Hideaway 120BF Installation & Service Manual Boilers - Glow-worm
Contents
1. 221765B 11 00 Glowworm Instructions for Use Installation and Servicing Tobeleft withthe user 1388 Hideaway 120B G C No 41 313 28 Balanced Flue Boiler C Genchmark This is a Cat L Appliance BS 6332 BS 5258 Reference in these instructions to British Standards and Statutory Regulations Requirements apply only to the United Kingdom For lreland 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 All replacement parts REGISTER YOUR GLOW2. 8 2 Boiler Flueways Unscrew the union nut securing the gas service cock to the gas valve see diagram 8 1 Remove the mains inlet connector by pulling downwards see diagram 8 1 Remove split pin on the thermostat phial pocket and withdraw the phial and capillary see diagram 4 5 Remove the five screws retaining the combustion chamber cover and burner assembly see diagram 8 2 Ease the gas service cock away from the gas valve and unhook the pipe support bracket from the tie bar to enable the assembly of cover control box gas valve and burners to be withdrawn forwards Remove graphite coated nut to release baffle tray and remove from combustion chamber taking care not or damage the insulation material in the sides of the chamber Remove the self tapping screws which retain the flueway cleaning door and lift door clear see diagram 8 3 Remove the baffles from the heat exchanger see diagram 8 6 Place a sheet of paper in the combustion chamber to catch any flue debris Access for flueway cleaning is made through the cleaning door and combustion chamber apertures Thoroughly clean boiler flueways and fins from top and bottom with a suitable stiff brush Remove any debris from the base of the combustion chamber Check that the flueways are clear view with the aid of a mirror or reflector 8 3 Burners and Injectors Refer to Section 8 2 for instructions on how to remove cover burners and controls assembly Remove
3. NIE ot t a Sade WHEN REMOVED EY GDEEN MAINS SUPPLY THERMOSTAT _ FUSEDATIA l sal Lu gt Z Lu Lu oc O CONTROL BOX AND GAS VALVE WIRING Diagram 9 5 221765B 20 10 Fault Finding Electrical 10 1 Electrical IMPORTANT the preliminary electrical system checks as contained in the British Gas Multimeter Instruction book or similar publication are the first checks to be carried out during a fault finding procedure On completion of the service fault finding task which has required the breaking and remaking of electrical connections then checks earth continuity polarity and resistance to earth must be repeated Refer to functional flow diagram 10 1 electrical fault finding chart diagram 10 2 and wiring diagram 9 5 L GAS VALVE S Y CONTROL SOLENOID THERMOSTAT O O Y Y LLE w VIEW OF z PLUG WHEN REMOVED BLACK BROWN e N FUNCTIONAL FLOW WIRING Diagram 10 1 Co Carry out preliminary electrical system checks to make sure that the electricity supply is available at the boiler Check that any remote time or temperature controls are calling for duty Make sure that the system is filled the gas supply is available and the pilot is lit START Isolate electricity supply at the external isolator Remove the mains inlet con
4. Flue Duct Length Fit the distributor tube see diagram 4 2 or 4 4 for position see diagram 4 3 for alignment Fit appropriate fittings and plugs into the boiler connections IMPORTANT NOTE do not route any pipes across the front of the boiler thermostat pocket the controls burner supply pipe combustion chamber cover or flueway cleaning door The gas supply pipe should be run along the left hand side of the boiler If the flue duct length necessitates the use of the flue extension kit that is 410 to 610mm 16 to 24inches this will need to be assembled before positioning the boiler Read the separate instructions supplied with the kit in conjunction with Section 4 8 Balanced Flue Terminal When suitable installation clearances are available position the boiler in readiness to connect pipework If suitable clearances are not available it will be necessary to preplumb the gas and water connections before positioning the boiler When the front tappings are used it is essential that any pipework of fittings be assembled as shown indiagram 4 7 that is do not stick out more than shown 221765B 10 UPPER CASING BRACKET Kw el ENE l Poi a NUT No 8 SCREW 8 0888 9 ey CAPTIVE NUT I FRONT CASING BRACKET CASING BRACKETS FITTING Diagram 4 1 DOMESTIC GRAVITY z FLOW TO ANY OF THE o S 3 REMAINING UPPER CONNECTIONS Thermostat phial and
5. L or Red The Green and yellow cable must be connected to the terminal marked E or Green or the earth symbol To Light the Boiler WARNING If the pilot light goes out for any reason do not attempt to relight until 3 minutes have elapsed Remove the door by pulling forwards with the fascia at the top Lift up to disengage from the bottom side lugs Refer to diagram 1 to identify controls Check that the mains electrical supply to the boiler is switched OFF THERMOSTAT CONTROL KNOB B PIEZO IGNITION BUTTON C GAS CONTROL a KNOB A SETTING POINTS GAS CONTROL KNOB OFF 4 PILOT IGNITION MAIN BURNER Diagram 1 221765B Instructions for Use Push in slightly and turn gas control knob A clockwise until is against its setting point Turn thermostat control knob B anticlockwise until O is against its setting point Pushin slightly and turn gas control knob A anticlockwise until 4 is against its setting point then depress fully and hold in Push in and release piezo ignition button C until the pilot burner lights Air may be present in the supply pipe so the lighting of the pilot may need to be repeated until all the air has been expelled When the pilot is alight view through window E keep gas control knob A fully pushed in for about 15 seconds then release If the burner fai
6. Re 15 1 2 in B t A SPECIAL TOP CASING WATER CONNECTIONS TO SUIT 600mm 235 in WORKTOPS IS AVAILABLE Re1 lin B S P T S P T WATER CONNECTIONS Rc1 reduced with DISTRIBUTOR TUBE to Rc 3 4 3 4 in B S P T pumped return 1071 F MIN G MIN Lt fa H Ke fe el K E 9 Sa G MIN k millimetres Approx inches Important Notice This boiler is for use only on G20 gas Wherever possible all materials appliances and components used shall comply with the requirements of applicable British Standards Where no British Standard exists materials and equipment should be fit for their purpose and of suitable quality and workmanship 1 1 Data Weight of boiler 147 0kg 324lb Water content 11 7litre 2 57gall Gas connection Rc1 2 inBSP Water connection Rc1 1 in BSP Electrical supply 230V 50Hz fused 3A Burner Aeromatic 2 off All dimensions are given in millimetres except as noted The Seasonal Efficiency Domestic Boilers UK SEDBUK is 72 0 The value is used in the UK Government s Standard Assessment Procedure SAP for energy rating of dwellings The test data from which it has been calculated have been certified by B S I 1 2 Range Rating This boiler is range rated and may be adjusted to suit individual system requ
