2000225229A.11.03
Instructions for Use
Installation and Servicing
To be l ef t wi t h t he user
Micron
70FF
G.C. No. 41-047-50
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 current edition of I.S.813
"Domestic Gas Installations" 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
FOR 1ST YEAR GUARANTEE PROTECTION
All labour charges
All call-out charges
CALL 0208 247 9857
Hepworth Heating Ltd.,
Nottingham Road, Belper, Derbyshire. DE56 1JT
General/Sales enquiries:
Tel: (01773) 824141 Fax: (01773) 820569
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.
Introduction 3
INSTRUCTIONS
Lighting the Boiler 3
FOR USE
General Data 1 4
INSTALLATION
Flue and Ventilation 2 7
INSTRUCTIONS Water Systems 3 8
Flue and Appliance Preparation 4 10
Boiler Installation 5 13
Commissioning 6 17
Instructions to the User 7 19
Servicing 8 20
SERVICING
Fault Finding 9 21
INSTRUCTIONS
Replacement of Parts 10 25
Spare Parts 11 28
2000225229A 2
Instructions for Use
All CORGI Registered Installers carry a CORGI ID card, and
Introduction
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
particular regard to edges.
WARNING. It is important that the case is not disturbed or
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
A sealed water system must be filled and pressurised by a
company or the local gas undertaking.
competent person.
Only light the boiler when you are sure that the system has been
Electrical Supply Failure
filled and pressurised.
Failure of the electrical supply will cause the burner to go out.
The pressure gauge should show at least 0.7bar, anything less
Should this occur, operation of the appliance will normally
than this figure could indicate a leak and you MUST contact your
resume after the electrical supply is restored.
installation/servicing company.
If the boiler does not relight after an electrical supply failure the
If there is any doubt about the boiler being full of water consult
overheat safety cutoff device may need resetting, as indicated
your installation/servicing company.
by illuminated reset light. Open the controls cover and turn
temperature control to 0 (anticlockwise) and then back to
ALL SYSTEMS.
original position, refer to diagram 9.1.
Turn the electrical supply on to the boiler and check that all
Note: If the boiler is switched OFF, manually, wait at least 30
remote controls are calling for heat. Check also that the
seconds before switching on again.
programmer (if fitted) is in the ON mode.
Safety Temperature Limiter
To Turn the Boiler On
If the safety Temperature Limiter operates on any other occasion
Open the controls cover, see diagram 9.1.
than an electrical supply failure, follow the procedure as in
Turn the control knob clockwise to any position between O and
Electrical Supply Failure . If the overheat operates again, turn
MAX. The maximum temperature setting is approx. 82OC
the appliance off and contact your installation/servicing company.
(180OF), see diagram 9.1.
Protection Against Freezing. The boiler lighting operation is now automatic as follows:
In this boiler there is a built-in frost protection, which will cause The fan will operate for 10 seconds prior to the start of the
the boiler, when it is switched off at the control knob, to operate ignition sparks, the gas valve solenoids will open and the burner
in the event of the water temperature in the boiler dropping to will light. This is shown by the "Burner Lit" LED on the control
6oC or 7oC. The boiler will switch off again when the temperature panel lighting up.
of the water in the boiler reaches about 15oC.
The burner will remain alight until switched off by the control
Note: The frost protection will not operate if the electrical supply thermostat, any remote control or the programmer.
is turned off.
Note: If the boiler is switched OFF, by hand, wait at least 30
If the boiler is to be out of use for any long period of time during seconds before switching on again.
severe weather conditions we recommend that the whole of the
When the boiler switches off, the boiler will go out.
system, including the boiler, be drained off to avoid the risk of
The automatic lighting sequence will operate again when heat
freezing up. Make sure that, if fitted, the immersion heater in the
is required.
cylinder is switched off.
Shut the controls cover.
Maintenance
It should be noted that this is a fan flue appliance and fan
To ensure the continued efficient and safe operation of the
operation may be heard.
boiler it is recommended that it is checked and serviced as
necessary at regular intervals. The frequency of servicing will
To Turn the Boiler Off
depend upon the particular installation conditions and usage,
For short periods, turn the control knob anti-clockwise to 0 Off.
but in general once a year should be enough.
To relight, turn the control knob to any position between 0 and
If this appliance is installed in a rented property in the UK there
MAX .
is a duty of care imposed on the owner of the property by the
For longer periods, turn the control knob fully anti-clockwise to
current issue of The Gas Safety (Installation and Use)
0 Off and switch off the electrical supply to the boiler.
Regulations, Section 35.
To relight follow the lighting sequence given above.
It is the law that any servicing is carried out by a competent
person.
Programmer
To obtain service, please call your installer or Heatcall (Glow-
worm s own Service Organisation) using the telephone number An optional programmer is available, which will automatically
given on the front cover of these instructions. switch your central heating system on and off once or twice a
day at whatever times you choose.
Please be advised that the Benchmark logbook should be
Note: If the programmer is manually switched on then off when
completed by the installation engineer on completion of
the boiler is cold, the boiler may continue to operate for about
commissioning and servicing.
30 seconds before switching off.
3 2000225229A
Installation - 1 General
D
A
B
TOP, SIDE
E E
FLUE
J
Q
OPTION
L
K
H
C C
WATER CONNECTIONS
G
F
22mm COPPER PIPE
GAS CONNECTIONS
N
RC1/2 (1/2 in BSPT)
REAR FLUE
OPTION
P M
MODEL A B C D E F G H J K L M N P Q
70FF 298 75 122 370 146 556 67.5 85 115 128 126 156 100 157 40 92 108
STD/EXD. EASYFIT STD/EXD. EASYFIT
All dimensions are given in millimetres
Diagram 1.1
Domestic Gas Installations , the current Building Regulations
Important Notice
and reference should be made to the current ETCI rules for
This boiler is for use on natural gas (G20) as distributed in the
Electrical Installation.
United Kingdom and Ireland and cannot be used on any other
gas.
In GB the following Codes of Practice apply:
This boiler can be used on open vented or sealed water
BS4814, BS6798, BS5440 Part 1 and 2, BS5546 Part 1, BS5449,
systems.
BS6891, BS6700, BS7074 Part 1 and 2, BS7593, BS7671.
Domestic hot water must be provided by pumped circulation.
In IE: I.S.813, BS5546, BS 5449, BS 7074, BS 7593.
Wherever possible, all materials, appliances and components
Manufacturer s instructions must not be taken as overriding
used shall comply with the requirements of applicable British
statutory requirements.
Standards.
Where no British Standards exists, materials and equipment
1.2 Data
should be fit for their purpose and of suitable quality and
workmanship. See diagrams 1.1, 1.2 and Table 1.
All dimensions are given in millimetres
Sheet Metal Parts
The Seasonal Efficiency Domestic Boilers UK (SEDBUK) is
WARNING. When installing or servicing this boiler care should
78.2%.
be taken when handling sheet metal parts, to avoid any possibility
The value is used in the UK Government s Standard Assessment
of personal injury.
Procedure (SAP) for energy rating of dwellings. The test data
from which it has been calculated have been certified by B.S.I.
