation is now automatic as follows:
freezing up. Make sure that, if fitted, the immersion heater in the
The fan operates and after a short period of time, the spark
cylinder is switched off. Alternatively, there is a built-in frost
ignition operates, the solenoid opens, then the burner will light
protection which will cause the boiler when it is switched off at
shown by the  Burner On neon on the control panel lighting up.
the control knob to operate in the event of the water temperature
in the boiler dropping to 6oC or 7oC. The boiler will switch off
The burner will remain alight until switched off by the control
again when the temperature of the water in the boiler reaches
thermostat, any remote control or the programmer.
about 15oC. This will only be fully effective if the external
Note: If the boiler is switched OFF, by hand, wait at least 30
controls are set so that the pump runs continuously, that is they
seconds before switching on again.
are calling for heat.
When the boiler switches off, the burner will go out.
Note: The frost protection will not operate if the electrical supply
is turned off.
The automatic lighting sequence will operate again when heat
is required.
Maintenance
Shut the controls cover.
To ensure the continued efficient and safe operation of the
boiler it is recommended that it is checked and serviced as
To Turn the Boiler Off
necessary at regular intervals. The frequency of servicing will
For short periods, turn the control knob anti-clockwise to  0 Off.
depend upon the particular installation conditions and usage,
To relight, turn the control knob to any position between  0 and
but in general once a year should be enough.
 MAX .
If this appliance is installed in a rented property there is a duty
For longer periods, turn the control knob fully anti-clockwise to
of care imposed on the owner of the property by the current
 0 Off and switch off the electrical supply to the boiler.
issue of The Gas Safety (Installation and Use) Regulations,
Section 35. To relight follow the lighting sequence given above.
It is the law that any servicing is carried out by a competent
Optional Programmer
person.
A programmer is available, which will automatically switch your
To obtain service, please call your installer or Heatcall (Glow-
central heating system on and off once or twice a day at
worm s own Service Organisation) using the telephone number
whatever times you choose.
given on the front cover of these instructions.
Please be advised that the  Benchmark logbook should be
completed by the installation engineer on completion of
commissioning and servicing.
3 221899A
Installation - 1 General
D
A
TOP / SIDE
B
FLUE OPTION
J
E
R
M
L
K
H
C C
WATER CONNECTIONS
REAR
22mm COPPER PIPE F
G
FLUE OPTION
GAS CONNECTION
P
RC 1/2 (1/2 in. BSPT)
N
Q
MODEL A B C D E F G H J K L M N P Q R
40FF 262 75 102 360 139 500 68 85 115 115 126 156 100 104 4 40 68 108
STD/EXD. EASYFIT STD/EXD. EASYFIT
All dimensions are given in millimetres Diagram 1.1
Important Notice The value is used in the UK Government s Standard Assessment
Procedure (SAP) for energy rating of dwellings. The test data
This boiler is for use on natural gas (G20) as distributed in the
from which it has been calculated have been certified by B.S.I.
United Kingdom and Ireland and cannot be used on any other
gas.
1.3 Range Rating
This boiler can be used on open vented or sealed water systems.
This boiler is range rated and may be adjusted to suit individual
Domestic hot water must be provided by pumped circulation.
system requirements, refer to diagram 1.2 for data label position,
ratings and settings.
Wherever possible, all materials, appliances and components
used shall comply with the requirements of applicable British
Standards. 1.4 Heating System Controls
Where no British Standards exists, materials and equipment The heating system should have installed: a programmer and
should be fit for their purpose and of suitable quality and room thermostat controlling the boiler.
workmanship.
Thermostatic radiator valves may be installed in addition to the
room thermostat.
Sheet Metal Parts
Note: For further information, see The Building Regulations
WARNING. When installing or servicing this boiler care should
1991 - Conservation of fuel and power, 1995 edition - Appendix
be taken when handling sheet metal parts, to avoid any possibility
G, table 4b.
of personal injury.
An optional programmer for fitting on the boiler is availble, kit no.
458065.
1.1 Statutory Requirements
The installation of the boiler must be carried out by a CORGI
1.5 Gas Supply
registered installer in accordance with the relevant requirements
The gas installation shall be in accordance with the current issue
of the current issue of:
of BS6891. The supply from the governed meter must be of
The manufacturer s instructions supplied.
adequate size to provide a steady inlet working pressure of
20mbar (8in wg) at the boiler.
The Gas Safety (Installation and Use) Regulations, The Building
Regulations, The Building Standards (Scotland) Regulations
On completion test the gas installation for soundness using the
(applicable in Scotland), Local Water Company Bye-laws,
pressure drop method, purge in accordance with the above
The Health and Safety at Work Act, Control of Substances
standard.
Hazardous to Health (COSHH), The Electricity at Work
Regulations and any local regulations which may apply.
1.6 Electrical Supply
Detailed recommendations are contained in the current issue of
WARNING. This boiler must be earthed.
the following British Standards and Codes of Practice:
All system components shall be of an approved type and shall
BS4814, BS6798, BS5440 Part 1 and 2, BS5546 Part 1, BS5449,
be connected in accordance with the current issue of BS7671
BS6891, BS6700, BS7074 Part 1 and 2, BS7593, BS7671.
and any applicable local regulations.
Manufacturer s instructions must not be taken as overriding
All external wiring between the appliance and the electrical
statutory requirements.
supply and earthing requirements shall comply with the current
IEE Regulations.
1.2 Data
Connection of the boiler and system controls to the mains supply
See Table 1 and diagrams 1.1 and 1.2.
must be through a common isolator and must be fused 3A,
maximum. This method of connection must be by a fused
All dimensions are given in millimetres (except as noted).
double pole isolating switch, with a minimum contact separation
The Seasonal Efficiency Domestic Boilers UK (SEDBUK) is
of 3mm on both poles. The switch should be readily accessible
77.3%.
and preferably adjacent to the appliance. It should supply the
appliance only and be easily identifiable as so doing.
221899A 4
6784
PUMPED
FLOW
PUMPED
RETURN
1 General
Alternatively, an unswitched shuttered socket outlet and 3A
1.12 Boiler Clearances
fused 3 pin plug, both to the current issue of BS1363 may be
used provided that they are not used in a room containing a bath Refer to diagram 1.3.
or shower.
This boiler must be positioned so that at least the minimum
Wiring to the boiler must be PVC 850C insulated cable, not less operational and servicing clearances are provided.
than 0.75mm2 (24/0.20mm).
Additional clearances may be required for installation.
If fixtures are positioned next to the boiler ensure access is
1.7 Contents of Packaging
provided for pipework installation.
The boiler is delivered in one pack with the flue system packed
At least a minimum clearance of 300mm from a permanently
separately.
fixed surface must be left in front of the boiler for servicing, see
diagram 1.3.
1.8 Water System
1.13 Room Ventilation
This boiler may be fitted to an open vented or a sealed water
system.
The boiler is room sealed and does not require the room or
space containing it to have permanent air vents.
1.9 Draining Tap
System
HEPWORTH HEATING LTD.,
BELPER,DERBYS. DE56 1JT
A draining tap must be provided at the lowest points of the
458111
MICRON 40FF
system which will allow the entire system and hot water cylinder
TYPE C C C
12, 32, 52
230V ~ 50Hz 66W Fused at 3A
to be drained.
NO x Class 2 PMS = 3.0 bar
For use on G20 gas only
GC No. 41-047-17
Supply pressure 20 mbar
Draining taps should be to the current issue of BS2879.
0086 GB IE
This boiler is intended exclusively
Boiler
to be installed on a gas supply 86/AU/000
with a governed meter INJECTOR: 3.0mm 205757
A draining point is fitted at the bottom right hand side of the heat
RANGE RATING MIN MID MAX
exchanger.
9.95 11.50 13.04
HEAT Q = kW
INPUT NETT Btu/h 33957 39222 44493
When draining is required cover the controls to avoid water
HEAT P = kW 8.79 10.26 11.72
damage.