7. Regulations Section 35 which imposes a duty of care on all persons who let out any property containing a gas appliance Fit the plinth front by locating the sides over the boiler plinth then lowering to engage the upper and lower hooks see diagram 7 3 Fit the door by locating the hooked runner at the bottom into the slots in the side casings and pushing on to the studs on the side casings Reminder Leave these instructions and the Benchmark logbook with the user 221765B 16 SPARK GAP 13 1 2 in N DIMENSION FLAME APPROX 8 DIMENSION ED Ft t Pu Pilot shield Ciel omitted for clarity VIEWING WINDOW PILOT z BURNER ASSEMBLY PILOT FLAME DIMENSION Diagram 7 2 B oO STUD a DOOR FASCIA PLINTH FRONT PLINTH DOOR FITTING Diagram 7 3 8 Servicing Before commencing any servicing turn off the gas supply at the gas service cock see diagram 8 1 and isolate the electrical supply to the boiler Always test for gas soundness after completing any servicing or replacement of parts 8 1 Gain Access to the Boiler Pull the door forward at the top to disengage studs and lift to release from the slots see diagram 7 3 Lift the plinth front up and forwards to withdraw see diagram 7 3 If the top casing is removed during servicing care must be taken not to damage or lose any plastic pegs when replacing it Refer to Section 5 3 Top Casing when refitting
8. B 10mm 3 g in FRONT OVERHANG SIDE CASING DOOR BOILER SHOWN WITH piip I ROLLED EDGE FLUSH i SIDE CASING DOOR BOILER SHOWN WITH I SQUARE EDGE FLUSH TOP CASING FITTING Diagram 5 3 CAPTIVE NUT top casing STRAP fitted when no g amp STRAP FITTING No top casing No 8 SECURING SCREW 0909 SIDE CASING R H Diagram 5 4 13 221765B 6 Electrical Wiring 6 1 Control Box Cable Connection WARNING This boiler must be earthed Remove the screw and cover from the mains inlet connector supplied loose see diagram 6 1 Using heat resistant flexible cable of a suitable length and rating as stated in Section 1 7 Electrical connect the three wires to the appropriate terminals in the connector Engage slots and lugs replace cover and secure with screw Connect the mains inlet connector to the control box and use three of the cable clips from the loose items pack pushed onto the edge of the right hand panel in position CB as shown on diagram 6 2 to ensure the cable does not touch any hot surfaces 6 2 Pump Cable Connection Heat resistant cable as above must be used if the pump is to be fitted inside the casing Supportthe cable in a similar manner to Control Box Connection only fit clips to the casing at P or AP as diagram 6 2 6 3 System Controls The electrical installation must be made in accordance with the current issue of BS7
9. Fit test meter interrupter into the magnet unit Fit appliance thermocouple into the test meter interrupter Hold down control tap in ignition position Ignite burner allowing thermocouple to attain operating temperature Measure the OPEN CIRCUIT voltage Faulty thermocouple Replace Note the open circuit reading then measure the CLOSED CIRCUIT voltage Note this voltage Referring to the diagnosis graph mark the open circuit voltage on the VERTICAL axis and the closed circuit voltage on the HORIZONTAL axis Note the point where these two values intersect on the graph THERMOCOUPLE area of the Faulty thermocouple CIRCUIT IS graph is the Replace SATISFACTORY intersect Faulty magnet unit in gas tap Replace multifunctional control THERMOCOUPLE FAULT FINDING Diagram 10 3 10 2 Thermocouple To test the thermocouple a meter with a range of 0 to 30mV is required together with a thermocouple interrupter similar to the Minitest 6 Multimeter and interrupter 1546 Refer to thermocouple fault finding chart diagram 10 3 and diagnosis graph diagram 10 4 10 3 Pilot Refer to pilot fault finding chart diagram 10 5 0 2 4 6 8 10 12 14 16 18 20 22 Closed Circuit Voltage millivolts DIAGNOSIS GRAPH FOR THERMOCOUPLE CIRCUIT Diagram 10 4 221765B 22 10 Fault Finding Pilot PILOT WILL NOT LIGHT START HERE Check gas line open all cocks rectify any blockages purge out any air Does
10. L see diagram 7 1 If ordering from British Gas also quote the GC number of the part and appliance S 12 Diagram 11 1 Key No Part No Description GC No 1 203377 Gas control valve 394151 2 205746 Injector 2 ASE 3 203414 Pilot burner 312 426 4 203508 Injector pilot 395 674 5 202407 Thermocouple c w nut 392 850 5 202415 Thermocouple c w nut 6 202571 Thermostat c w screws 7 204687 Control knob assy thermostat 8 202713 Piezo unit 9 WW4609 Ignition lead assembly 136 464 10 202605 Spark electrode 395 720 11 208302 Sight glass 312 419 12 212031 O ring gas valve 312 602 Because of our constant endeavour for improvement details may vary slightly from those shown in these instructions 221765B 24
11. Remove the packaging and then the boiler from its pallet by removing the screws The boiler casing panels are packed separately within the main carton They are designed to enable gas and water connections to be made before fitting the casing The casing brackets distributor tube and loose items in a plastic bag are packed in the corner fitment 4 2 Casing Brackets Fit the two upper and two front casing brackets as shown in diagram 4 1 using eight of the No 8 screws Push the captive nuts supplied loose on to the casing brackets as shown in diagram 4 1 4 3 Planning Water Connections Gravity Domestic and Pumped Heating It is important that all connections are made as shown in diagram 4 2 Heating flow either one of the two upper front connections may be used Domestic gravity flow any one of the three remaining upper connections may be used Heating return the water distributor tube MUST be fitted into either one of the front lower connections on all installations see diagram 4 3 The distributor tube is packed in the top fitment Domestic gravity return any one of the three remaining lower connections may be used for the gravity domestic hot water return 221765B 4 Installation Fit plugs into all unused connections NOTE if only limited clearance is available it is recommended that the front tappings are used 4 4 Planning Water Connections Fully Pumped Systems It is important that
12. Replacement Parts 9 18 INSTRUCTIONS Fault Finding 10 21 Spare Parts 11 24 221765B 2 Instructions for Use General Information Please read these instructions and follow them carefully for the safe and economical use of your boiler The boiler is automatic in operation once the pilot has been lit and the controls set Glow worm Hideaways are central heating boilers to provide heating and if required an indirect domestic hot water supply Important Notice This boiler is for use only on G20 gas Gas Safety Installation and Use Regulations In your own interests and that of safety is the law that ALL gas appliances are installed by a competent person in accordance with the current issue of the above regulations Warning Make sure that nothing obstructs the rear side grille or clearances See page 4 for minimum clearances Boilers Installed in a Compartment If the boiler is fitted in a compartment cupboard etc do not obstruct the purpose built compartment vents or the grille on the boiler Do not use the compartment for storage purposes Maintenance To ensure the continued efficient and safe operation of the boiler itis recommended that it is checked and serviced as necessary at regular intervals The frequency of servicing will depend upon the particular installation conditions and usage but in general once a year should be enough It is the law that servicing must be carried out by a competen