1.1 Statutory Requirements
The appliance is suitable only for installation in GB and IE and
1.3 Range Rating
should be installed in accordance with the rules in force.
This boiler is range rated and may be adjusted to suit individual
system requirements, refer to diagram 1.2 for data label position,
In GB the installation of the boiler must be carried out by a
ratings and settings.
competent person as described in the following regulations:
The manufacturer s instructions supplied.
1.4 Heating System Controls
The Gas Safety (Installation and Use) Regulations.
The heating system should have installed: a programmer and
room thermostat controlling the boiler.
The appropriate Buildings Regulations either The Building
Thermostatic radiator valves may be installed, however they
Regulations, The Building Regulations (Scotland),The Building
must not be fitted in a room where the room thermostat is
Regulations (Northern Ireland).
located.
The Water Fittings Regulations or Water byelaws in Scotland.
Note: For further information, see the current issue of the
The Health and Safety at Work Act, Control of Substances
Building Regulations, approved document L1 (in the UK) and
Hazardous to Health (COSHH).
the references:
The Current I.E.E. Wiring Regulations. 1) GIL 59, 2000: Central heating system specification (CheSS)
and
Where no specific instructions are given, reference should be
2) GPG 302, 2001: Controls for domestic central heating
made to the relevant British Standard Code of Practice.
system and hot water. BRECSU.
In IE, the installation must be carried out by a competent person
An optional programmer for fitting on the boiler is availble, kit no.
and installed in accordance with the current edition of I.S.813
458065.
2000225229A 4
7059
PUMPED
FLOW
PUMPED
RETURN
1 General
1.5 Gas Supply
1.6 Electrical Supply
The gas installation shall be in accordance with the relevant WARNING. This boiler must be earthed.
standards.
All system components shall be of an approved type and shall
be connected in accordance with the current issue of BS7671
In GB this is BS6891.
and any applicable local regulations.
In IE this is the current edition of I.S.813 "Domestic Gas
External wiring must be correctly earthed, polarised and in
Installations".
accordance with the relevant standards.
The supply from the governed meter must be of adequate size
In GB this is BS6891.
to provide a steady inlet working pressure of 20mbar (8in wg) at
In IE this is the current edition of I.S.813 "Domestic Gas
the boiler.
Installations".
On completion test the gas installation for soundness using the
Connection of the boiler and system controls to the mains
pressure drop method, purge in accordance with the above
supply must be through a common isolator and must be fused
standard.
3A, maximum. This method of connection must be by a fused
double pole isolating switch, with a minimum contact separation
of 3mm on both poles. The switch should be readily accessible
and preferably adjacent to the appliance. It should supply the
appliance only and be easily identifiable as so doing.
Alternatively, an unswitched shuttered socket outlet and 3A
fused 3 pin plug, both to the current issue of BS1363 may be
used provided that they are not used in a room containing a bath
or shower.
Wiring to the boiler must be PVC 850C insulated cable, not less
than 0.75mm2 (24/0.20mm).
1.7 Contents of Packaging
The boiler is delivered in two or more packs, depending on flue
system, refer to diagram 4.1 for contents.
1.8 Water System
This boiler may be fitted to an open vented or a sealed water
system.
1.9 Draining Tap
PMS = 3.0 bar, is: Maximum water-side operating pressure.
The appliance flue type is a C12 and C32. This refers to a concentric
flue where the fan is downstream of the heat exchanger. The C12 is
System
a horizontal flue termination and the C32 is a vertical flue termination.
A draining tap must be provided at the lowest points of the
system which will allow the entire system and hot water cylinder
to be drained.
Draining taps should be to the current issue of BS2879.
Boiler
A draining point is fitted at the bottom right hand side of the heat
DATA exchanger.
LABEL
When draining is required, cover the controls to avoid water
damage.
Diagram 1.2
If required remove the combustion chamber front cover to
improve access.
TABLE 1.
1.10 Safety Valve
TOTAL DRY WEIGHT
49.2 kg A safety valve need not be fitted to an open vented system.
(Including Terminal)
LIFT WEIGHT
40.3 kg
WATER CONTENT
3.35 litre (0.74 gallon)
Rc 1/2 in.
GAS CONNECTION
81W
ELECTRICITY RATING
Internal fuse Type T3.15A
2x22mm copper pipes from
WATER CONNECTION
back of case
230V~50Hz, fused 3A
ELECTRICITY SUPPLY
Top left of inside of case
DATA LABEL
5 2000225229A
9444
7316
1 General
6mm
6mm *
6mm
2mm
2mm
10mm FROM A NON-PERMANENT
320mm FROM A PERMANENT
FRONT
VIEW
*190mm with Easyfit top flue fitted,
*160mm with standard/extended top flue fitted,
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
1.11 Location
1.14 Boilers in a Compartment
This boiler is not suitable for outdoor installation.
Where the installation of the boiler will be in an unusual position,
the current issue of BS6798 gives detailed guidance on these
This boiler may be installed in any room, although particular
requirements.
attention is drawn to the installation of a boiler in a room
containing a bath or shower where reference must be made to
An existing cupboard or compartment modified for the purpose
the relevant requirements.
may be used, providing minimum clearances are maintained.
Details of essential requirements for cupboard or compartment
In GB this is the current I.E.E. WIRING REGULATIONS and
design are given in the current issue of BS6798.
BUILDING REGULATIONS.
The doorway opening should be of sufficient size to allow for
In IE reference should be made to the current edition of I.S.813
easy removal of the boiler.
"Domestic Gas Installations" and the current ETCI rules.
Where the boiler is fitted in a cupboard or compartment,
Any electrical switch or boiler control utilising mains electricity
permanent ventilation is not required.
should be placed so that it cannot be touched by a person using
the bath or shower. The electrical provisions of the Building
Standards (Scotland) apply to such installations in Scotland.
1.15 Timber Frame Building
The boiler must be mounted on a flat wall which is sufficiently
If the boiler is to be installed in a timber frame building it should
robust to take its total weight.
be fitted in accordance with the Institute of Gas Engineers
The boiler may be fitted to a wall made of combustible material.
document IGE/UP/7/1998. If in doubt seek advice from the local
gas undertaking or Hepworth Heating Ltd.
1.12 Boiler Clearances
1.16 Anti-theft Kits
Refer to diagram 1.3.
Anti-theft kits are available for these appliances, contact
This boiler must be positioned so that at least the minimum
Hepworth Heating Ltd. for further information.
operational and servicing clearances are provided.
Additional clearances may be required for installation.
If fixtures are positioned next to the boiler ensure access is
provided for pipework installation.
At least a minimum clearance of 320mm from a permanently
fixed surface must be left in front of the boiler for servicing, see
diagram 1.3.
1.13 Room Ventilation
The boiler is room sealed and does not require the room or
space containing it to have permanent air vents.
2000225229A 6
2 Flue and Ventilation
The flue must be installed in accordance with the rules in force
2.2 Flue Options
in the countries of destination.