OUTPUT 30000 35000 40000
Btu/h
Cat.I
mbar 7.8 11.0 14.3 2H
HOT BURNER
If required remove the combustion chamber front cover to
in wg
PRESSURE 3.1 4.4 5.7 EN437
improve access.
SERIAL No.
1.10 Safety Valve
PMS = 3.0 bar, is: Maximum water-side operating pressure.
A safety valve need not be fitted to an open vented system.
The appliance flue type is a C12, C32 and C52. This refers to a
concentric or twin flue where the fan is downstream of the heat
1.11 Location
exchanger. The C12 is a horizontal flue termination, the C32 is a
vertical flue termination and the C52 has seperate ducts to two
This boiler is not suitable for outdoor installation.
terminals that may terminate in zones of different pressure.
This boiler may be installed in any room, although particular
attention is drawn to the requirements of the current issue of
BS7671 with respect to the installation of a boiler in a room
containing a bath or shower. Any electrical switch or boiler
control utilising mains electricity should be placed so that it
cannot be touched by a person using the bath or shower.
DATA
The electrical provisions of the Building Standards (Scotland)
LABEL
apply to such installations in Scotland.
The boiler must be mounted on a flat wall which is sufficiently
robust to take its total weight.
Diagram 1.2
The boiler may be fitted to a wall made of combustible material.
6mm
*
6mm
6mm
2mm
2mm
10mm FROM A NON-PERMANENT
300mm FROM A PERMANENT
FRONT
*190mm with Easyfit top flue fitted,
*160mm with standard/extended top flue fitted, VIEW
20mm without top flue fitted
Increased top clearance is required if flow pipe enters from
50mm
below to permit access to air vent.
MINIMUM CLEARANCES FROM WALLS, CEILING, FLOOR,
CUPBOARD, WORKTOPS AND INFLAMMABLE MATERIALS Diagram 1.3
5 221899A
7262
7316
7064
1 General
1.14 Boilers in a Compartment
TABLE 1.
Where the installation of the boiler will be in an unusual position,
TOTAL DRY WEIGHT
the current issue of BS6798 gives detailed guidance on these 36.4 kg (80lb)
(Including Terminal)
requirements.
29.7 kg (65.34lb)
LIFT WEIGHT
An existing cupboard or compartment modified for the purpose
may be used, providing minimum clearances are maintained.
WATER CONTENT
2.2 litre (0.48 gallon)
Details of essential requirements for cupboard or compartment
design are given in the current issue of BS6798.
Rc 1/2 in.
GAS CONNECTION
The doorway opening should be of sufficient size to allow for easy
removal of the boiler.
ELECTRICITY RATING 66W Internal fuse Type F4A
Where the boiler is fitted in a cupboard or compartment, permanent
2x22mm copper pipes from
WATER CONNECTION
ventilation is not required.
back of case
ELECTRICITY SUPPLY 230V~50Hz,fused 3A
1.15 Timber Frame Building
Top left hand inside of case
DATA LABEL
IIf the boiler is to be installed in a timber frame building it should
be fitted in accordance with the Institute of Gas Engineers
document IGE/UP/7/1998. If in doubt seek advice from the local
1.16 Anti-theft Kits
gas undertaking or Hepworth Heating Ltd.
Anti-theft kits are available for these appliances, contact
Hepworth Heating Ltd. for further information.
2 Flue and Ventilation
The flue must be installed in accordance with the rules in force
in the countries of destination.
C
2.1 Terminal Position A
The minimum acceptable siting dimensions for the terminal
B,C
B,C
from obstructions, other terminals and ventilation openings are
K
shown in diagram 2.1.
L
L
G
A K
The terminal must be exposed to the external air, the position K
M F
F
F
allowing free passage of air across it at all times. A
G
E G
G
Car ports or similar extensions of a roof only, or a roof and one
G
wall, require special consideration with respect to any openings,
Under Car Port etc.
doors, vents or windows under the roof. Care is required to
protect the roof if it is made of plastic sheeting. If the car port
consists of a roof and two or more walls, seek advice from the D
J
local gas company before installing the boiler.
F
K
If the terminal is fitted within 600mm below plastic guttering or
H,I
painted soffit an aluminium shield 1500mm long should be fitted
immediately beneath the guttering or eaves. If the terminal is
fitted within 450mm below painted eaves or a painted gutter, an
aluminium shield 750mm long should be fitted immediately
MINIMUM SITING DIMENSIONS FOR MINIMUM
beneath the guttering or eaves.
FANNED FLUE TERMINALS POSITION SPACING in mm
2.2 Flue Options
A DIRECTLY BELOW, ABOVE OR HORIZONTALLY
TO AN OPENING, AIR BRICK, OPENING
There are various flue systems to choose from, as follows:
WINDOWS, AIR VENT OR ANY OTHER
VENTILATION OPENING. 300
Standard Top Outlet Flue Pack - Pt.No. 230483
B BELOW GUTTER, DRAIN/SOIL PIPE 25
Easyfit Top Outlet Flue Pack - Pt. No. 232057
C BELOW EAVES 25
Standard Rear Outlet Flue Pack - Pt. No. 230482
D BELOW A BALCONY OR CAR PORT 25
Extended Top Outlet Flue Pack - Pt. No. 230487
E FROM VERTICAL DRAIN PIPES AND SOIL PIPES 25
1 Metre Extension Kit - Pt. No. 230484
F FROM EXTERNAL CORNERS 25
A flue system up to 3 metres in length can be made by
G ABOVE ADJACENT GROUND OR BALCONY LEVEL 300
connecting 1 metre flue extension kits together.
H FROM A SURFACE FACING THE TERMINAL 600
Optional Wall Liner Kit No. 900862
I FACING TERMINALS 1200
A Flue Bend Kit or Vertical Flue Kit up to 4 metres can be
J FROM OPENING (DOOR/WINDOW) IN
supplied, see Hepworth Heating "Flue Options Guide" for
CAR PORT INTO DWELLING 1200
configurations available.
K VERTICAL FROM A TERMINAL 1500
45o Flue Bend Pack - Pt. No. 230485
L HORIZONTALLY FROM A TERMINAL 300
M FROM INTERNAL CORNERS 25
90o Flue Bend Pack - Pt. No. 230486
In Line Flue Adapter Kit - Pt. No. 230488
Diagram 2.1
Vertical Flue Kit No. 458115
221899A 6
0103M
2 Flue and Ventilation
2.3 Terminal Guard
A terminal guard is required if persons could come into contact
with the terminal or the terminal could be subject to damage.
If a terminal guard is required, it must be positioned to provide
a minimum of 50mm clearance from any part of the terminal and
be central over the terminal, see diagram 2.2.
A suitable guard, reference Type  K3 , can be obtained from:
Tower Flue Components Ltd.,
Morley Road, Tonbridge,
Kent. TN9 1RA
Diagram 2.2
3 Water Systems
The installation of the boiler must comply with the requirements
of the current issue of BS6798.
OPEN VENTED FULLY PUMPED WATER SYSTEM
RECOMMENDED RELATIONSHIP BETWEEN
PUMP COLD FEED AND VENT
3.1 Frost Protection
22mm VENT
There is a built-in frost stat in this boiler. See Protection Against 450mm (MIN.)
MIN.
Freezing in Instructions for Use. Where other parts of the
HEIGHT
system are vulnerable this should also be considered as specified
in the current issue of BS5422.
15mm (MINIMUM)
3.2 Pump
COLD FEED
The pump, with integral valves, should be fitted in the heating FEED AND
EXPANSION
flow pipework from the boiler, it should be set to produce a
CISTERN
temperature difference of 11oC (20oF), between the flow and
return, with the boiler thermostat set at  MAX , which is about
82oC (180oF).
1METRE
MIN.
The pressure loss of the boiler at 15.3 litre/minute giving 11oC
temperature difference is 150mm head of water.