13. burner and shield to the combustion chamber cover Hook pilot injector over pilot tube olive when refitting Check that the pilot flame length is as shown in diagram 7 2 Replace thermostat phial as Section 8 5 9 5 Spark Electrode Gain access to the boiler as Section 8 1 Disconnect the thermocouple nut and withdraw thermocouple from pilot burner see diagram 9 2 Disconnect the nut retaining the spark electrode and remove When re assembling check that spark gap is as shown in diagram 7 2 9 6 Insulation Panels Gain access to the boiler as Section 8 1 Remove the burner assembly as Section 8 2 Remove the two screws retaining each side insulation panel within the combustion chamber and remove panel see diagram 9 3 Release the rear insulation panel upper clips and lift panel out Refit thermostat phial as Section 8 5 9 7 Boiler Thermostat Follow the relevant instructions in Section 8 1 Remove the mains inlet connector by pulling downwards see diagram 8 1 Remove the retaining split pin from the phial pocket then withdraw the phial and capillary see diagram 4 5 Pull off the thermostat control knob Gain access to inside of the control box by removing the securing screw located at the top of control box and unhooking at the bottom see diagram 9 4 Remove the two screws which secure the boiler thermostat to the control box see diagram 9 4 Tilt the thermostat so that the electrical connections can be re
14. the boiler is fitted in a cupboard or compartment the high and low level permanent air vents must have effective areas in accordance with the Compartment Air Vent Table Both the high level and the low level air vents must communicate with the same room or must both be on the same wall to outside air COMPARTMENT AIR VENT TABLE COMPARTMENT VENTILATION HIGH LEVEL LOW LEVEL REQUIREMENTS VENT AREA VENT AREA VENTILATION FROM ROOM 62in 406cm 62in OR SPACE FROM P ay gt a OUTSIDE 203cm 31in 203cm 31in 1112 Under Car Port etc MINIMUM SITING DIMENSIONS FOR BALANCED FLUE TERMINALS POSITION MINIMUM SPACING A DIRECTLY BELOW AN OPENABLE mm WINDOW AIR VENT OR ANY OTHER VENTILATION OPENING 300 B BELOW GUTTER DRAIN SOIL PIPE 300 C BELOW EAVES 300 D BELOW A BALCONY OR CAR PORT 600 E FROM VERTICAL DRAIN PIPES AND SOIL PIPES 75 F FROM INTERNAL OR EXTERNAL CORNERS 600 G ABOVE ADJACENT GROUND OR BALCONY LEVEL 300 H FROM A SURFACE FACING THE TERMINAL 600 I FACING TERMINALS 600 J FROM OPENING DOOR WINDOW IN CARPORT INTO DWELLING 1200 K VERTICAL FROM A TERMINAL 1500 L HORIZONTALLY FROM A TERMINAL 300 Diagram 3 1 4 Installation Before fixing the boiler make sure that the location selected is in accordance with the requirements of Section 1 8 4 1 Unpacking
15. the two screws and nuts securing each burner support bracket to the combustion chamber cover see diagram 8 4 Remove the graphite coated nuts on supply feed pipe at the rear of the burner to release the burners taking care not to damage the pilot burner and shield when removing Remove the nuts washers and burner end caps see diagram 8 5 Remove the distributors from inside the burners then clean the burners and components thoroughly with a vacuum cleaner Check that the main burner injectors are not blocked or damaged Clean or renew as necessary Do notclean with a wire or sharp instrument see diagram 8 4 8 4 Service Checks Inspect the thermocouple and pilot burner clean or renew as necessary 17 GAS N SERVICE 5 COCK 5 turn off MAINS INLET CONNECTOR ISOLATION OF pull downwards GAS AND ELECTRICITY Diagram 8 1 o GRAPHITE JE Q COATED NUT BAN BAFFLE TRAY Pea PIPE SUPPORT BRACKET COMBUSTION CHAMBER SECURING COVER a SCREW 5 ACCESS FOR SERVICING Diagram 8 2 3 8 ae FLUEWAY CLEANING 6 DOOR m oo000 0000 ACCESS TO FLUEWAY Diagram 8 3 221765B 8 Servicing Check the condition of the insulation panels in the combustion chamber renew if necessary Check the condition of the seals on the cleaning door and the combustion chamber cover renewing if necessary 8 5 Re assembly Make sure that the baffle t
16. 197 46 in 10 5 lt __ 3g in 494 MIN 19746 in a f L T CUPBOARDS MINIMUM CLEARANCES LEVEL WITH WORKTOP Diagram 1 3 WORKTOP OR FIXTURE 9 ice 10 3 in 3 1 in CUPBOARD i ae 2 CUPBOARD gin BOILER gin BOILER 3g in WITH WITHOUT TOP TOP CASING CASING CUPBOARD MINIMUM CLEARANCES UNDER WORKTOP FIXTURES Diagram 1 4 1 General Data A special top casing part No 424820 can be purchased to enable the boiler casings to be arranged flush with 600mm 23 gin deep work tops and kitchen units Where the installation of the boiler will be in an unusual location special procedures are necessary the current issue of BS6798 gives guidance on this A compartment used to enclose the boiler must be designed and constructed specifically for this purpose An existing cupboard or compartment modified for the purpose may be used Details of essential features of cupboard design are given in the current issue of BS6798 If the boiler is to be installed in a compartment make sure that nothing will obstruct the openings vents in the compartment 1 9 Heating System Controls The heating system should have installed a programmer and room thermostat controlling the boiler Thermostatic radiator valves may be installed in addition to the room thermostat lt o Oo 3 BOI
17. 671 The electrical isolator must isolate both the appliance and system controls 6 4 Testing Checks to ensure electrical safety should be carried out by a competent person In the event of an electrical fault after installation of the boiler preliminary system checks must be carried that is earth continuity polarity and resistance to earth as described in the British Gas Multimeter Instruction Book or equal publication 221765B foe N S MAINS INLET CONNECTOR Diagram 6 1 oO O P 230 25 1 Fit 2 pump cable clips at positions P Alternative pump Fit 4 control cable clips if feed is box feed cable on the left hand side clips at positions at positions AP CB CABLE CLIP POSITIONS Diagram 6 2 14 7 Commissioning Please ensure the Benchmark logbook is completed and left with the user 7 1 Preliminaries With the pump removed the whole of the system should be thoroughly flushed out with cold water Refitthe pump andfillthe system Examine for water soundness and vent all air from the system and pump Make sure that all valves are open 7 2 Initial Lighting Testing and Adjustment CAUTION The following procedure should be carried out by a competent person Identify the boiler controls by reference to diagram 7 1 Check that the gas service cock K is closed indicator slot vertical Make sure that the thermostat phial is fully inserted in the phi