There are various flue systems to choose from, as follows:
Standard Top Outlet Flue Pack - Pt.No. 230483
2.1 Terminal Position
Easyfit Top Outlet Flue Pack - Pt. No. 232057
The minimum acceptable siting dimensions for the terminal
from obstructions, other terminals and ventilation openings are
Standard Rear Outlet Flue Pack - Pt. No. 230482
shown in diagram 2.1. For Ireland the minimum distances for
Extended Top Outlet Flue Pack - Pt. No. 230487
flue terminal positioning must be those detailed in I.S.813
1 Metre Extension Kit - Pt. No. 230484
"Domestic Gas Installations".
A flue system up to 3 metres in length can be made by
The terminal must be exposed to the external air, the position
connecting 1 metre flue extension kits together.
allowing free passage of air across it at all times.
Optional Wall Liner Kit No. 900862
Car ports or similar extensions of a roof only, or a roof and one
A Flue Bend Kit or Vertical Flue Kit up to 4 metres can be
wall, require special consideration with respect to any openings,
supplied, see Hepworth Heating "Flue Options Guide" for
doors, vents or windows under the roof. Care is required to
configurations available.
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
45o Flue Bend Pack - Pt. No. 230485
local gas company before installing the boiler.
90o Flue Bend Pack - Pt. No. 230486
If the terminal is fitted within 600mm below plastic guttering or
In Line Flue Adapter Kit - Pt. No. 230488
painted soffit an aluminium shield 1500mm long should be fitted
immediately beneath the guttering or eaves. If the terminal is
Vertical Flue Kit No. 458115
fitted within 450mm below painted eaves or a painted gutter, an
aluminium shield 750mm long should be fitted immediately
beneath the guttering or eaves.
MINIMUM SITING DIMENSIONS FOR MINIMUM
FANNED FLUE TERMINALS POSITION SPACING in mm
A DIRECTLY BELOW, ABOVE OR HORIZONTALLY
TO AN OPENING, AIR BRICK, OPENING WINDOWS,
C AIR VENT OR ANY OTHER
A
VENTILATION OPENING. 300
B,C
B,C
B BELOW GUTTER, DRAIN/SOIL PIPE 25
K
L
L C BELOW EAVES 25
G
A K
K
D BELOW A BALCONY OR CAR PORT 25
F
F
F
A
G E FROM VERTICAL DRAIN PIPES AND SOIL PIPES 25
E G
M G
G
F FROM EXTERNAL CORNERS 25
G ABOVE ADJACENT GROUND OR BALCONY LEVEL 300
Under Car Port etc.
H FROM A SURFACE FACING THE TERMINAL 600
I FACING TERMINALS 1200
D
J FROM OPENING (DOOR/WINDOW) IN
J
F
CAR PORT INTO DWELLING 1200
K
H,I
K VERTICAL FROM A TERMINAL 1500
L HORIZONTALLY FROM A TERMINAL 300
M FROM INTERNAL CORNERS 25
Diagram 2.1
7 2000225229A
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.
Diagram 2.2
TN9 1RA
3 Water Systems
The installation of the boiler must comply with the requirements
of the current issue of BS6798, in Ireland, refer also to the
OPEN VENTED FULLY PUMPED WATER SYSTEM
RECOMMENDED RELATIONSHIP BETWEEN
current edition of I.S.813 Domestic Gas Installations .
PUMP COLD FEED AND VENT
In GB it is necessary to comply with the Water Supply (Water
22mm VENT
Fittings) Regulations 1999 (for Scotland, the Water Byelaws
450mm (MIN.)
2000, Scotland).
MIN.
HEIGHT
To comply with the Water regulations your attention is drawn to:
The Water Regulations guide published by the Water Regulations
Advisory Service (WRAS) gives full details of the requirements.
15mm (MINIMUM)
COLD FEED
In IE the requirements given in the current edition of I.S.813
Domestic Gas Installations and the current Building Regulations FEED AND
EXPANSION
must be followed.
CISTERN
3.1 Frost Protection
1METRE
There is a built-in frost stat in this boiler. See Protection Against
MIN.
Freezing in Instructions for Use. Where other parts of the
There must always
system are vulnerable this should also be considered as specified
be a cold water path
in the current issue of BS5422.
PUMP
to the return
connection
3.2 Pump
of the boiler.
FLOW
150mm
The pump, with integral valves, should be fitted in the heating
MAX.
flow pipework from the boiler, it should be set to produce a
temperature difference of 11oC (20oF), between the flow and
RET.
return, with the boiler thermostat set at MAX , which is about
IF REQUIRED
82oC (180oF).
22mm (MINIMUM)
BOILER
The pressure loss of the boiler at 30.6 litre/minute giving 11oC BY-PASS WITH
LOCKSHIELD VALVE
temperature difference is 950mm head of water.
Diagram 3.1
High resistance microbore systems may require a higher duty
pump.
The cold feed must be 15mm minimum size.
3.3 Bypass
It is important that the relative positions of the pump, cold feed
A bypass is usually unnecessary on systems using a 3 port and open vent are as shown in diagram 3.1.
diverter valve since one port will remain in the open position at
The unrestricted open vent from the boiler must rise continuously
all times. This allows satisfactory operation of the pump
to discharge over the feed and expansion cistern.
overrun.
However if thermostatic radiator valves are fitted to all radiators
3.5 Domestic Hot Water System
or two port valves are used a bypass is required.
General - All domestic hot water circuits, connections, fittings
The bypass connection must be at least 2 metres away from the
must be in accordance with the relevant standards and water
boiler.
supply regulations.
The flow through the boiler must not be allowed to fall such that
For GB: Guidance G17 to G24 and recommendation R17 to
there is a temperature difference greater than 20oC between the
R24 of the Water Regulations Guide.
flow and return.
For IE: The current edition of I.S.813 Domestic Gas Installations .
3.4 Water System
3.6 Cylinder
For an open vented system the boiler must be supplied from an
For all systems supplying domestic hot water the cylinder must
unrestricted water supply taken from a feed and expansion
be indirect. It is recommended that the cylinder be fitted with
cistern fitted at a maximum height of 27 metres above the boiler.
some form of temperature control.
2000225229A 8
7056
7645
RETURN
FLOW
CYLINDER
HEATING
3 Water Systems
3.7 Open Vented Fully Pumped Heating and
If fitting into an existing system the local authority must also be
Domestic Hot Water
advised.
The connections for the system MUST be as shown in diagrams
3.15 Filling a Sealed Water System
3.1 and 3.2.
Provision for filling the system at low level must be made.
Plastic pipes should not be connected directly to the boiler. An
The installation should comply with the appropriate requirements
intermediate metallic pipe of 1m in length should be fitted
of the current issue of BS 5449.
between the boiler and the plastic pipe system. Plastic pipes
should be type S to BS7291.
3.16 Water Makeup
3.8 Inhibitor
Provision must be made for replacing water lost from the
system. A make up vessel mounted above the highest point of
Attention is drawn to the current issue of BS5449 and BS7593
the system and connected through a non-return valve to the
on the use of inhibitors in central heating systems.
system on the return side of either the hot water cylinder or
When installing in an existing system take special care to drain
heating system.
the entire system, including radiators, then thoroughly cleaning
out before installing the boiler whether or not adding an inhibitor.