High resistance microbore systems may require a higher duty PUMP
pump.
FLOW
3.3 Bypass 150mm
MAX.
A bypass is unnecessary, unless thermostatic radiator valves
are fitted to all radiators.
RET.
There must
If required, a 15mm bypass must be fitted at least 2m away from IF REQUIRED
always be a cold
the boiler and adjusted such that there is a temperature difference 15mm (MINIMUM)
BOILER
water path to the
no greater than 200C between flow and return. BY-PASS WITH
return connection
LOCKSHIELD VALVE
of the boiler.
3.4 Water System
Diagram 3.1
For an open vented system the boiler must be supplied from an
unrestricted water supply taken from a feed and expansion
3.6 Cylinder
cistern fitted at a maximum height of 27 metres above the boiler.
For all systems supplying domestic hot water the cylinder must
The cold feed must be 15mm minimum size.
be indirect. It is recommended that the cylinder be fitted with
It is important that the relative positions of the pump, cold feed
some form of temperature control.
and open vent are as shown in diagram 3.1.
The unrestricted open vent from the boiler must rise continuously
3.7 Open Vented Fully Pumped Heating and
to discharge over the feed and expansion cistern.
Domestic Hot Water
3.5 Domestic Hot Water System The connections for the system MUST be as shown in diagrams
3.1 and 3.2.
General. The domestic hot water service must be in accordance
with the current issue of BS5546, refer also to the current issue
3.8 Inhibitor
of BS6700.
Attention is drawn to the current issue of BS5449 and BS7593
on the use of inhibitors in central heating systems.
When installing in an existing system take special care to drain
the entire system, including radiators, then thoroughly cleaning
out before installing the boiler whether or not adding an inhibitor.
7 221899A
7056
7065
RETURN
FLOW
CYLINDER
HEATING
3 Water Systems
3.9 Sealed Water Systems
3.15 Filling a Sealed Water System
The installation should comply with the appropriate requirements
Provision for filling the system at low level must be made.
of the current issue of BS4814, BS5449, BS6759, BS6798 and
The installation should comply with the appropriate requirements
BS7074 Part 1 and 2.
of the current issue of BS 5449.
3.10 Safety Valve
3.16 Water Makeup
A safety valve must be fitted to a sealed water system.
Provision must be made for replacing water lost from the
It shall be preset, nonadjustable with a lift pressure of 3bar,
system. A make up vessel mounted above the highest point of
incorporating seating of a resilient material, a test device and a
the system and connected through a non-return valve to the
connection for drain.
system on the return side of either the hot water cylinder or
The drain from the safety valve must be routed clear of any
heating system.
electrical fittings and positioned so that any discharge can be
seen.
PUMPED
PUMPED
3.11 Expansion Vessel - Sealed Systems Only
RETURN
FLOW
A diaphragm type expansion vessel, conforming to the current
22mm
22mm
issue of BS4814 (see also BS7074 Part 1 and 2) must be
PIPE
PIPE
connected at a point close to the inlet side of the circulating
pump, unless laid down differently by the manufacturer.
22mm
22mm
PIPE
PIPE
The expansion vessel volume depends upon the total water
system volume and the initial system design pressure. For any
system an accurate calculation of the vessel size is given in the
current issue of BS7074 Part 1.
Example: For an initial system design pressure of 0.7bar the
minimum total vessel volume required is 0.063xTotal System
volume.
22mm VENT & 15mm COLD FEED TO BE FITTED
IN ACCORDANCE WITH BS5449
Note. A higher initial design pressure requires a larger volume
expansion vessel.
Guidance on vessel sizing is also given in the current issue of
BS5449 and BS7074 Part 1.
The charge pressure must not be less than the static head of the
system, that is, the height of the highest point of the system INDIRECT
above the expansion vessel. CYLINDER
IF REQUIRED
1metre Min. ALTERNATIVE
The water content of the boiler is given in Data Table 1.
BYPASS 15mm
27 metres SYSTEM
MIN WITH
Max. CONTROL
LOCKSHIELD
3.12 Pressure Gauge - Sealed Systems Only
VALVES
VALVE
A pressure gauge with a set pointer and covering at least the HEATING
range of 0 to 4bar (0 to 60lb/in2) shall be permanently fitted to the SYSTEM
system in a position where it can be seen when filling the
PUMP
system.
3.13 Domestic Hot Water Cylinder
SINGLE FEED INDIRECT CYLINDERS ARE NOT SUITABLE.
FULLY PUMPED CIRCULATION
The domestic hot water cylinder must be of the indirect coil type.
BYPASS (DIAGRAMMATIC)
It must be suitable for working at a gauge pressure of 0.35bar
above the safety valve setting.
22mm FOR COMBINED FEED & VENT TO BE FITTED
IN ACCORDANCE WITH BS5449
3.14 Domestic Hot Water System - Unvented
Where a storage system will not have a vent to atmosphere the
installation must comply with Building Regulations and local
Water Company Bye-laws, see also the current issue of BS6700. INDIRECT
CYLINDER
If fitting into an existing system the local authority must also be
IF REQUIRED
advised.
1metre Min.
BYPASS 15mm
27 metres
MIN WITH
Max.
LOCKSHIELD
VALVE
HEATING
SYSTEM
PUMP
ALTERNATIVE
SYSTEM
CONTROL
VALVES
FULLY PUMPED CIRCULATION
BYPASS (DIAGRAMMATIC)
Diagram 3.2
221899A 8
6770
7067
4 Flue and Appliance Preparation
STD/EXTD
TOP OUTLET FLUE PACK
'X' plus 19mm (RH)
FLUE LENGTH
FLUE LENGTH
15mm
155mm (LH) = flue length
MAX 840mm (extd.)
MAX 840mm (extd.)
15mm
MAX 570mm (std/Easyfit)
EASYFIT
MAX 570mm (std/Easyfit)
'X' plus 47mm (RH)
SCREW
140mm*
(must include 50mm min.
& TAPE
4mm*
side clearance)
'X' plus 183mm (LH) = flue length
STD/EXTD
44.5mm*
SCREW
'X'
'Y' plus 22.5mm
& TAPE
= flue length
52mm
'Y'
EASYFIT
'Y' plus 50.5mm
TOP OUTLET/SIDE FLUE
*STD/EXTD flue only TOP OUTLET/REAR FLUE
= flue length
Note: Outer casing, mounting brackets & boiler details removed for clarity
REAR OUTLET FLUE PACK 510mm
15mm
MAX.
VIEW 'A'
SPIGOT
52mm
FOAM
SCREW
SEAL
FLUE
'Y'
& TAPE
VIEW 'A'
'Y' plus 67mm
Note: Outer casing, mounting brackets &
= flue length
boiler details removed for clarity
STD/EXTD. TOP OUTLET FLUE PACK STD. REAR OUTLET FLUE PACK
SCREW
& 1 METRE EXTENSION KIT & 1 METRE EXTENSION KIT
& TAPE
1 metre extension kits may be
1 metre extension kits
VIEW 'B'
joined together, but the total
may be joined together,
FOAM flue system must not
but the total flue
exceed 2 metres.
SEAL
system must not
Total must not exceed 3m MAX.
exceed 3 metres.
15mm
Total must not exceed 2m MAX.
15mm
VIEW 'B'
52mm
SCREW
SCREW
SCREW
& TAPE 'Y'
& TAPE
& TAPE
SCREW
'X'
& TAPE
STD/EXTD SIDE FLUE 'Y'
STD/EXTD REAR FLUE
'X' plus 19mm (RH)
'Y' plus 67mm = flue length
'Y' plus 22.5mm = flue length
155mm (LH) = flue length
EASYFIT
EASYFIT
'Y' plus 50.5mm = flue length
'X' plus 47mm (RH)
'X' plus 183mm (LH) = flue length
Note: Outer casing, mounting brackets & boiler details removed for clarity
NOTE :
MAXIMUM DISTANCE FROM
FLUE MINIMUM MINIMUM MAXIMUM
IF IT IS NECESSARY TO CUT THE DUCTS
"Y" "X"
PACKS WALL FLUE FLUE
TO ACHIEVE THE "FLUE LENGTH" MAKE SURE
BOILER MOUNTING FACE BOILER CASING TO
THICKNESS LENGTH LENGTH
THAT THE OVERLAPS ARE AS FOLLOWS :-
TO EXTERNAL WALL FACE EXTERNAL WALL FACE
THE OVERLAP FOR AIR DUCT = 25mm
TOP STD/
THE OVERLAP FOR FLUE DUCT = 50mm
EASYFIT
75 97 570 547 -
REAR
75 96 570 - 551
SIDE R.H.