18. BALANCED FLUE DUCT ie FROM BOILER 14 4 in f a A PREPARED HOLE IN THE WALL 485 3 Ngin 19 in MIN Y V4 RIALIISA IS ALALIIT PREPARED HOLE IN THE WALL DIMENSIONS Diagram 4 6 221765B 4 Installation AIR DUCT ASSEMBLY TERMINAL AND AIR DUCT STANDARD OR SHORT A a lo ae VIEW ON ARROW A VIEW ON ARROW B BOILER ia 1 in AIN BOILER 57 MAX 2 1 4 in TN oy 57 MAX a 2 1 4 in 57 MAX t PoR 2 17 in MINIMUM os CLEARANCE PIPEWORK CASING REAR omenon CLEARANCES Diagram 4 7 PIPEWORK 28mm Diagram 4 8 AIR DUCT po PLATE A 7 INNER BAFFLE FLUE DUCT ASSEMBLY SUTER WIRE GUARDS SCREW 4 Diagram 4 9 5 Casing Location Fitting 5 1 Side Vent Grille One side vent grille is supplied with the boiler and can be fitted atthe rear of the left or right hand side casing The grille is fitted on the opposite side to any pipework connections If required fit the grille using plastic pegs at the top and bottom see diagram 5 1 prior to fixing the side casing The plastic pegs are atight fit so they are best pushed home with a flat faced tool Discard the grille if water connections are made on both sides of the boiler or if the boiler is screened by fixtures 221765B 5 2 Side Casings Fit each side casing by locating the lugs into the appropriate slots in the boiler plinth see diagr
19. L kW 29 31 32 24 35 17 HEAT OUTPUT Btu h 100 000 110 000 120 000 BURNER mbar 13 8 SETTING PRESSURE in w g 5 5 HOT INJECTOR 205746 221765B General Data 1 5 B S I Certification This boiler is certificated by B S I for safety and performance Itis 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 B S I certification boiler warranty and could also infringe the Statutory Requirements 1 6 Gas Supply The gas installation shall be in accordance with the current issue of BS6891 The supply from the governed meter must be of adequate size to provide a steady inlet working pressure of 20mbar 8in wg at the boiler On completion test the gas installation using the pressure drop method and suitable leak detection fluid purge in accordance with the current issue of BS6891 1 7 Electrical WARNING This boiler must be earthed The electrical installation must be carried out by a competent person All external components shall be of the approved type and shall be connected in accordance with the current issue of BS7671 and any local regulations which apply Connection of the boiler and any system controls to the mains supply should be through an unswitched shuttered socket outlet and 3A fused 3 pin plug both to the current issue of BS1363 Alternatively a 3A
20. LER 700 271 5 in WALL OR FIXTURE FRONT CLEARANCE Diagram 1 5 Note For further information see The Building Regulations 1991 Conservation of fuel and power 1995 edition Appendix G table 4b 2 Water Systems 2 1 Water Pressure Head This boiler shall only be connected to a cistern supply with a minimum head of 1 metre 3ft and a maximum of 27 metres 90ft and having an open vent in the system The boiler must not be connected to a sealed water system 2 2 Inhibitor Attention is drawn to the current issue of BS5449 and BS7593 on the use of inhibitors in central heating systems If an inhibitor is to be used in the system contact should be made with an inhibitor manufacturer so they can recommended their most suitable product When using in an existing system take special care to drain the entire system including the radiators then thoroughly cleaning out before fitting the boiler whether or not adding an inhibitor 2 3 Gravity Domestic and Pumped Heating It is recommended that a cylinder thermostat is used to prevent the stored water temperature becoming unnecessarily high The primary flow and return must be 28mm The installation must comply with the current issue of BS5546 and BS6700 see diagram 2 1 If the above conditions cannot be met it is suggested that a fully pumped system be used Fully Pumped System Where asingle pumped flow and return is taken from the boiler refer to diagr
21. MBLY Diagram 9 2 REAR SIDE INSULATION INSULATION a Ag PANEL Q CLIP BAFFLE 9 Gn s TRAY f E screw lo gus Sn COATED NUT Diagram 9 3 INSULATION PANELS 221765B 9 Replacement of Parts Disconnect the lead at the spark electrode see diagram 9 2 Disconnect the gas valve plug from the valve see diagram 9 1 When reconnecting lead make sure that the clear end is fitted Release the control box by removing the securing screw located to the spark electrode at the top of control box and unhooking at the bottom see diagram 9 4 9 10 Electrical Control Box Pull the ignition lead off piezo unit see diagram 9 4 Gain access to the boiler as Section 8 1 When refitting control box make sure the thermostat capillary is Disconnect the mains inlet connector see diagram 8 1 positioned so that it passes through the cut out in the control Remove the retaining split pin from the phial pocket then box see diagram 9 4 withdraw phial and capillary see diagram 4 5 Refit thermostat phial refer to Section 8 5 LO Q O ELECTRICAL CONTROL BOX COVER HOOK THERMOSTAT CUT OUT FOR AND CAPILLARY CAPILLARY IGNITION LEAD BLACK END Nx COVER SECURING SCREW 4 THERMOSTAT SECURING a N SCREW 2 PIEZO UNIT ELECTRICAL D a CONTROL BOX THERMOSTAT ELECTRICAL CONTROL KNOB lt CONNECTORS OP SECURING SCREW CONTROL BOX Diagram 9 4 t Ali 3 vieworPLuG
22. RATE GALLON MINUTE o 012345678 910 o 1 2 T Ro 1 0 40 ni O w Oq rg 08 30 2L 50 dp O op Q l 0 6 N wa W w oe 20I Qa LL oa on ct 04 on Hg ES T 10 lt zE 02 ze 0 0 0 10 20 30 40 50 FLOW RATE LITRES MINUTE PRESSURE LOSS OF BOILER Diagram 2 3 3 Flue and Ventilation 3 1 Flue Detailed recommendations for flues are given in the current issue of BS5440 Part 1 The boiler must be installed so that the flue terminal is exposed to the external air Itis important that the position allows the free passage of air across it at all times 3 2 Terminal Positioning The minimum acceptable spacings for the terminal to obstructions other terminals and ventilation openings are given in diagram 3 1 Car port or similar extensions of a roof only or roof and one wall require special action with regard to openings doors and windows under the roof Care is required in protecting plastic roofs If the car port consists of a roof and two or more walls seek advice form the local gas undertaking Where the terminal is within 850mm 34in below plastic guttering or within 450mm 18in of painted eaves or gutter an aluminium shield 1 5 metres 5ft long should be fitted to the underside and immediately beneath the guttering The air inlet products outlet duct and the terminal of the boiler must not be closer than 25mm 1in to combustible material 3 3 Timber Frame Buildings If the boiler is to be insta
23. WORM APPLIANCE All labour charges FOR 1ST YEAR GUARANTEE PROTECTION An caout charges CALL 0208 247 9857 Customer Services Hepworth Heating Lidy Nottingham Road Belper Derbyshire DE56 1JT Tel 01773 828100 General Sales enquiries One Contact Local Service Fax 01773 828070 Tel 01773 824141 Fax 01773 820569 Important Information Testing and Certification This boiler is tested and certificated for safety and performance Itis therefore important that no alteration is made to the boiler without permission in writing from Hepworth Heating Ltd Any alteration not approved by Hepworth Heating Ltd could invalidate the certification boiler warranty and may also infringe the current issue of the Statutory Requirements see Section 1 4 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 re