3.9 Sealed Water Systems
The installation should comply with the appropriate requirements
of the current issue of BS4814, BS5449, BS6759, BS6798 and
28mm
28mm
BS7074 Part 1 and 2.
PIPE
PIPE
22mm
3.10 Safety Valve
22mm
PIPE
PIPE
A safety valve must be fitted to a sealed water system.
It shall be preset, nonadjustable with a lift pressure of 3bar,
incorporating seating of a resilient material, a test device and a
connection for drain.
The drain from the safety valve must be routed clear of any
electrical fittings and positioned so that any discharge can be
22mm VENT & 15mm COLD FEED
seen.
TO BE FITTED IN ACCORDANCE WITH BS 5449
3.11 Expansion Vessel - Sealed Systems only
A diaphragm type expansion vessel, conforming to the current
issue of BS4814 (see also BS7074 Part 1 and 2) must be
connected at a point close to the inlet side of the circulating
INDIRECT
pump, unless laid down differently by the manufacturer.
CYLINDER
IF REQUIRED
The expansion vessel volume depends upon the total water
1metre Min. ALTERNATIVE
BYPASS 22mm
system volume and the initial system design pressure. For any
27 metres SYSTEM
MIN WITH
system an accurate calculation of the vessel size is given in the
Max. CONTROL
LOCKSHIELD
current issue of BS7074 Part 1. VALVES
VALVE
HEATING
Example: For an initial system design pressure of 0.7bar the
SYSTEM
minimum total vessel volume required is 0.063xTotal System
PUMP
volume.
Note. A higher initial design pressure requires a larger volume
expansion vessel.
FULLY PUMPED CIRCULATION
Guidance on vessel sizing is also given in the current issue of
SYSTEM (DIAGRAMMATIC)
BS5449 and BS7074 Part 1, for IE refer to the current edition of
I.S.813 "Domestic Gas Installation".
22mm FOR COMBINED FEED & VENT
The charge pressure must not be less than the static head of the
TO BE FITTED IN ACCORDANCE WITH BS 5449
system, that is, the height of the highest point of the system
above the expansion vessel.
The water content of the boiler is given in Data Table 1.
INDIRECT
3.12 Pressure Gauge - Sealed Systems only
CYLINDER
A pressure gauge with a set pointer and covering at least the
IF REQUIRED
1metre Min.
range of 0 to 4bar (0 to 60lb/in2) shall be permanently fitted to
BYPASS 22mm
27 metres
the system in a position where it can be seen when filling the
MIN WITH
Max.
system. LOCKSHIELD
VALVE
HEATING
3.13 Domestic Hot Water Cylinder
SYSTEM
SINGLE FEED INDIRECT CYLINDERS ARE NOT SUITABLE.
PUMP
The domestic hot water cylinder must be of the indirect coil type.
ALTERNATIVE
It must be suitable for working at a gauge pressure of 0.35bar SYSTEM
CONTROL
above the safety valve setting.
VALVES
3.14 Domestic Hot Water System - Unvented
FULLY PUMPED CIRCULATION BYPASS
(DIAGRAMMATIC)
Diagram 3.2
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.
9 2000225229A
6770
PUMPED
RETURN
PUMPED
FLOW
7151
7152
4 Flue and Appliance Preparation
TOP OUTLET FLUE PACK STD/EXTD
'X' plus 24.5mm (RH)
FLUE LENGTH
FLUE LENGTH
159.5mm (LH) = flue length
MAX 840mm (extd.)
15mm
MAX 840mm (extd.)
15mm
MAX 570mm (std/Easyfit)
EASYFIT MAX 570mm (std/Easyfit)
'X' plus 52.5mm (RH)
144.5mm*
(must include 50mm min.
SCREW
9.5mm*
side clearance)
& TAPE
'X' plus 187.5mm (LH) = flue length
STD/EXTD
31.5mm*
SCREW
'X'
'Y' plus 35mm
& TAPE
= flue length
52mm
'Y'
EASYFIT
'Y' plus 63.5mm
*STD/EXTD flue only
TOP OUTLET/SIDE FLUE
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
EASYFIT/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
'Y'
STD/EXTD SIDE FLUE
STD/EXTD REAR FLUE
'X' plus 24.5mm (RH)
'Y' plus 35mm = flue length
159.5mm (LH) = flue length
EASYFIT
EASYFIT
'Y' plus 63.5mm = flue length
'X' plus 52.5mm (RH)
'X' plus 187.5mm (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
75 111 570 535 -
REAR
75 102 570 - 546
SIDE R.H.
75 237 570 - 411
SIDE L.H.
TOP EXTD.
REAR 75 111 840 805 -
SIDE R.H. 75 102 840 - 815
SIDE L.H. 75 237 840 - 680
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
OPTIONAL
starting. FLUE
COLLAR
Refer to diagram 4.1.
If you are using a Flue Bend or a Vertical Flue Kit, please follow
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
4.2 Flue Preparation
All flue assemblies are designed for internal installation, given
EASYFIT TOP
that there is sufficient clearances opposite to the flue for the
FLUE OUTLET
installation of the flue.
115mm MINIMUM
If there is insufficient clearance the flue can be installed from HOLE 115mm
outside.
TOP FLUE OUTLETS
For a wall thickness up to 300mm and provided that there is
115mm
sufficient space an optional wall liner kit is available for the flue
MINIMUM
to be installed from the inside.
HOLES
For a wall thickness of over 300mm the external flue hole will
need to be made good from the outside.
EASYFIT TOP
This applies also if you use the flue kit without the optional wall
FLUE OUTLET SIDE FLUE
liner kit, irrespective of wall thickness.
115mm MINIMUM
BOILER
HOLE
FIXING POINT
4.3 Rear and Side Flue Application
Select the boiler location and flue application, with due regard
FLUE
to the terminal position, see diagram 2.1.
CENTRE LINE
Take the template from the boiler pack and temporarily position
it on the wall, making sure that the minimum clearances are
maintained, see diagram 4.3.
REAR FLUE BOILER
OUTLET FIXING POINT
Mark the centre line position of the flue, "Top" or "Rear" as
115mm
diagram 4.3.
MINIMUM
For a side flue, extend centre line of "Top" to L.H. or R.H. corner.
BOILER
HOLE
Mark the position of the centre of the flue and boiler, as
CENTRE LINE
diagram 4.3.
Diagram 4.3
4.4 Flue Hole Cutting
Having marked out the flue centre cut a hole for the flue using,
MOUNTING
WALL
preferably, a 115mm minimum core drill.
BRACKET
PLUG
Note: If required an optional wall liner kit, part no. 900862, is
available complete with instructions.
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.
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 required.
PLUG
SECURING
SCREW
4.6 Flue Duct
Extend the telescopic flue to the required length, making sure
that the minimum overlap is no less than 25mm, and that the flue
terminal projects 15mm minmum beyond wall face, see diagram MOUNTING
4.1. BRACKET
FIXED TO BOILER
Carefully drill though air duct pilot hole and secure with self
tapping screw provided in fittings pack, see diagram 4.1.