75 232 570 - 415
SIDE L.H.
TOP EXTD.
REAR 75 97 840 817 -
SIDE R.H. 75 96 840 - 821
SIDE L.H. 75 232 840 - 685
REAR STD.
REAR 75 142 510 443 -
Diagram 4.1
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4 Flue and Appliance Preparation
NOTE : Make sure that the ductings do not slope down towards
the boiler.
4.1 Flue Position and Length
Determine flue application, length and terminal position before
starting.
Refer to diagram 4.1. OPTIONAL
FLUE
If you are using a Flue Bend or a Vertical Flue Kit, please follow
COLLAR
the instructions supplied with the kit.
To make a neat finish to the flue outlet a flue collar kit, part No.
900850, with instructions, is available, see diagram 4.2. Diagram 4.2
Note: If required an optional wall liner kit, part no. 900862, is
available complete with instructions.
EASYFIT TOP
FLUE OUTLET
4.2 Flue Preparation
115mm MINIMUM
All flue assemblies are designed for internal installation, given
HOLE 115mm
that there is sufficient clearances opposite to the flue for the
installation of the flue.
TOP FLUE OUTLETS
115mm
If there is insufficient clearance the flue can be installed from
outside. MINIMUM
HOLES
For a wall thickness up to 300mm, provided that there is
sufficient space and the optional wall liner kit is used, the flue
EASYFIT TOP
can be installed from the inside.
FLUE OUTLET SIDE FLUE
For a wall thickness of over 300mm the external flue hole will
115mm MINIMUM
BOILER
need to be made good from the outside, this also applies if you
HOLE
FIXING POINT
use the flue kit without the optional wall liner kit, irrespective of
wall thicness.
FLUE
4.3 Rear, Top and Side Flue Application
CENTRE LINE
Select the boiler location and flue application, with due regard
to the terminal position, see diagram 2.1.
REAR FLUE BOILER
Take the template from the boiler pack and temporarily position
OUTLET FIXING POINT
it on the wall, making sure that the minimum clearances are
115mm
maintained, see diagram 4.3.
MINIMUM
BOILER
Mark the centre line position of the flue, "Top" or "Rear" as HOLE
CENTRE LINE
diagram 4.3.
For a side flue, extend centre line of "Top" to L.H. or R.H. corner.
Diagram 4.3
Mark the position of the centre of the flue and boiler, as
diagram 4.3.
MOUNTING
4.4 Flue Hole Cutting
WALL
BRACKET
Having marked out the flue centre cut a hole for the flue using, PLUG
preferably, a 115mm minimum core drill.
4.5 Wall Mounting Bracket
Reposition the template, making sure of dimensional alignment
with the flue hole.
Mark the boiler fixing points and mounting bracket positions,
see diagram 4.4, drill and insert plugs.
Note: The lower mounting bracket is fixed to the boiler.
Drill the holes and insert wall plugs.
Secure the top mounting bracket to the wall with two No.12x2in
wood screws one on each side of the bracket, see diagram 4.4.
WALL
Alternative fixing positions are provided in the bracket, if
PLUG
required.
SECURING
SCREW
4.6 Flue Duct
Extend the telescopic flue to the required length, making sure
MOUNTING
that the minimum overlap is no less than 25mm, and that the
BRACKET
flue terminal projects 15mm minmum beyond wall face, see
FIXED TO BOILER
diagram 4.1.
Carefully drill though air duct pilot hole and secure with self
Diagram 4.4
tapping screw provided in fittings pack, see diagram 4.1.
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4 Flue and Appliance Preparation
Seal the joint with the tape provided.
WITH WALL LINER KIT ONLY
If the flue system requires the addition of flue extension kits,
drill, seal and secure them with the self tapping screw and tape
WALL THICKNESS-
provided. The completed flue system must not exceed 3metres,
UP TO 300mm
see relevant part of diagram 4.1.
FOAM SEAL
Note: Should any one of the flue sections require cutting to
obtain desired flue system length, cut the 1metre extension kit
at the end opposite the expanded end.
If the boiler is not to be fitted for some time cover the hole in the
wall.
Note: If a horizontal flue extension is required it must be used
Q
in conjunction with the standard flue, see diagram 4.1.
IMPORTANT: When using the standard flue kit (either rear
outlet or top outlet fixing), the terminal restrictor must be
15mm
fitted. This is not fitted for any other flue type/arrangement. FOAM SEAL
Note: There are two restrictors in the loose items pack, use
the one stamped  A for the Micron 40FF.
Q-35mm
Take the terminal restrictor and position the clamping bracket
making sure the clamping bracket nib protrudes in the slot of the
terminal restrictor and secure with locking screw, but do not
tighten, see diagram 4.6.
Engage the terminal restrictor on the flue terminal by hooking
it over the terminal end and engaging the clamping bracket
Q
behind the inner ring of the terminal securing it by tightening the
locking screw, see diagram 4.6
4.7 Internal Access Flue
WALL THICKNESS-
If access to the outside wall is not practical, the flue system can
OVER 300mm
be installed from inside. Use of the optional wall liner kit is
Diagram 4.5
required.
4.8 Rear Flue Fixing
STANDARD 510mm REAR AND
Fit the self adhesive foam seal provided in the flue pack around
the air duct at the position shown in diagram 4.1.
STANDARD 570mm TOP FLUE ONLY
Make sure that the ductings do not slope down towards the
FLUE
boiler.
TERMINAL
Make good around the flue outside after installation of the
boiler.
CLAMPING
Important: If the wall liner kit is used, the self adhesive foam seal
BRACKET
included in the wall liner kit must be used in place of the one
supplied with the flue pack, see diagram 4.5 for position of self
adhesive seal.
4.9 Top, Side Flue Fixing
Make sure that the ductings do not slope down towards the
boiler.
Make good the area around the flue inside and outside after
installation of the boiler.
Important: If the wall liner kit is used, the self adhesive foam seal
included in the wall liner kit must be used in place of the one
LOCKING
supplied with the flue pack, see diagram 4.5 for position of self
adhesive seal. SCREW
4.10 Flue Positioning
RESTRICTOR
CLAMPING
Push the flue assembly into and through the hole such that it is
BRACKET NIB
within the wall, and does not stick out into the room. Do not push
the flue assembly too far into the hole as it has to be pulled back
into the boiler and secured.
TERMINAL RESTRICTOR
SHOWN FITTED
Diagram 4.6
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5 Boiler Installation
5.1 Unpacking
VIEW ON
Open the carton, check the items supplied against the boiler
COVER TOP
pack contents list on the carton flap.
5.2 Boiler Preparation
CASE
SECURING
With the boiler still in the bottom tray, remove the casing front
SCREWS
cover. To do this open the controls cover first, then by undoing
the two screws at the bottom and the one at the top, lift the front
cover off, see diagram 5.1.
Place front cover in a safe place on one side until required.
Remove boiler from carton.
From the fittings pack, slide a tubing nut and washer on to the
return and flow tail pipes which are supplied with the boiler, see
diagram 5.2.
Connect the return and flow tail pipes to the boiler, see diagram
5.2.
Fit suitable compression fittings to the tail pipes.