24. al pocket J and is securely located by the retaining split pin Check that the mains electrical supply is switched off Set thermostat control knob B to O Remove the burner pressure test point screw G and connect a suitable pressure gauge Open gas service cock K indicator horizontal Turn gas control knob A to 4 pilot ignition position and depress Atthe same time push and release piezo ignition button C until the pilot burner lights view through window E At this stage air may be present in that gas pipes so this operation may need to be repeated several times When the pilot burner lights keep control knob A fully pushed in for about 15 seconds Ifthe pilot burner fails to stay alight repeat the lighting procedure only now keep the control knob pushed for a little longer If the gas control knob A is turned to a safety lock prevents it being turned on again until 3 minutes have elapsed Make sure that the pilot is alight and stable see diagram 7 2 for the approximate flame length Switch on the electrical supply Set any remote controls so that they are calling for heat Turn control knob A to main burner position Setthe thermostat control knob B between MIN and MAX the main burner will light MAX is about 82 C 180 F Test for gas soundness around boiler gas components with a suitable leak detection fluid Ten minutes a
25. all connections are made as shown in diagram 4 4 Flow either one of the two upper front connections may be used Return the water distributor tube MUST be fitted into the return connection on all installations see diagram 4 3 The distributor tube is packed in the top fitment 4 5 Thermostat Pocket Fit the thermostat phial pocket supplied in the top fitment into the front tapping adjacent to the heating flow connection and plug the other front pocket connection Carefully unwind the thermostat capillary insert phial fully into the pocket and secure with the location washer behind the retaining split pin supplied in the loose items pack see diagram 4 5 4 6 Pump Within Boiler Casing If the pump is to be fitted inside the boiler casing see diagram 6 2 ensure that a heat shield kit is obtained and fitted Kit No 425839 The kit contains a flueway cleaning door with heat shield attached 4 7 Positioning Connecting Boiler If the boiler casings are to fit flush with any kitchen units the distance the boiler is away from the wall must be measured and dimension G increased by this amount see diagram 1 1 Having selected the position of the boiler mark out and cut a hole through the wall where the boiler is to be installed to the dimensions shown in diagram 4 6 after checking that sufficient clearances will be left around the boiler as described in Section 1 8 Boiler Location refer also to Section 3 5
26. am 2 2 2 5 Circulation Pump The pump should be set to give a temperature difference of 11 C 20 F across the system At the appropriate flow rate the resistance through the boiler can be found from the pressure loss graph diagram 2 3 If possible use a pump with integral valves if not fit valves as close as possible each side of the pump Note If the pump is to be fitted inside the boiler casing a heat shield kit is required Kit No 425839 REFER TO BS 5546 0869 4 22mm VENT d 15mm COLD FEED INDIRECT CYLINDER 27metre Max BOILER Q To Heating Circuit DRAIN OFF COCK Distributor tube in pumped return connection f Diagram 2 1 4 22mm VENT 0870 15mm COLD FEED 1 metre MIN 27metres MAX TO INDIRECT CYLINDER To Heating Circuit Distributor tube in pumped return connection FULLY PUMPED SYSTEM DRAIN OFF COCK DIAGRAMMATIC Diagram 2 2 221765B 2 Water Systems 2 6 Cylinder For all systems supplying domestic hot water the cylinder must be indirect and to the appropriate British Standard 2 7 Safety Valve A safety valve need not be fitted to an open vented system 2 8 Draining Tap A drain tap must be provided at the lowest points of the system which will allow the entire system including the boiler and domestic hot water cylinder to be drained Drain taps shall comply with the current issue of BS2879 FLOW
27. am 5 2 depending on the required casing height see diagram 1 2 Secure the side casings to the casing brackets at the front and top 5 Casing Location Fitting 5 3 Top Casing The top casing can be fitted in four alternative positions that is with either a rolled or square front edge flush with the door or overhanging it by 10mm inch Select either a rolled or square front edge and for a flush fitting top casing fit four plastic pegs into holes A as shown in diagram 5 3 For overhanging top casing fit four plastic pegs into holes B The plastic pegs are a tight fit so they are best pushed home with a flat faced tool Fit the top casing by engaging the pegs in to the holes in the side casings and then make sure that they are fully engaged by pushing the pegs down For boilers fitted under work tops not using the casing top the strap should be fitted as diagram 5 4 PLASTIC PEG 9 S g SIDE VENT GRILLE i a If required will fit to G o left or right side casing C SIDE CASING R H SHOWN I SIDE VENT GRILLE Diagram 5 1 UPPER CASING S BRACKET lt A LOCATING LUG AND SLOTS o o LH 9 MIN 2 MID gt SMAX MAX cI MID D FRONT 9 CASING A p MIN BRACKET BOILER PLINTH SIDE CASINGS FITTING Diagram 5 2 PLASTIC PEG 4 0886 TOP CASING PEG POSITIONS IN TOP CASING A FRONT EDGE FLUSH
28. discarded if preferred when fitting the boiler under a worktop or fixture See diagram 1 2 When the boiler is to be installed level with work surfaces etc minimum clearances should be provided as shown in diagram 1 3 Work tops which overhang the cupboard sides almost in contact with the casing top require a larger minimum air gap Flush sided fixtures require the same overall minimum space but can have a reduced air gap on one side Boilers to be installed under work tops or fixtures with or without the casing top fitted should be positioned to provide minimum clearances as shown in diagram 1 4 221765B To facilitate minimum clearances it may be necessary to modify the kitchen units or fixtures depending upon which type of connections are used A front access clearance should be provided as shown in diagram 1 5 The minimum gap behind the top casing is as shown in diagram 1 1 The boiler can be sited further away from the wall if required to align with kitchen units etc Refer to Section 3 5 Combustible wall material must be 25mm 1in away from flue components Refer to Section 3 5 O 3 To BOILER BOILER S floor WITH TOP WITHOUT level CASING TOP CASING MAX 900 351 5 in MID 890 35in MIN 860 34in MAX 867 341g in MID 857 333 4 in MIN 827 321 5 in BOILER CASING ALTERNATIVE FLOOR LEVEL HEIGHT POSITIONS BOILER CASING HEIGHT S Diagram 1 2 N WORKTOP 494 MIN D