Diagram 4.4
11 2000225229A
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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,
WALL THICKNESS- FOAM SEAL
drill, seal and secure them with the self tapping screw and tape
UP TO 300mm
provided. The completed flue system must not exceed 3metres,
see relevant part of diagram 4.1.
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.
Q
Make sure to cut square and remove any burrs.
If the boiler is not to be fitted for some time cover the hole in the
wall.
15mm
FOAM SEAL
Note: If a horizontal flue extension is required it must be used
in conjunction with the standard flue, see diagram 4.1.
Q-35mm
IMPORTANT: When using the standard flue kit (either rear
outlet or top outlet fixing) or Easyfit, the terminal restrictor
must be fitted. This is not fitted for any other flue type/
arrangement, extension kits etc.
Note: There are three restrictors in the loose items pack,
use the one stamped "D" for the Micron 70FF.
Q
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
WALL THICKNESS-
tighten, see diagram 4.6.
OVER 300mm
Engage the terminal restrictor on the flue terminal by hooking
it over the terminal end and engaging the clamping bracket
Diagram 4.5
behind the inner ring of the terminal securing it by tightening the
locking screw, see diagram 4.6
STANDARD 510mm REAR AND
4.7 Internal Access Flue
STANDARD 570mm TOP FLUE ONLY
If access to the outside wall is not practical, the flue system can
EASYFIT 570mm or less
be installed from inside. Use of the optional wall liner kit is
required.
FLUE
TERMINAL
4.8 Rear Flue Fixing
CLAMPING
Fit the self adhesive foam seal provided in the flue pack around
the air duct at the position shown in diagram 4.1.
BRACKET
Make sure that the ductings do not slope down towards the
boiler.
Make good around the flue outside after installation of boiler.
Important: If the wall liner kit is used, the self adhesive foam seal
included 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
LOCKING
boiler.
SCREW
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 must be used in place of the one supplied with the flue
RESTRICTOR
CLAMPING
pack, see diagram 4.5 for position of self adhesive seal.
BRACKET NIB
4.10 Flue Positioning
Push the flue assembly into the hole such that it is 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
With the boiler still in the bottom tray, remove the casing front
SECURING
cover. Open the controls cover first, then by undoing the two
SCREWS
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 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
CONTROLS COVER
Diagram 5.1
and return pipe incorporating an air vent is available, kit No.
458585, see diagram 5.3.
Note: If the installer wishes to adapt the standard pipework he
RETURN
TUBING
may do so, but must incorporate an air-vent at the highest point
TAIL PIPE
NUT
on the flow pipe and the highest point of the return pipe, see
RUBBER
diagram 5.11.
FLOW
WASHER
TAIL
5.3 Mounting the Boiler
PIPE
Ensure to fit the blanking plate and gasket on the boiler flue
outlet not being utilised, see diagram 5.6.
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-tap screws provided, see diagram 5.6.
HEATING
HEATING
RETURN
Note: The spigot would only be fitted to the top flue outlet where
FLOW
28mm
a vertical flue kit or in certain flue bend orientations is incorporated.
PIPE
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
and 458114.
Important: Secure lower bracket to wall with screw into wall
plug already prepared.
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 diagram1.3
TAIL PIPE
in Instructions for Use, it may be necessary to remove the
FLOW
control knob to enable the control box to be fully swung out.
AIR VENT
RETURN
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-tap screws
provided, see diagram 5.9.
Note: Ensure that the taptite and self-tap screws are positioned
TUBING
as shown in diagram 5.8 to enable the air deflector to be fitted
NUT
correctly.
If fixing to the back of the boiler, i.e. spigot, slide the flue into the
WASHER
spigot until it engages in the bayonet connection and then twist
clockwise 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.
Disconnect the the blue and purple electrical connections to the
fan, and the air pressure switch tube connections, see diagram
WASHER
5.5.
Note: Remove the electrical connections by pulling insulation
boots only.
Remove the securing screw at the front, see diagram 5.5.
Diagram 5.3
The fan assembly may now be slid forward.
13 2000225229A
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5 Boiler Installation
Rear Flue fixing.
MOUNTING
Fit the fan elbow and secure with jubilee clip to the fan outlet, do
BRACKET
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.
Top flue fixing
Fit the two O rings from the loose items pack onto the flue duct
MOUNTING
extension, there are recesses on the flue duct extension for
BRACKET
locating them, see diagram 5.7.
Fit the air deflector in position using the rear left hand taptite
screw and the one diametrically opposite which hold the top
SECURING
turret and secure with the wing nuts provided, see diagram 5.8.
SCREW
NOTE:
Note: Apply soap to seals on flue duct extension piece to help
PIPES REMOVED FOR CLARITY
Diagram 5.4
it slide on, be careful not to damage O ring.
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
RED AIR
so that the nibs are upper most, see diagram 5.7.
PRESSURE
PRESSURE
ELECTRICAL
Locate the fan elbow with jubilee clip on the fan outlet, do not TUBE
TUBE
tighten yet, see diagram 5.7. CONNECTIONS
Reconnect the blue and purple electrical connections to the fan,
the polarity of the connections is not important.
Reposition the fan assembly and draw down the flue duct
extension piece onto the fan elbow, see diagram 5.7.
Fit the retaining clamp of the fan elbow, bending the straps
around the fan elbow raised clamping surfaces 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
SECURING
clamping surfaces.
SCREW
Secure the fan elbow to the fan outlet with the Jubilee clip.
Continued.
Secure the fan assembly by replacing securing screw, see
diagram 5.5.
Reconnect the air pressure switch tubes, ensuring they are in
the correct orientation, as shown in diagram 10.7.
WING
5.4 Water Circulation System
NUT (2)
Complete the water connections to the boiler.
Fill, vent and flush the system.
Check for any water leaks and put right.
AIR
DEFLECTOR
5.5 Gas Connection
Make the gas connection to the Rc1/2in gas service cock, see
diagram 6.2.
NOTE:
REMOVE ELECTRICAL
The whole of the gas installation, including the meter, should be
CONNECTIONS BY GRIPPING
inspected, tested for soundness and purged in accordance with
the current issue of BS6891 and in IE the current edition of THE BOOT ONLY
Diagram 5.5
I.S.813 "Domestic Gas Installation".
2000225229A 14
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5 Boiler Installation
5.6 Control Box Access 5.9 Testing
Slacken the control box securing screw, see diagram 5.10. Checks to ensure electrical safety must be carried out by a
Swing the box out on its hinge. competent person.
5.7 Electrical Connection
WARNING. This boiler must be earthed.
Note: If an optional programmer is to be installed, it should be
SCREWS
fitted at this stage, see separate installation instructions supplied
(4)
REAR FLUE
with programmer
FIXING
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.
GASKET
Standard colours are, brown - live (L), blue - neutral (N) and
green/yellow - earth ( ).
The mains cable outer insulation must not be cut back external
to the cable clamp.
Make sure the cable is suitably secured.
When making connections, make sure that the earth conductor
is made of a greater length than the current carrying conductors,
SPIGOT
so that if the cable is strained the earth conductor would be the
last to become disconnected.