For pipework entering the boiler from below, an optional flow
pipe incorporating an air vent is available, kit No. 458130. The
CONTROLS COVER Diagram 5.1
return tail pipe supplied with the boiler will need to be cut, see
diagram 5.3.
Note: If the installer wishes to adapt the standard pipework he
may do so, but must incorporate an air-vent at the highest point
on the flow pipe, see diagram 5.11. TUBING
NUT
TAIL PIPE
5.3 Mounting the Boiler
Ensure to fit the blanking plate and gasket on the boiler flue
outlet not being utilised, see diagram 5.6.
RETURN
If the rear flue outlet is to be utilised for the installation of the flue,
it will be necessary to connect the flue spigot and gasket to the
outlet, using self tapping screws provided, see diagram 5.6.
FLOW
Note: The spigot would only be fitted to the top flue outlet where
a vertical flue kit or in certain flue bend orientations is incorporated.
Instructions are supplied with these kits.
Lift the boiler into position, hooking over the top mounting
bracket.
Note: Anti-theft screw kits are are available, part no s: 458113,
458114.
Important: Secure lower bracket to wall with screw into wall
plug already prepared.
RUBBER
WASHER
Note: It will be necessary to move the control box to access the
Diagram 5.2
bracket by slackening its retaining screw and swinging it out on
its hinge, see diagram 5.10.
Where the boiler is located in a restricted place, see diagram
FLOW
TAIL PIPE
1.3, it may be necessary to remove the control knob to enable
the control box to be fully swung out.
AIR VENT
If the top flue outlet is to be utilised, secure the top turret and
gasket or flue spigot and gasket depending on desired flue
orientation in position with the 2 taptite and 2 self tapping
RETURN
screws provided, see diagram 5.9.
Note: Ensure that the taptite and self-tap screws are positioned
as shown in diagram 5.8 to enable the air deflector to be fitted
TUBING
correctly.
NUT
If fixing to the back of the boiler, i.e. spigot, slide the flue into the
RUBBER
spigot until it engages in the bayonet connection and then twist
WASHER
anticlockwise to lock, see diagram 4.1.
Make sure the fitting of the flue to the boiler is correct.
The fan assembly may also be removed or slid forward about
halfway out of the boiler, to ease access, by removing the
securing screw at the front, see diagram 5.5.
The fan assembly may also be removed or slid forward about
halfway out of the boiler, to ease access.
Disconnect the the blue and purple electrical connections to the
fan, and the air pressure switch tube connections, see diagram
5.5. Diagram 5.3
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5 Boiler Installation
Note: Remove the electrical connections by pulling insulation
MOUNTING
boots only.
BRACKET
Remove the securing screw at the front, see diagram 5.5.
The fan assembly may now be slid forward.
Rear Flue fixing
Fit the fan elbow and secure with jubilee clip to the fan outlet, do
not tighten yet, see diagram 5.7.
Fit the retaining clamp of the fan elbow, bending the straps
around the fan elbow raised clamping surfaces but do not fasten
the clasp, see diagram 5.7.
It is important that the retaining clamp is fitted the correct way
round, so that the straps locate on to the fan elbow raised
clamping surfaces.
Reconnect the blue and purple electrical connections to the fan,
the polarity of the connections is not important.
Pull the flue duct into the fan elbow to engage.
Important: It is essential to make certain that the flue duct
is fully located into the fan elbow until it can go no further.
Fasten the fan elbow retaining clamp clasp thus securing it, see
diagram 5.7.
Secure the fan elbow to the fan outlet with the Jubilee clip.
Reposition fan assembly.
MOUNTING
Top Flue fixing
BRACKET
Fit the two  O rings from the loose items pack onto the flue duct
extension, there are recesses on the flue duct extension for
locating them, see diagram 5.7.
Fit the air deflector in position using the rear left hand taptite SECURING
screw and the one diametrically opposite which hold the top SCREW
turret and secure with the wing nuts provided but do not fully
NOTE:
tighten, see diagram 5.8.
PIPES REMOVED FOR CLARITY Diagram 5.4
Swing the air deflector out from right hand side (the slot in air
deflector allows you to do this) to allow easy access to fitting fan
assembly.
IMPORTANT:
Note: Apply soap to seals on flue duct extension piece to help REMOVE ELECTRICAL CONNECTIONS
it slide in, be careful not to damage  O ring.
BY GRIPPING THE BOOT ONLY
Insert flue duct extension piece into top turret, see diagram 5.7.
CLEAR AIR
Note: Make sure that the flue duct extension piece is positioned
PRESSURE TUBE
ELECTRICAL
so that the nibs are upper most, see diagram 5.7.
CONNECTIONS
Locate the fan elbow with jubilee clip on the fan outlet, do not
tighten yet, see diagram 5.7.
Reconnect the blue and purple electrical connections to the fan,
SECURING
the polarity of the connections is not important.
SCREW
Reposition the fan assembly and draw down the flue duct
extension piece onto the fan elbow, see diagram 5.7.
Fit the retaining clamp on the fan elbow raised clamping
surfaces, bending the straps around the fan elbow and fastening
the clasp thus securing it to the flue duct extension, see diagram
5.7.
It is important that the retaining clamp is fitted the correct way
round, so that the straps locate on to the fan elbow raised
clamping surfaces.
Secure the fan elbow to the fan outlet with the Jubilee clip.
Swing the air deflector in position and secure, see diagram 8.7.
Continued.
Secure the fan assembly by replacing securing screw, see
diagram 5.5.
Reconnect the air pressure switch tube, see diagram 5.5.
Diagram 5.5
5.4 Water Circulation System
Complete the water connections to the boiler.
Fill, vent and flush the system.
Check for any water leaks and put right.
13 221899A
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5 Boiler Installation
5.5 Gas Connection
Make the gas connection to the Rc1/2in gas service cock, see
REAR FLUE FIXING
diagram 6.2.
The whole of the gas installation, including the meter, should be
inspected, tested for soundness and purged in accordance with
the current issue of BS6891.
5.6 Control Box Access
SCREWS
(4)
Slacken the control box securing screw, see diagram 5.10.
Swing the box out on its hinge.
5.7 Electrical Connection
WARNING. This boiler must be earthed.
Note: If an optional programmer is to be installed, it should be
fitted at this stage, see separate installation instructions supplied
GASKET
with programmer
Take care not to damage any internal wiring.
Using heat resistant (85oC) cable of at least 0.75mm2 (24/
0.2mm) and of a suitable length, thread through the grommet at
the rear of the control box, through the cable clamp and connect
to appropriate terminals. Tighten cable clamp screws, see
diagram 5.10.
Standard colours are, brown - live (L), blue - neutral (N) and
SPIGOT
green/yellow - earth ( )
The mains cable outer insulation must not be cut back external
to the cable clamp.
BLANKING
Make sure the cable is suitably secured.
PLATE
When making connections, make sure that the earth conductor
is made of a greater length than the current carrying conductors,
SCREWS
so that if the cable is strained the earth conductor would be the (4)
TOP FLUE FIXING
last to become disconnected.
Diagram 5.6
RETAINING
FLUE DUCT
CLAMP
EXTENSION
TOP
TURRET
PRESS
NIBS
PRESS
FLUE
FAN ELBOW
DUCT
PRESS
CLAMPING
" O " RINGS
EXTENSION
CLASP
SURFACE
FAN
RETAINING
ELBOW
CLAMP
RETAINING
CLAMP
FAN ELBOW
JUBILEE
REAR
JUBILEE CLIP
CONNECTION TOP
CLIP
(within casing) CONNECTION
Diagram 5.7
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5 Boiler Installation
1. Test insulation resistance to earth.
5.8 Pump Connection
2. Test earth continuity and short circuit of all cables.
The pump must be connected to the external controls.
3. Test the polarity of the mains.
5.9 Testing
The installer is requested to advise and give guidance to the
user of the controls scheme used with the boiler.
Checks to ensure electrical safety must be carried out by a
competent person.
Fit the casing.