29. fter lighting check the burner setting pressure and adjust if necessary as follows remove cover F see diagram 7 1 and turn adjustment screw anti clockwise to decrease see Data Table or refer to L Data Label for setting pressure After adjusting replace cover If any doubt exists the gas rate should be checked at the meter This should be in the range of HIDEAWAY 120B 3 5m h to 4 2m h 125 to 148 ft h Stick the self adhesive arrow indicator from the loose items pack to the data label against the rating the boiler is going to be set to Allow the water system to reach maximum working temperature and examine for water soundness The system should then be turned off and drained rapidly whilst still hot to complete the flushing process The system should then be filled again vented and examined for water soundness Shown closed l A GAS CONTROL KNOB H CONTROL BOX A 2 B TERMOSTAT CONTROL J PHIAL POCKET C PIEZO IGNITION BUTTON alternative positions 6 3 E VIEWING WINDOW K GAS SERVICE COCK J F GOVERNOR ADJUSTMENT L DATA LABEL COVER M GAS CONTROL VALVE G BURNER PRESSURE N PILOT ADJUSTMENT TEST POINT SCREW BOILER COMPONENTS ry pn Peai open 9017 OFF PILOT IGNITION MAIN BURNER SETTING POINT Diagram 7 1 15 221765B 7 Commissioning 7 3 Operational Checks Check operation
30. fused double pole isolating switch may be used having a minimum double pole contact separation of 3mm serving the boiler and system controls only Heat resistant flexible cable of at least 0 75mm 24 0 20mm to BS6500 Table 16 must be used for all connections within the boiler casing 1 8 Boiler Location This boiler is not suitable for outside installation The boiler may be installed in any room although particular attention is drawn to the requirements of the current issue of BS7671 with respect to the installation of the boiler in a room containing a bath or shower Any electrical switch or boiler control utilising mains electricity should be so situated that it cannot be touched by a person using the bath or shower The electrical provisions of the Building Standards Scotland Regulations are applicable to such installations in Scotland The boiler must stand on a level floor conforming with the local authority requirements and building regulations The base temperature is within the requirements of BS5258 The boiler may be stood on a wooden floor but a metal base plate is required to protect plastic tiles and similar floor coverings Suitable clearance needs to be available at the sides of the boiler to facilitate direct connection of pipework and making good around the flue assembly The actual clearance required will vary with site conditions The casing can be fitted to the boiler at various heights The top casing can be
31. g procedure to relight Refer also to Protection Against Freezing Gas Leak or Fault If a gas leak fault exists or is suspected the boiler must be turned off including the electrical supply and must not be used until the fault has been put right Advice help should be obtained from the local gas undertaking or your installation servicing company Protection Against Freezing Ifthe boiler is to be out of use for any period of time during severe weather conditions we recommend the whole system including the boiler be drained off to avoid the risk of freezing up If an immersion heater is fitted to the hot water cylinder make sure it is switched off 221765B Sheet Metal Parts WARNING This boiler contains metal parts components and care should be taken when handling and cleaning with particular regard to edges Cleaning Keep the casing clean by wiping it occasionally with a damp soapy cloth and dry with a polishing cloth Do not use abrasive cleaners Replacement Parts Boiler Identification If replacement parts are required apply to your local supplier Please quote the name of the boiler and its serial number which can be found on the data label positioned on the boiler top to the rear of the inclined flueway cleaning door Clearances Minimum clearances must be left around the boiler as shown in diagrams 1 3 1 4 and 1 5 General Data Refer to BOILER CASING HEIGHT diagram GAS CONNECTION
32. irements The Tables give the appropriate settings and ratings The boiler heat input is factory preset to its maximum rating This should be adjusted to suit individual system requirements The arrow indicator from the loose items pack should be stuck on the data label to indicate the setting 1 3 Sheet Metal Parts WARNING When installing or servicing this boiler care should be taken to avoid any possibility of personal injury when handling sheet metal parts 1 4 Statutory Requirements The installation of this boiler must be carried out by acompetent person in accordance with the relevant requirements of the current issue of Manufacturer s instructions supplied The Gas Safety Installation and Use Regulations The Building Regulations The Bye laws of the Local Water Company The Building Standards Scotland Regulations applicable in Scotland The Health and Safety at Work Act Control of Substances Hazardous to Health Electricity at Work Regulations and any applicable local regulations Detailed recommendations are contained in the current issue of the following British Standards and Codes of Practice BS6798 BS5440 Part 1 and 2 BS5546 BS5449 Part 1 BS6700 BS6891 BS7478 BS7593 BS7671 Manufacturers instructions must in not be taken as overriding statutory requirements RANGE RATING min medium max NOMINAL kW 37 0 40 55 44 13 HEAT INPUT GROSS Btu h 126 250 138 370 150 560 NOMINA
33. lating to the electrical equipment designed for use within certain voltage limits 3 Directive 89 336 EEC on the approximation of the Laws of the Member States relating to electromagnetic compatibility INFORMATION FOR THE INSTALLER AND SERVICE ENGINEER Under Section 6 of The Health and Safety at Work Act 1974 we are required to provide information on substances hazardous to health CERAMIC FIBRE INSULATION PADS GLASSYARN These can cause irritation to skin eyes and the respiratory tract If you have a history of skin complaint you may be susceptible to irritation High dust levels are usual only if the material is broken Normal handling should not cause discomfort but follow normal good hygiene and wash your hands before eating drinking or going to the lavatory If you do suffer irritation of the eyes or severe irritation to the skin seek medical attention THERMOSTATS These contain very small amounts of xylene in the sealed phial and capillary If broken under normal circumstances the fluid does not cause a problem but in case of skin contact wash with cold water If swallowed drink plenty of water and seek medical attention CONTENTS DESCRIPTION SECTION PAGE No INSTRUCTIONS Introduction 3 ighti i 4 FOR USE Lighting the Boiler General Data 1 5 Poea LETON Water Systems 2 7 INSTRUCTIONS Flue and Ventilation 3 8 Installation 4 9 Casing Location Fitting 5 12 Electrical Wiring 6 14 Commissioning 7 15 SERVICING Servicing 8 17