BLANKING
PLATE
5.8 Pump Connection
Route pump cable as mains, see diagram 5.10.
SCREWS
Connect to control box terminal block, see diagram 9.5.
(4)
TOP FLUE FIXING
Diagram 5.6
FLUE DUCT RETAINING
EXTENSION CLAMP
TOP
TURRET
PRESS
PRESS
FLUE
DUCT
FAN
PRESS
FAN ELBOW
EXTENSION
ELBOW
CLASP
CLAMPING
SURFACE
" O " RINGS
NIBS
RETAINING
CLAMP
FAN ELBOW
REAR
JUBILEE
JUBILEE
CONNECTION
CLIP
CLIP
TOP
(within casing)
CONNECTION
Diagram 5.7
15 2000225229A
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9355
6791
5 Boiler Installation
After installation of the system, preliminary electrical system
checks as below should be carried out:
1. Test insulation resistance to earth.
2. Test earth continuity and short circuit of all cables.
NOTE : A SWITCH LIVE (Ls) SHOULD BE CONNECTED
3. Test the polarity of the mains.
FROM AN EXTERNAL CONTROL.
The installer is requested to advise and give guidance to the
IF NO EXTERNAL CONTROL IS AVAILABLE INSERT A
user of the controls scheme used with the boiler.
LINK BETWEEN Lp & Ls.
Fit the casing.
MAINS
b
TO
SUPPLY
g/y
AIR
PUMP
230V ~ 50Hz
br
DEFLECTOR
BLOCK LP LS N PL PN
CONNECTOR
SELF-TAP br
bl b y p
SCREWS
(2)
CABLE
SECURING
CLAMP
SCREW
CONTROL BOX
TAPTITE
SCREWS
(2)
WING NUT
Diagram 5.8
TOP TURRET FLUE HINGE PIN
OUTLET
GROMMET
Diagram 5.10
SCREWS (4)
"T" PIECE
AIR VENT
FLOW
GASKET
TOP
TURRET
RETURN
FLUE
DUCT
EXTENSION
AIR VENT
Diagram 5.11
Diagram 5.9
2000225229A 16
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6 Commissioning
Isolate the boiler from the electrical supply.
Important Note: The warning notice attached to the
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
Commissioning should be carried out by a competent person in
FASCIA
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
Fill until the pressure gauge registers 2.7bar (40lbf/in2). Clear
any air locks and check for water soundness.
Check the operation of the safety valve, by allowing the water
SECURING
pressure to rise until the valve opens. The valve should open
SCREWS
within +/- 0.3bar (+/- 4.3lbf/in2) of the pre-set pressure. Where
this is not possible conduct a manual check and test.
Note: Fit a suitable discharge pipe to the safety valve and route CONTROLS COVER Diagram 6.1
it to outside the building so that any discharge can be seen but
will not cause injury to persons, damage to property or any
electrical installation.
MULTIFUNCTIONAL
Release cold water to initial system design pressure.
CONTROL
The set pointer on the pressure gauge should be set to coincide
GAS
with the indicating pointer.
PRESSURE
ADJUSTMENT
6.3 Initial Lighting and Testing
SCREW
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 the '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 the control box, refer to diagram
GAS COCK
5.10. Swing open control box.
(ON)
Turn the gas service cock On , see diagram 6.2. A 14mm
spanner may be required for this.
BURNER
Purge in accordance with the current issue of BS6891.
PRESSURE
Replace control box. TEST POINT
GAS COCK
Turn on the electrical supply.
(OFF)
WARNING. The multifunctional control and fan operate on
mains voltage, terminals will become live.
NOTE: Do not adjust any
other setting screws
If programmer control fitted, make sure it is in the ON mode.
Diagram 6.2
Note: If the programmer is manually switched on then off when
the boiler is cold, the boiler may continue to operate for about
30 seconds before switching off.
Make sure that any remote controls are calling for heat.
Turn the temperature control clockwise to 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.
To re-start the lighting sequence, turn the temperature control
to 0 , then fully clockwise to Max .
After the burner has lit, the Burner on neon on the control panel
will come on.
17 2000225229A
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6 Commissioning
6.4 Testing - Electrical
Table 2
Turn the boiler temperature control knob fully clockwise to the
maximum setting, which is approx. 82OC (180OF).
70FF MIN. MED. MAX.
The lighting sequence is automatic as follows:
The fan will operate for 10 seconds prior to the start of the APPROX. m3/h 2.05 2.21 2.34
ignition sparks, the gas valve solenoids will open and the burner
GAS RATE ft3/h 72.3 77.9 82.5
will light. This is shown by the "Burner Lit" LED on the control
panel lighting up.
The burner will stay alight until switched off, either by the
The gas rates shown in Table 2 are for guidance only, dependent
temperature control or remote system control. At this point the
on the heat setting.
fan will overrun by 5 seconds.
Turn the temperature control knob fully anticlockwise to O .
To make sure that the flame supervision device is working
Isolate from electrical supply.
correctly the following should be done.
Remove the pressure gauge from the test point and refit screw,
With the burner alight, turn the gas service cock "OFF", see
making sure a gas tight seal is made.
diagram 6.2.
Refit control box and fascia.
After a short period the burner will go out and fan will overrun for
5 seconds.
Note: The fixing holes of the fascia are slotted to allow fine
adjustment to align control cover with casing.
The correct working of the flame supervision device is shown by
the "Burner Lit" LED going out and the lighting sequence
When the temperature control is turned to the O position, by
starting up, as follows:
hand, wait at least 30 seconds before turning On again.
1. Fan starts.
There may be an initial smell given off from the boiler when new,
this is quite normal and it will disappear after a short period of
2. Spark ignition operates for 10 seconds.
time.
3. Fan will overrun for 5 seconds.
4. The fan will start again.
6.6 Testing - All Water Systems
5. After 10 seconds the spark ignition operates, this continues
Allow the system to reach maximum working temperature and
for a further 10 seconds.
examine for water leaks.
6. Fan will overrun for 5 seconds.
There should be no undue noise in the system.
This sequence is repeated ONCE more and the boiler will shut
The boiler should then be turned off and the system drained off
down. The following illumination will happen with the LED on
as rapidly as possible, whilst still hot.
the front of the control panel, "Reset" permanently ON and
Refill system.
"Burner Lit" flashing fast (8 Hz).
If the above lighting sequence fails, refer to section 9 - Fault
6.7 Open Vented System
Finding.
Ensure there is no pumping over of water or entry of air at the
To continue, turn the gas service cock "On", see diagram 6.2.
open vent above the feed and expansion cistern.
To restart the lighting sequence, turn the temperature control
6.8 Adjustment - Fully Pumped Open Vented
knob to "O" then fully clockwise to "Max".
and Sealed Water Systems
During Normal Operation when the boiler switches "Off", the
When commissioning the system the boiler should first be fired
burner will go out. The automatic lighting sequence will work
on full service, that is, central heating and domestic hot water.
again when heat is required.
Adjust the pump to the system design setting then balance the
system, making adjustments as necessary.