After installation of the system, preliminary electrical system
checks as below should be carried out:
MAINS
b
SUPPLY
g/y
230V~50Hz
br
AIR LS N
BLOCK
CONNECTOR
DEFLECTOR
bl b
g/y g/y
SELF-TAP
SCREWS (2)
CABLE
SECURING
CLAMP
SCREW
TAPTITE
SCREWS (2)
HINGE PIN
CONTROL
GROMMET
BOX
WING NUT
Diagram 5.8 Diagram 5.10
TOP TURRET
FLUE OUTLET
RETURN
TAIL PIPE
SCREWS
(4)
TUBING
NUT
FLOW
TOP
GASKET
TURRET
FLUE
DUCT
RUBBER
EXTENSION
WASHER
AIR VENT
Diagram 5.11
Diagram 5.9
15 221899A
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6 Commissioning
Important Note : The warning notice attached to the
Isolate the boiler from the electrical supply.
front of the boiler casing must only be removed by
Loosen the burner pressure test point screw and connect a
the user.
suitable pressure gauge, see diagram 6.2.
Please ensure the  Benchmark logbook is completed and left
Replace control box.
with the user.
Switch on the electrical supply to the boiler.
6.1 All Systems
FASCIA
Commissioning should be carried out by a competent person in
accordance with the current issue of BS6798.
UNDER ALL CIRCUMSTANCES the case must be correctly
fitted and sealed, unless fault finding.
Make sure that the system has been thoroughly flushed out with
cold water without the pump in place.
Refit the pump, fill the system with water, ensuring that all the
air is properly vented from the system and pump.
6.2 Sealed Water Systems Only
FASCIA
Fill until the pressure gauge registers 2.7bar (40lbf/in2). Clear
SECURING
any air locks and check for water soundness.
SCREWS
Check the operation of the safety valve, by allowing the water
pressure to rise until the valve opens. The valve should open
within +/- 0.3bar (+/- 4.3lbf/in2) of the pre-set pressure. Where
Diagram 6.1
CONTROLS COVER
this is not possible conduct a manual check and test.
Note: Fit a suitable discharge pipe to the safety valve and route
it to outside the building so that any discharge can be seen but
will not cause injury to persons, damage to property or any BURNER
GAS COCK
electrical installation. PRESSURE
(OFF)
TEST POINT
Release cold water to initial system design pressure.
The set pointer on the pressure gauge should be set to coincide
with the indicating pointer.
6.3 Initial Lighting and Testing
CAUTION. This work must be carried out by a competent
person, in accordance with the current issue of BS6798.
Make sure that boiler case is fitted securely
Make sure that all naked lights and cigarettes are out.
Open the control cover, refer to 'Instructions for Use' and
identify the controls, see diagram 9.1.
Remove fascia, see diagram 6.1.
Check that the boiler is isolated from the electrical supply.
Make sure that the temperature control is turned to the  0  Off
position, see diagram 9.1.
Undo the screw which holds control box , see diagram 5.10.
Swing open control box. GAS PRESSURE
GAS COCK
ADJUSTMENT
Turn the gas service cock  On , see diagram 6.2. A 14mm
(ON)
SCREW
spanner may be required for this.
(CUP REMOVED)
Purge in accordance with the current issue of BS6891.
Replace control box.
MULTIFUNCTIONAL
CONTROL
Turn on the electrical supply.
NOTE: Do not adjust any
WARNING. The multifunctional control and fan operate on
other setting screws Diagram 6.2
mains voltage, terminals will become live.
If programmer control fitted, make sure it is in the ON mode.
Make sure that any remote controls are calling for heat.
Table 2
Turn the temperature control clockwise to  Max .
40FF MIN. MED. MAX.
The ignition system will operate to light the boiler. After a pre-
set time if ignition has not taken place the boiler will shutdown.
APPROX. m3/h 1.07 1.23 1.40
To re-start the lighting sequence, turn the temperature control
to  0 , then fully clockwise to  Max .
GAS RATE ft3/h 37.69 43.53 49.4
After the burner has lit, the  Burner on neon on the control panel
will come on.
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6 Commissioning
The gas rates shown in Table 2 are for guidance only, dependent
6.4 Testing - Electrical
on the heat setting.
Turn the boiler temperature control knob fully clockwise to the
Turn the temperature control knob fully anticlockwise to  0 .
maximum setting, which is about 82oC (180oF).
Isolate from the electrical supply.
The lighting sequence is automatic as follows:
Remove the pressure gauge from the test point and refit screw,
The fan operates and after a short period of time, the spark
making sure a gas tight seal is made.
ignition operates, the solenoid opens, then the burner will light
shown by the "Burner On" neon on the control panel lighting up.
Refit control box and fascia.
The burner will stay alight until switched off, either by the
Note: The fixing holes of the fascia are slotted to allow fine
temperature control or a remote system control.
adjustment to align control cover with casing.
To make sure that the flame supervision device is working
When the temperature control is turned to the  0 position, by
correctly the following should be done.
hand, wait at least 30 seconds before turning On again.
With the burner alight, turn the gas service cock  Off , see
There may be an initial smell given off from the boiler when new,
diagram 6.2.
this is quite normal and it will disappear after a short period of
time.
After a short period the burner will go out.
The correct working of the flame supervision device is shown by
6.6 Testing - All Water Systems
the  Burner On neon going out and the ignition sequence
Allow the system to reach maximum working temperature and
starting up.
examine for water leaks.
After a short period the boiler will shut down.
There should be no undue noise in the system.
If the above does not happen, refer to fault finding Section 9.
The boiler should then be turned off and the system drained off
To carry on turn the gas service cock  On , see diagram 6.2.
as rapidly as possible, whilst still hot.
To re-start the lighting sequence, turn the temperature control
Refill system.
knob to  0 then fully clockwise to Max.
During normal operation when the boiler switches  Off , the
6.7 Open Vented System
burner will go out. The automatic lighting sequence will work
Ensure there is no pumping over of water or entry of air at the
again when heat is required.
open vent above the feed and expansion cistern.
6.5 Testing - Gas
6.8 Adjustment - Fully Pumped Open Vented
With the boiler on proceed as follows:
and Sealed Water Systems
Undo the screw which secures control box, see diagram 5.10,
When commissioning the system the boiler should first be fired
on full service, that is, central heating and domestic hot water.
Open control box, see diagram 5.10.
Adjust the pump to the system design setting then balance the
WARNING. The multifunctional control and fan operate on
system, making adjustments as necessary. .
mains voltage, terminals will be live.
Test for gas soundness around the boiler gas components 6.9 Thermostatic Radiator Valves
using a suitable leak detection fluid, in accordance with the
If thermostatic radiator valves are fitted care must be taken to
current issue of BS6891.
ensure that there is an adequate flow rate through the boiler
Check the burner gas pressure at least 10 minutes after the when they close, refer to the current issue of BS7478 for
boiler has lit, refer to Data Label. guidance. If fitted to all radiators ensure a bypass is fitted and
adjust to achieve a temperature difference no greater than 20oC
If necessary remove cap and adjust the gas pressure to obtain
between flow and return with the thermostatic valves closed.
the required setting turning screw clockwise, to decrease
pressure, see diagram 6.2.
6.10 Completion
Replace cap.
Adjust the boiler temperature control and any system controls to
Should any doubt exist about the gas rate, check it using the gas
their required settings.
meter test dial and stop watch, at least 10 minutes after the
burner has lit, making sure that all other gas burning appliances
and pilot lights are off.
7 Instructions to the User
Instruct and demonstrate the safe and efficient operation of the boiler, heating system and domestic hot water system.
Advise the user, that to ensure the continued efficient and safe operation of the boiler it is recommended that it is checked and serviced
at regular intervals. The frequency of servicing will depend upon the particular installation and usage, but in general once a year
should be enough.
Draw attention, if applicable, to the current issue of the Gas Safety (Installation and Use) Regulations, Section 35, which imposes
a duty of care on all persons who let out any property containing a gas appliance.