34. lled in a timber frame building it should be fitted in accordance with the Institute of Gas Engineers document IGE UP 7 1998 Ifin doubt seek advice from the local gas undertaking or Hepworth Heating Ltd 3 4 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 aminimum of 50mm clearance from any part of the terminal and be central over the terminal 221765B A suitable guard is available from Tower Flue Components Ltd Morley Road Tonbridge Kent TN9 1RA reference type F 3 5 Flue Duct Length The flue lengths quoted below allow the minimum rear clearance of 3mm inch behind the boiler although the boiler can be installed further away from the inside wall In such cases any extra clearance behind the boiler must be added to the wall thickness to obtain the flue duct length Check the wall thickness flue duct length where the boiler is fitted Flues available are Standard pack 280 to 410mm 11 to 16inches Short pack 150 to 280mm 6 to 11inches The short flue pack part No 425504 is available to order Standard pack is part No 424886 3 6 Room Ventilation The boiler is room sealed and does not require the room or space containing it to have permanent air vents 3 Flue and Ventilation 3 7 Cupboard Compartment Ventilation Where
35. ls to stay alight wait 3 minutes then repeat the lighting procedure only now keep control knob A pushed in for a little longer before releasing Press in and turn gas control knob A anticlockwise until is against its setting point Ifthe gas control knob A is turned to a safety lock prevents it being turned on again for a short period No attempt should be made to relight the pilot until 3 minutes have elapsed Make sure that the pilot is alight and stable then switch on the electrical supply Set any system controls to ON or HIGH Turn the boiler thermostat knob B clockwise until MAX is against its setting point and the main burner will light Adjust thermostat to required setting between MIN and MAX MAX is about 82 C 180 F Refit the door by locating the hooked runner at the bottom into the slot in the side panels and pushing onto the studs To Turn the Boiler Off For short periods turn the boiler thermostat control knob B anticlockwise to O The pilot will stay alight To relight the main burner turn thermostat control knob B clockwise to the desired setting between MIN and MAX For longer periods depress slightly and turn gas control knob A fully clockwise until is against its setting point Turn thermostat control knob B anticlockwise to O Isolate the boiler from the electrical supply Follow full lightin
36. mage the O ring seal at the flange Inspectthe condition of the O ring seal and renew if necessary Remove the union half and refit into the replacement valve on the inlet left hand side Use a little jointing compound on the external thread only to ensure gas soundness It will be necessary to purge air from the gas line after changing the gas valve refer to Section 7 2 221765B 18 9 2 Injectors Gain access to the boiler as Section 8 1 Unscrew the injectors from the manifold and renew as necessary When replacing the injectors use a little jointing compound on the external thread only to ensure gas soundness Replace thermostat phial as Section 8 5 9 3 Thermocouple Gain access to the boiler as Section 8 1 Disconnect the thermocouple by unscrewing nuts at the gas valve and pilot burner see diagrams 9 1 and 9 2 Withdraw the thermocouple When replacing tighten the thermocouple nut only a quarter turn beyond finger tight 9 4 Pilot Burner Gain access to the boiler as Section 8 1 Remove the cover and burner controls assembly as Section 8 2 Disconnect the ignition lead at the electrode see diagram 9 2 Disconnect the thermocouple nut at the pilot burner Disconnect the pilot tube nut ease out the tube and injector which is hooked on to the pilot tube 9 Replacement of Parts Remove the nut retaining the spark electrode and remove Remove the two screws and nuts securing the pilot
37. moved Withdraw boiler thermostat from control box complete with capillary tube and phial Refer to diagram 9 5 to connect electrical connectors Replace the thermostat phial as the relevant part of Section 8 5 Make sure that the capillary is positioned so that it passes through the cut out in the control box see diagram 9 4 9 8 Piezo Unit Pull door forward at the top to disengage the studs and lift to release from slots see diagram 7 3 Remove mains inlet connector by pulling downwards see diagram 8 1 Gain access to inside of the control box by removing the securing screw located at the top of control box and unhooking at the bottom see diagram 9 4 Disconnect the ignition lead at the piezo unit Note To ease the removal of the piezo unit it is advisable to temporarily remove the boiler thermostat from the control box Depress the retaining tabs and remove the Piezo unit 9 9 Ignition Lead Gain access to the boiler as Section 8 1 Disconnect the ignition lead at the piezo unit see diagram 9 4 and section 9 8 19 PILOT TUBE o S GAS VALVE lt 4 L PLUG P GAS Yt GAS VALVE OUTLET FLANGE oI scREW yy 4 THERMOCOUPLE NUT REMOVAL OF GAS VALVE Diagram 9 1 SECURING SCREW 2 CE AND NUT 2 A THERMOCOUPLE SPARK ELECTRODE s 0935 IGNITION LEAD CLEAR END PILOT SHIELD PILOT PILOT TUBE BURNER PILOT ASSEMBLY INJECTOR PILOT ASSE
38. nector and cover to expose supply cable connections Reconnect inlet connector restore power Is there 220 to 240V between L and N YES NO Isolate electricity supply to the unit at the Check that all remote time or temperature external isolator Remove the control box cover controls are calling for duty Check continuity of red cable between terminal L in the inlet connector and Thermostat terminal C Is there continuity Fault y cable renew NO YES Turn boiler thermostat to maximum Connect ohmmeter across thermostat terminals NC and C Is there continuity NO YES Faulty thermostat renew Turn boiler thermostat OFF Is continuity interrupted NO YES Connect ohmmeter and check the continuity of brown cable between terminal L on gas gt Faulty cable renew valve plug and terminal NC at thermostat Is there continuity NO YES Connect ohmmeter between terminal N in inlet connector and gas valve plug terminal N Faulty cable renew Is there continuity NO YES Disconnect ohmmeter and reconnect gas valve plug Faulty gas valve renew Restore power to unit Does burner light gt se NO YES Boiler in order Isolate electricity supply and refit mains inlet connector cover ELECTRICAL FAULT FINDING Diagram 10 2 21 221765B 10 Fault Finding Thermocouple F g Disconnect appliance thermocouple from the multifunctional control Check that all connections are clean and in good condition
39. of the flame failure device as follows with the main burner alight turn the gas valve control knob A fully clockwise to its stop this will extinguish the main and pilot burners The safety device should close before 60 seconds have elapsed a click from the gas valve will indicate it has closed Remove the pressure gauge and refit the pressure test point screw G make sure that a gas tight seal is made Turn thermostat B to O then relight the pilot burner as Section 7 1 Relight the main burner Check that the boiler thermostat and all automatic controls are operating correctly Do not attempt to adjust the thermostat calibration screw Relight the main burner and check for gas soundness with a suitable leak detection fluid 7 4 Completion and User Information Instruct and demonstrate the efficient and safe operation of the boiler heating and hot water system Hand the Instructions for Use to the user for their retention making sure that they are understood Advise that to ensure the 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 installation conditions and usage but in general once a year should be enough It is that law that any servicing must be carried out by a competent person Draw attention if applicable to the current issue of the Gas Safety Installation and Use