6.5 Testing - Gas
With the boiler on proceed as follows:
6.9 Thermostatic Radiator Valves
Undo the screw which secures control box, see diagram 5.10.
If thermostatic radiator valves are fitted care must be taken to
Open control box, see diagram 5.10.
ensure that there is an adequate flow rate through the boiler
when they close, refer to the current issue of BS7478 for
WARNING. The multifunctional control and fan operate on
guidance. If fitted to all radiators ensure a bypass is fitted and
mains voltage, terminals will be live.
adjust to achieve a temperature difference no greater than 20oC
Test for gas soundness around the boiler gas components
between flow and return with the thermostatic valves closed.
using a suitable leak detection fluid, in accordance with the
current issue of BS6891.
6.10 Completion
Check the main burner gas pressure at least 10 minutes after
Adjust the boiler temperature control and any system controls
the boiler has lit, refer to Data Label.
to their required settings. In addition it is necessary to complete
the "Benchmark" logbook.
If necessary remove cap then adjust the gas pressure to obtain
the required setting turning screw clockwise to decrease
For IE, it is necessary to complete a "Declaration of Conformity"
pressure, see diagram 6.2.
to indicate compliance to I.S.813. An example of this is given in
Replace cap. the current edition of I.S.813.
Should any doubt exist about the gas rate, check it using the gas
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.
2000225229A 18
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 in the UK.
The user shall not interfere with or adjust sealed components.
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.
19 2000225229A
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.
Products of Combustion Check
CLEAR AIR
Note: To obtain a products of combustion reading, remove the
PRESSURE
cap from the sampling point, located on top of the inner casing,
TUBES
see diagram 8.1.
Connect the analyser tube onto the nipple.
RED AIR
Switch on the electrical supply and gas supply then operate the
boiler. PRESSURE
TUBE
On completion of the test switch off the electrical supply and the
gas supply, remove analyser tube and replace sampling point
Diagram 8.1
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
(8 off)
Unless stated otherwise all parts are replaced in the reverse
order to removal.
8.1 Access
Remove the boiler case, see diagram 5.1 and Section 5.2.
8.2 Burner
Remove front combustion chamber cover which is secured by
two screws, see diagram 10.5. Diagram 8.2
Remove electrode bracket by undoing screw and withdrawing
off locating pin, see diagram 8.5.
ELECTRODE
RETAINING PINS
BURNER
BRACKET
The HT lead and earth lead (still connected) will allow electrode
to hang down at the front of the appliance.
Remove control box retaining screw and swing control box out,
see diagram 5.10.
Remove burner retaining screws, located under boiler casing,
see diagram 8.3.
Pull out burner together with the baffle support, see
diagram 8.3.
To remove baffle support from burner, slide off retaining pins
see diagram 8.3.
Use a vacuum cleaner or suitable stiff brush 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
SCREW
manifold pins and horizontal, see diagram 8.4.
BURNER RETAINING
BAFFLE SUPPORT SCREWS
Diagram 8.3
Note: It is advisable while servicing the burner to check the
combustion insulation and replace if damaged, see Section
10.10.
LOCATION
PIN
8.3 Cleaning Heat Exchanger Flueways
BURNER
LOCATION
Disconnect the air pressure switch tube connections, red from
INJECTORS
PIN
fan, both clear tubes from test nipple, see diagram 8.1.
Remove the blue and purple electrical connections from the fan
see diagram 5.5.
Remove the fan assembly complete with the flue elbow, see
diagram 5.5 and Section 5.3.
Place a sheet of paper in the base of the combustion chamber
and over the injectors to prevent particles entering.
Remove the baffles, see diagram 8.2.
Diagram 8.4
Clean the heat exchanger flueways with a suitable stiff brush.
Remove the paper together with any debris.
2000225229A 20
7231
12312
7173
7171
8 Servicing
Important: Where the flue has a rear connection (from back
of casing), see diagram 5.6, it is essential to make certain
ELECTRODE
that the flue duct is fully located into the fan elbow until it
can go no further, enabling the flue duct to make a complete
3.4 + 1.3
seal when secured.
8.4 Injector Manifold
With the burner removed the injector manifold can be inspected
and cleaned as necessary, see diagram 8.4.
For cleaning do not use a wire or sharp instrument on the holes.
If any injectors are 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
RETAINING
After completing a service and before fitting the case, check
BRACKET
condition of the case seal and renew if necessary.
Examine flue hood and terminal to make sure they are clean
PROTECTION
and clear of obstructions.
SLEEVE
SCREW
Refit all parts.
Diagram 8.5
Light the boiler and carryout the functional checks as described
in Section 6.
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 9.3, Pump Overrun
Fault Finding, see diagram 9.2, Fault Finding Wiring Diagram,
see diagram 9.4, Pictorial Wiring Diagram, see diagram 9.5.
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 the
overheat device may need resetting.
Open the control cover, see diagram 9.1 and if the RESET neon
is lit, turn temperature control 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
Diagram 9.1
CONTROLS COVER
fault finding chart.
Pump Overrun Operation
The PCB has a timed pump overrun facility.
The pump should run for several minutes after remote controls have stopped calling for heat.
Before using the fault finding chart ensure all wiring is correct and in good condition, the pump is not faulty and check the PCB fuse.
NO
Does the pump run when SL is applied ?
Faulty PCB. Replace
YES
NO
Does pump continue to run after
SL is interrupted?
YES
NO
Does pump stop after several
minutes?
YES
System satisfactory.
Diagram 9.2
21 2000225229A
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9 Fault Finding
Diagram 9.3
2000225229A 22
10270
9 Fault Finding
LED Fault Coding
LED 1 LED 2 LED STATUS CONDITION
(RESET) (BURNER LIT)
Non - Volatile Lockout
Burner Lit
PCB Failure
Other Errors
Simultaneous Reversed Polarity
Simultaneous Lighting Sequence - Thermistor
Simultaneous Lighting Sequence - Fan/APS
Software Sequence Error
Alternating
Software Error
Ignition Lockout
Slow Flashing (2Hz)
Fast Flashing (8Hz)
KEY
Pn - Pump Neutral Pl - Pump Live
bk BLACK
N
br BROWN
O/H
b BLUE
CUTOFF AIR
b b
p PURLPLE
PRESSURE
b
r RED SWITCH
y YELLOW
(C)
gy GREY
EV1
(N/O) (N/C)
FAN
PL PI
EV2
SL Pn
bk br b p br p r gy y br bk
y br
SPARK
ELECTRODE
AIR PRESSURE SWITCH CONNECTIONS
FUSE
SL MAIN TERMINAL STRIP CONNECTIONS
TYPE T3.15A
PRINTED CIRCUIT BOARD CONNECTIONS
Diagram 9.4
23 2000225229A
10275
10277
9 Fault Finding
AIR
PRESSURE
SWITCH
KEY
br BROWN
b BLUE
r
g/y GREEN/YELLOW
y
g
g GREY
bk BLACK
b
p PURPLE
y YELLOW
p
r RED
FAN
GAS
CONTROL
VALVE
SAFETY
TEMPERATURE
LIMITER
br
br
THERMISTOR
ELECTRODE
bk bk
bk b
br br br
g/y
g/y
P.C.B (CONTROL BOARD)
g
y p
r
b
RESET LED BURNER LIT LED
T3.15A FUSE
b
g/y
MAINS SUPPLY
PUMP
230V~50Hz
br
* KEY TO TERMINAL BLOCK
LP LS N PL PN
BLOCK CONNECTOR
LP = LIVE (Permanent)
br
bl p LS = LIVE (Switched)
y
b
= NEUTRAL
N
= EARTH MAIN
= EARTH PUMP
g/y g/y
PL = PUMP LIVE
PN = PUMP NEUTRAL
* NOTE: A switch live (Ls) should be connected
from an external control.