It is the Law that servicing is carried out by a competent person.
Advise the user of the precautions necessary to prevent damage to the system and building in the event of the heating system being
out of use during frost and freezing conditions.
Reminder - Leave these instructions and the  Benchmark logbook with the user.
17 221899A
8 Servicing
REMEMBER, When replacing a part on this appliance, use only
SAMPLING
spare parts that you can be assured conform to the safety and
POINT
performance specification that we require. Do not use
reconditioned or copy parts that have not been clearly authorised
by Hepworth Heating Ltd.
CLEAR AIR
PRESSURE
Products of Combustion Check
TUBES
Note: To obtain a products of combustion reading, remove the
cap from the sampling point, located on top of the inner casing,
see diagram 8.1.
Connect the analyser tube onto the nipple.
Switch on the electrical supply and gas supply then operate the
boiler.
On completion of the test switch off the electrical supply and the
Diagram 8.1
gas supply, remove analyser tube and replace sampling point
cap.
Servicing
Before servicing turn off the gas and isolate the electrical supply
to the boiler.
After completing a service always test for gas soundness, make
electrical checks and carry out functional check on controls.
BAFFLE
Unless stated otherwise all parts are replaced in the reverse
(6 off)
order to removal.
8.1 Access
Remove the boiler case, see diagram 5.1 and Section 5.2.
8.2 Burner
Diagram 8.2
Remove front combustion chamber cover which is secured by
two screws, see diagram 8.3.
Pull back electrode protection sleeve and disconnect electrode
COMBUSTION
SCREW
SCREW
connection along with earth connection, see diagram 8.6.
CHAMBER
Remove the burner retaining screw located at the right hand COVER
side of the burner, see diagram 8.4.
When completed, take hold of burner and slide it to the left
clearing the injector and remove. Take care not to damage the
combustion chamber insulation
Use a vacuum cleaner or suitable stiff brush (not wire) to clean
the burner thoroughly, making sure that all the burner ports are
clear and unobstructed.
On refitting and after cleaning the heat exchanger make sure
the burner is fitted correctly, that is, located on the injector and
horizontal.
Note: It is advisable while servicing the burner to check the
Diagram 8.3
combustion chamber insulation and replace if damaged, see
Section 10.10.
8.3 Cleaning Heat Exchanger Flueways
BURNER
Disconnect the air pressure switch tube connection, both clear
tubes from test nipple, see diagram 8.1.
Remove the blue and purple electrical connections from the fan
see diagram 5.5.
If top outlet installation: Remove air deflector, or it may just be
swung back by loosening the wing-nuts, to enable fan assembly
to be removed, see diagram 8.7 and Section 5.3.
Remove the fan assembly complete with the flue elbow, see
diagram 5.5 and Section 5.3
BURNER
RETAINING
Place a sheet of paper in the base of the combustion chamber
SCREW
and over the injector to prevent particles entering.
Diagram 8.4
Remove the baffles, see diagram 8.2.
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8 Servicing
Clean the heat exchanger flueways with a suitable stiff brush.
Remove the paper together with any debris.
SCREW
8.4 Injector
With the burner removed the injector can be inspected and
cleaned as necessary, see diagram 8.5.
3.6 + 1.1
For cleaning do not use a wire or sharp instrument on the hole.
If removed, use a little suitable sealant on the external thread
when refitting to make sure a gas tight seal is made.
8.5 Operational Checks
After completing a service and before fitting the case, check
condition of the case seal and renew if necessary.
Examine flue hood and terminal to make sure they are clean
and clear of obstructions. ELECTRODE
Refit all parts.
PROTECTION
Light the boiler and carryout the functional checks as described SLEEVE
in Section 6.
EARTH
Diagram 8.6
WING NUT
(2)
AIR
DEFLECTOR
BURNER
INJECTOR
Diagram 8.5 Diagram 8.7
9 Fault Finding
9.1 Electrical
Important. On completion of the Service/Fault Finding task
CONTROL
which has required the breaking and remaking of the electrical
KNOB
connections the earth continuity, polarity, short circuit and
resistance to earth checks must be repeated using a suitable
multimeter.
Refer to: Boiler Fault Finding, see diagram 9.2, Fault Finding
Wiring Diagram, see diagram 9.3, Pictorial Wiring Diagram, see
diagram 9.4.
9.2 Electrical Supply Failure
Failure of the electrical supply will cause the burner to go out.
Operation will normally resume on the restoration of the electrical
supply.
If the burner does not relight after an electrical supply failure
open the control cover, see diagram 9.1 and if the reset neon is
lit, see diagram 9.1, turn control knob on the front of the control
box to  0 , and then back again, see diagram 9.1.
If the safety temperature limiter operates at any other time, do
as above, the burner should relight. If the fault persists refer to
fault finding chart.
CONTROLS COVER
Diagram 9.1
19 221899A
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9 Fault Finding
Before carrying out fault finding, ensure that gas, electricity and water are available at the boiler.
Ensure that any external controls are calling for heat and circuit water is cold. If overheat neon
lit - check water system for overheating, reset by turning temperature control knob off and on.
If neon 6 is lit flame failure has occured. Reset boiler by turning temperature control to off and then on.
Do not operate the boiler without combustion chamber front fitted.
NO
Is there 230V ac between
NO
Is neon 1 lit?
Check power supply
Ls and N
YES
YES
NO
Is neon 2 lit?
Faulty PCB.
YES YES
Disconnect the 2 way
Replace.
thermistor plug from the PCB.
Check that there is a resistance
NO
Faulty thermistor.
between 14k - 2.5kOhms.
Replace.
Check for 230V ac
NO
NO
Is neon 3 lit?
between N and normally
Faulty PCB.
YES closed contact of air
Replace.
pressure switch.
YES
YES NO
Check for 230V ac
Is there 230Vac
Is the fan turning?
between N and common
on fan?
contact on air NO
Faulty air pressure
NO
YES
pressure switch.
switch. Replace.
Faulty Faulty
NO
Does sparking take place ? Faulty PCB.
PCB. fan.
Replace.
(Listen for spark discharge.)
Check for 230V ac
NO
NO
YES between N and brown
Faulty PCB.
Does burner light?
and between N and black,
Replace.
YES 3 way connector on PCB.
Is integrity of
YES
NO
Is neon 4 lit? electrode and
NO
Check continuity of
Faulty harness.
HT lead good?
YES
gas valve harness.
Replace.
NO
YES
YES
Faulty
Appliance working Replace as
Faulty gas valve.
PCB.
satisfactorily. necessary
Replace.
Diagram 9.2
N
KEY
bk BLACK r RED AIR
b b b
PRESSURE
br BROWN y YELLOW
SWITCH
b BLUE gy GREY
p PURLPLE
(C)
EV1
b
(N/O) (N/C)
FAN
EV2
O/H
SL CUTOFF
bk br br
p r gy y br bk
SPARK
ELECTRODE
AIR PRESSURE SWITCH CONNECTIONS
FUSE
MAIN TERMINAL STRIP CONNECTIONS
TYPE F4A
PRINTED CIRCUIT BOARD CONNECTIONS
Diagram 9.3
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9 Fault Finding
AIR
NEON KEY (see P.C.B)
PRESSURE
SWITCH
NEON 1 = = MAINS ON
NEON 2 = = DEMAND ON
r
y
g
NEON 3 = = FAN RUNNING
b
NEON 4 = = BURNER LIT
p
= SAFETY
NEON 5 =
FAN
TEMPERATURE
GAS
LIMITER
CONTROL
NEON 6 =
= FLAME FAILURE
VALVE
KEY
SAFETY
TEMPERATURE
br BROWN
LIMITER
b BLUE
g/y GREEN/YELLOW
br
g GREY
br
bl BLACK
p PURPLE
y YELLOW
r RED
THERMISTOR
ELECTRODE
bl bl br br bl br b
g/y
g/y
P.C.B (CONTROL BOARD)
F4A FUSE
g
y p
bl
r
b
b
NEON 1 NEON 5 NEON 6
NEON 4
NEON 3
b
NEON 2
MAINS SUPPLY
g/y
230V~50Hz
br
KEY TO TERMINAL BLOCK
LS N
BLOCK CONNECTOR
LS = LIVE (Switched)
bl b N = NEUTRAL
= EARTH MAIN
g/y g/y
Diagram 9.4
21 221899A
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10 Replacement of Parts
Important Notes
Note. Replacement of parts must only be carried out by a
competent person.