40. pilot light Apply match to pilot burner instead of pressing piezo unit button Does pilot light Undo tubing nut at pilot burner Turn gas valve knob to Pilot Ign Press gas valve knob Does gas flow freely Rectify blockage in pilot injector or renew pilot injector Undo tubing nut at pilot outlet of gas valve Press gas valve knob Does gas flow freely Change blocked pilot tube Change gas valve BOILER PILOT FAULT FINDING Does pilot stay alight when gas valve knob is released PILOT SATISFACTORY Does pilot flame envelop thermocouple Check aeration If necessary Clean pilot rectify blockage in pilot injector or replace Check thermocouple circuit using Thermocouple and Boiler Overheat Cut Off fault finding On pressing piezo unit button is there a spark across electrode gap Pull ignition lead off electrode Hold end of lead close to pilot burner and operate piezo unit Is there a spark across gap Pull ignition lead off piezo unit Using blade of a screwdriver touch unit chassis and leave approx 4mm gap from connection tag on piezo unit Operate piezo Is there a spark across gap Change ignition lead Check electrode gap Reposition or replace electrode as necessary 0905 Diagram 10 5 221765B 11 Spare Parts When ordering spare parts please quote the part number and description stating the model and serial number from the data label
41. pocket must be adjacent y to heating flow O rr connection C ALTERNATIVE at aaa HEATING RETURN TO RETURN ANY OF THE With distributor 3 REMAINING aa LOWER CONNECTIONS WATER CONNECTIONS GRAVITY DOMESTIC PUMPED HEATING Diagram 4 2 1277 UPPE BOILER MARKER UPPER MARKER must lie between the two outer NOTCHES ry 7 DISTRIBUTOR TUBE must be in pumped return connection R DISTRIBUTOR TUBE Diagram 4 3 4 Installation When using a rear tapping with Rc1 1inch BSP fittings for 28mm o d pipework it is recommended that a short nipple and a R thread BSP copper elbow is used If the pipework is required to run back to the wall make sure that it will clear the boiler air duct and if working to minimum clearance does not stick out too far from the boiler see diagram 4 8 Make the water connections to the system pipework Make the connection to the gas supply at the union gas service cock Test the complete gas installation for soundness and purge in accordance with the current issue of BS6891 When the boiler is finally positioned with the balanced flue duct sticking out into the prepared hole in the wall and pipework connected make good to the inside of the wall face around the boiler flue assembly 4 8 Balanced Flue Terminal Take the balanced flue assembly from its carton and remove the four screws to release the outer baffle see diagram 4 9 Remove the four outer wire gua
42. ray is replaced and secured with the graphite coated nuts previously removed Make sure that the thermostat phial is fully inserted into the phial pocket and secured with the location washer behind the retaining split pin see diagram 4 5 Make sure flueway baffles are positioned as diagram 8 6 8 6 Operational Checks Light the boiler and carryout the operational checks as described in Sections 7 2 and 7 3 COMBUSTION CHAMBER 3 io supply Main COVER PIPE BURNER 2 INJECTOR 2 GRAPHITE BURNER COATED NUT 2 2 al SUPPORT BRACKET 2 REMOVAL OF BURNER Diagram 8 4 oO Q 2 SECURING NUT BURNER END CAP WASHER BURNER SERVICING Diagram 8 5 l 5 HEAT EXCHANGERS Diagram 8 6 9 Replacement Parts Before removing or replacing any parts turn the gas off at the gas service cock see diagram 8 1 and isolate the electrical supply to the boiler ALWAYS test for gas soundness after replacing any gas carrying component Unless stated otherwise replacement of parts is in the reverse order to removal 9 1 Gas Valve Gain access to boiler see Section 8 1 Disconnect the gas valve plug thermocouple nut and pilot tube connections at the gas valve see diagram 9 1 Support the valve and remove the four right hand flange screws to disconnect the gas valve from the burner supply pipe Ease the gas service cock union out and remove the valve taking care not to da
43. rds then pull off the inner baffle flue duct assembly Place the air duct assembly into the prepared hole from the outside engaging it over the boiler air duct Slide it until the wall plate contacts the outer wall surface Cut and fix four pieces of the yellow tape provided into the four corners at the joint in the air duct running the tape on the inside of the duct about 25mm 1inch along the joint from the corners Fix four further pieces along the joints overlapping the corner tapes to make a good seal Cement around the wall plate to make good and provide a weatherproof seal Refit the inner baffle flue duct assembly over the boiler flue duct and slide in until the baffle contacts the wire guards Seal the flue duct joint on the inside using the semi transparent heat resistant tape provided in a similar way to the air duct sealing procedure making sure that a good seal is made at the corners Refit the wire guards outer baffle and secure with the screws previously removed 11 oO amp ALTERNATIVE FLOW Must be adjacent A to THERMOSTAT t a PHIAL POCKET ALTERNATIVE Q lt gt RETURN With distributor tube not shown WATER CONNECTIONS FULLY PUMPED SYSTEMS Diagram 4 4 Oo THERMOSTAT LOCATION 0 CAPILLARY gt WASHER RETAINING SPLIT PIN S PHIAL P POCKET SECURING THE THERMOSTAT PHIAL Diagram 4 5 _ 360 y C 144 in in A
44. t person If this appliance is installed in a rented property there is a duty of care imposed on the owner of the property by the current issue of the Gas Safety Installation and Use Regulations Section 35 To obtain service please call your installer or Heatcall Glow worm s own service organisation using the telephone number given on the front panel Please be advised that the Benchmark logbook should be completed by the installation engineer on completion of commissioning and servicing All CORGI Registered Installers carry a CORGI ID card and have a registration number Both should be recorded in your boiler Logbook You can check your installer is CORGI registered by calling CORGI direct on 01256 372300 Boiler Electrical Supply WARNING This boiler must be earthed The boiler must only be connected to a 230V 50Hz supply protected by a 3A fuse maximum All wiring must be in accordance with the current issue of BS7671 Heat resistant flexible cable having a conductor size of 0 75mm to the current issue of BS6500 Table 16 must be used To Connect an Electrical Plug The standard colours of three core flexible cable are Brown live Blue neutral Green and Yellow earth As the markings on your plug may not correspond with these colours continue as follows The Blue cable must be connected to the terminal marked N or Black The Brown cable must be connected to the terminal marked
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