If no external control is available insert a link
between Lp & Ls.
Diagram 9.5
2000225229A 24
10274
10 Replacement of Parts
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.
10.1 Access
Gain Access as Section 5.2.
THERMISTOR
10.2 Electrical Thermistor, Part No. 227036
P.C.B.
Slacken control box securing screw and swing out the control
CONNECTION
box, see diagram 5.9.
Diagram 10.1
Disconnect the thermistor plug from the control board by slightly
bending the retaining latch and removing the plug, see diagram
10.1.
THERMISTOR
Remove fan assembly, see section 5.3.
PHIAL
Remove the plastic R clips which retain all leads at the rear of
SECURING
RETAINING
boiler.
SCREW
WIRE
Remove the retaining wire and withdraw the electrical thermistor
from its phial, see diagram 10.2.
RETAINING
Remove thermistor lead from the plastic R clips at rear of case
BRACKET
and the cable clips (these are located down left hand side of
boiler).
Draw thermistor lead followed by thermistor out through the
case grommet.
Re-assembly note. When fitting the thermistor make sure it is
fully inserted into the phial, see diagram 10.2. Take care when
re-threading as not to damage thermistor.
Refit the cable clips and the plastic R clips retaining the leads.
ELECTRICAL
Refit the plastic retaining tag.
CONNECTORS
Refit the thermistor lead plug.
SAFETY
Refit fan assembly.
TEMPERATURE
Important: Where the flue has a rear connection (from back
LIMITER
Diagram 10.2
of casing), see diagram 5.6, it is essential to make certain
that the flue duct is fully located into the fan elbow until it
can go no further, enabling the flue duct to make a complete
seal when secured.
P.C.B. FUSE
P.C.B.
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 device, 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 safety temperature limiter is
secure.
Note: Polarity of electrical connections is not important.
10.4 Control Board (PCB), Part No.
P.C.B.
2000227135 - diagram 10.3
EXTENSION SUPPORT
Remove casing, see Section 5.2.
PIECE
Slacken control box securing screw, see diagram 5.10.
CONTROL
KNOB
Note: To ease access the control box may be pulled away from
Diagram 10.3
the boiler by removing the hinge pins, see diagram 5.10.
25 2000225229A
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7322
12006
10 Replacement of Parts
Carefully pull the control knob and extension piece away from 10.11 Air Pressure Switch, Part No. 227128 -
diagram 10.6
the PCB.
Gain Access as Section 5.2.
Carefully pull the board away from its supports.
Remove the air pressure tubes and electrical connections from
Disconnect the electrical plugs by slightly bending back the
the switch, release the screw and remove the switch.
retaining latches to allow withdrawal.
When fitting the replacement make sure that the plastic tubes
Disconnect the HT lead and spark earth lead.
are fitted as shown in diagram 10.6 and the electrical connections
When refitting refer to wiring diagram 9.5.
as shown in diagram 9.5
Take care when replacing the control knob and extension by
supporting the potentiometer on the P.C.B.
SOLENOID
EXTENDED
SECURING
SECURING
10.5 Electrode, Part No. 202636
SCREW
SCREWS (4)
Remove casing, see Section 5.2.
Remove combustion chamber front cover, see diagram 10.5
Remove HT lead from electrode, see diagram 8.5.
Remove earth lead from electrode retaining bracket, see
diagram 8.5.
Undo retaining bracket securing screw and withdraw bracket,
see diagram 8.5.
Undo electrode securing screw and withdraw electrode.
When refitting, check spark gap, see diagram 8.5.
10.6 Multifunctional Control, Part No. 230509
SOLENOIDS
- diagram 10.4
ELECTRICAL
Gain access as Section 5.2. PLUG
Diagram 10.4
Slacken control box securing screw, and swing out the control
box, see diagram 5.10.
Disconnect the electrical plug.
REAR INSULATION
Disconnect from the gas cock by removing the four extended
screws from the flanged connection at the right hand side.
Support the multifunctional control, disconnect from the manifold
by removing the tubing nut from the left 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 or in IE, the current edition of
I.S.813 "Domestic Gas Installations".
10.7 Solenoid - diagram 10.4
Remove the electrical plug from the multifunctional control.
SIDE INSULATION
Remove the securing screw and then the solenoid assembly.
SIDE INSULATION
10.8 Burner
RETAINING
Remove the burner as Section 8.2.
SCREW
10.9 Injectors, Part No. 205764
Remove the burner as Section 8.2.
Remove the injectors 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.
Sides
Slide the insulation out.
FRONT INSULATION
Rear
Diagram 10.5
With the side insulation removed the rear insulation can be
removed and replaced.
2000225229A 26
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10 Replacement of Parts
10.12 Fan, Part No. 227035 - diagram 10.7
SECURING
Refer to Section 5.3. SCREW (2)
Remove the electrical connections and disconnect the air
tubes.
Note: Remove the electrical connections by pulling insulation
boots only.
Remove the fan assembly securing screw at the front, then
AIR
withdraw the assembly.
PRESSURE
The fan is secured to the flue hood by three screws. SWITCH
The polarity of the electrical connections are not important.
CLEAR AIR
ELECTRICAL
TUBE
CONNECTIONS
RED AIR TUBE
Diagram 10.6
IMPORTANT:
REMOVE ELECTRICAL CONNECTIONS
BY GRIPPING THE BOOT ONLY
CLEAR AIR
RED AIR TUBE
TUBE
ELECTRICAL
CONNECTIONS
FAN
ASSEMBLY
SECURING
FAN
SCREW
SECURING
SCREW(3)
Diagram 10.7
27 2000225229A
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7165
11 Spare Parts
11.1 Part Identification
11.2 Ordering
The part number on the diagram location will help to identify the
When ordering any spare parts please quote the number and
part.
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.
Part No Description Location GC Part No
801136 Multifunctional control Diagram 10.4 E24965
227035 Fan Diagram 10.7 E24976
227128 Air pressure switch Diagram 10.6 *******
227036 Electrical thermistor Diagram 10.1 & 10.2 E24967
202636 Spark electrode Diagram 8.5 E24957
204697 Control knob Diagram 10.3 E24870
205764 Injector Diagram 8.4 *******
227098 Fuse Diagram 10.3 *******
2000227135 Control board Diagram 10.3 *******
227038 Safety temperature limiter Diagram 10.2 E24897
Because of our constant endeavour for improvement, details may vary slightly from those shown in these instructions.
2000225229A 28
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