Before replacing any parts isolate the boiler from the electrical
supply and turn the gas supply off at the gas service cock, see
diagram 6.2.
Unless stated otherwise, all parts are replaced in the reverse
order to removal.
After replacing any parts always test for gas soundness and if
necessary carryout functional check of controls.
THERMISTOR
P.C.B. CONNECTION
10.1 Access
Gain Access as Section 5.2. Diagram 10.1
10.2 Electrical Thermistor, Part No.227057
- diagram 10.1 and 10.2
ELECTRICAL
SECURING
Slacken control box securing screw , and swing out the control
CONNECTORS
SCREW
box, see diagram 5.10.
Disconnect the thermistor plug from the control board by slightly
THERMISTOR
bending the retaining latch and removing the plug, see diagram
PHIAL
10.1.
Remove fan assembly, see section 5.3.
UNION NUT
Remove the plastic R clips which retain all leads at the rear of
boiler.
Remove the retaining wire and withdraw the electrical thermistor
from its phial, see diagram 10.2.
Remove thermistor lead from the plastic R clips at rear of case
and the cable clips (these are located down left hand side of
boiler).
Draw thermistor lead followed by thermistor out through the
case grommet. RETAINING
RETAINING
SAFETY
WIRE
BRACKET
Re-assembly note. When fitting the thermistor make sure it is
TEMPERATURE
fully inserted into the phial, see diagram 10.2. Take care when
LIMITER
Diagram 10.2
re-threading as not to damage thermistor.
Refit the cable clips and the plastic R clips retaining the leads.
Refit the plastic retaining tag.
Refit the thermistor lead plug.
PCB FUSE
PCB
Refit fan assembly. Part No. 227098
SUPPORT
10.3 Safety Temperature Limiter,
Part No. 227038 - diagram 10.2
Gain Access as Section 5.2.
Remove air pressure switch, see diagram 10.6.
Remove the electrical connections from the Safety Temperature
Limiter, see diagram 10.2.
Undo retaining bracket screw and remove together with Safety
Temperature Limiter.
When refitting use the heat sink compound provided.
Re-assembly note. Check that the Safety Temperature Limiter
is secure.
PCB
Note: Polarity of electrical connections is not important.
10.4 Control Board (PCB), Part No.227030
- diagram 10.3 EXTENSION
PIECE
Remove casing, see Section 5.2.
CONTROL
KNOB
Slacken control box securing screw, see diagram 5.10.
Part No. 204697
Note: To ease access the control box may be pulled away from
Diagram 10.3
boiler by removing the hinge pins, see diagram 5.10.
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10 Replacement of Parts
Carefully pull the control knob and extension piece away from
10.11 Air Pressure Switch, Part No.227032
the PCB.
- diagram 10.6
Carefully pull the board away from its supports.
Gain Access as Section 5.2.
Disconnect the electrical plugs by slightly bending back the
Remove the air pressure tube and electrical connections from
retaining latches to allow withdrawal.
the switch, release the screws and remove the switch.
Disconnect the HT lead and spark earth lead.
When fitting the replacement make sure that the plastic tube is
When refitting refer to wiring diagram 9.4.
fitted, as shown in diagram 10.6 and the electrical connections
are made as shown in diagram 9.4.
Take care when replacing the control knob and extension by
supporting the potentiometer on the P.C.B.
10.5 Electrode, Part No. 202635
SOLENOID
ELECTRICAL
Proceed as Section 8.2.
SECURING SCREW
PLUG
Remove burner from combustion chamber, refer to Section 8.2.
To remove the electrode, unscrew the retaining bracket, see
diagram 8.6.
Take the electrode out from below.
When removing and replacing the electrode take care not to
damage it.
When refitting, check spark gap, see diagram 8.6.
10.6 Multifunctional Control, Part No. 230512
- diagram 10.4
Gain Access as Section 5.2.
EXTENDED SECURING
Slacken control box securing screw, and swing out the control
SOLENOIDS
SCREWS (4)
box, see diagram 5.10.
Diagram 10.4
Disconnect the electrical plug.
Disconnect the gas cock, on the left hand side.
RETAINING
Support the multifunctional control , remove the four extended
SCREW
screws from the flanged connection at the right hand side.
Remove and discard the original  O ring from the flanged
connection and fit the new  O ring supplied, into recess, before
fitting the replacement multifunctional control.
After assembly test for gas soundness and purge in accordance
with the current issue of BS6891.
10.7 Solenoid - diagram 10.4
FRONT INSULATION
Remove the electrical plug from the multifunctional control.
Remove the securing screw and then the solenoid assembly.
REAR INSULATION
CHAMFER
10.8 Burner
SIDE INSULATION
Remove the burner as Section 8.2.
10.9 Injector, Part No.205757
'A'
Remove the burner as Section 8.2.
Remove the injector as Section 8.4.
10.10 Insulation - diagram 10.5
Combustion Chamber Front
Gain Access as Section 5.2.
Remove the combustion chamber front, then the insulation.
CHAMFER
SIDE INSULATION
Sides
Slide the insulation out. Make note of position of chamfer on
insulation pieces i.e. Left hand: chamfer bottom front. Right
VIEW ON 'A'
hand: chamfer top rear, see diagram 10.5.
Rear
With the side insulation removed the rear insulation can be
Diagram 10.5
removed and replaced.
23 221899A
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10 Replacement of Parts
10.12 Fan, Part No. 227033 - diagram 10.7
Refer to Section 5.3.
If top outlet installation: Remove air deflector, or it may just be
IMPORTANT:
swung back by loosening the securing screws, to enable fan
REMOVE ELECTRICAL CONNECTIONS
assembly to be removed, see diagram 8.7 and Section 5.3.
BY GRIPPING THE BOOT ONLY
Remove the electrical connections and disconnect the air tube.
CLEAR
Note: Remove the electrical connections by pulling insulation
AIR TUBE
boots only.
ELECTRICAL
Remove the fan assembly securing screw at the front, then
CONNECTIONS
withdraw the assembly.
The fan is secured to the flue hood by three screws.
The polarity of the electrical connections is not important.
SECURING
SCREW (2)
AIR
PRESSURE
SWITCH
FAN
ASSEMBLY
FAN
SECURING
SCREW (3)
ELECTRICAL
SECURING
CLEAR
CONNECTIONS
SCREW
AIR TUBE Diagram 10.6 Diagram 10.7
11 Spare Parts
11.1 Part Identification
The part number and the diagram location will help to identify the part.
11.2 Ordering
When ordering any spare parts please quote the number and description from the list together with the model name and serial number.
If ordering from the local gas undertaking also quote the GC number of the appliance and part.
Part No Description Location GC Part No
801159 Multifunctional control - 40FF Diagram 10.4. E24851
227033 Fan - 40FF Diagram 10.7. E24884
227032 Air pressure switch Diagram 10.6. E24881
227057 Electrical thermistor Diagram 10.1 & 10.2. E24871
202635 Spark electrode - 40FF Diagram 8.6. E24837
204697 Control knob Diagram 10.3. E24870
205757 Injector - 40FF Diagram 8.5. E24960
227098 Fuse Diagram 10.3. *******
227030 Control board - 40FF Diagram 10.3. E24877
227038 Safety temperature limiter Diagram 10.2. E24897
Because of our constant endeavour for improvement details may vary slightly from those in the instructions.
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