Glow worm Hideaway 80C FF
Contents
1. or the earth symbol 2000225006B Instructions for Use To Turn the Appliance On Turn the electrical supply on to the boiler and check that all remote controls are calling for heat Turn the boiler temperature control clockwise to any position between 0 and Max see diagram 1 MAX is approximately 82 C 180 F The boiler lighting operation is now automatic as follows The fan operates and after a short period of time the spark ignition operates the solenoid opens then the burner will light shown by the burner ON neon green on the control panel lighting up The burner will remain alight until switched off by the control thermostat or any remote control Note If the boiler is turned OFF at the boiler temperature control wait at least 30 seconds before switching on again When the boiler switches off the burner will go out The automatic lighting sequence will operate again when heat is required It should be noted that this is a fanned flue appliance and fan operation may be heard If the reset neon lights turn the boiler temperature control to O off wait 30 seconds then repeat the lighting instructions To Turn the Appliance Off For short periods turn the boiler temperature control fully anti clockwise to 0 off To relight turn the boiler temperature control to any position between 0 and Max For longer periods turn the boiler temperature control fully a2. Note If the side in fill panels are being fitted they should be fitted at the same time as the side casing see next section 4 7 Side In fill Panel if required The side in fill panel is supplied with the boiler which can be fitted at the rear of the left and right hand side casing but can be discarded if the water connections are made on both sides of the boiler or if the boiler is screened by fixtures The in fill panel will usually be fitted on the side where there are no pipework connections Insert the push fit plastic location peg supplied through the in fill panel and side casing holes and secure with the spring clips see diagram 4 9 NOTE The boiler is assembled at the factory with the control box and heat shield fitted in the lower casing height position UPPER CASING BRACKET Diagram 4 8 13 SIDE CASING SPRING R H SHOWN CLIP UPPER VIEW PLASTIC PEG IN FILL PANEL SIDE CASING SPRING R H SHOWN CLIP LOWER VIEW IN FILL PANEL Diagram 4 9 O position E sa NING vor a N position 3 SELF TAPPING SCREWS HIGH for height position adjustment only LOW position SELF D TAPPING o SCREWS 3 1 z Diagram 4 10 2000225006B 4 Installation 4 8 Flue Boiler Connection Remove the three self tapping screws from the lower part of the control box support bracket see diagram 4 10 paperer 5 id FAN Und
3. Sides Undo the burner support bracket nuts and remove support bracket and insulation see diagram 10 6 Refit support bracket with new side insulation Rear Bend forward rear insulation securing nibs one on each side to release insulation Fit new insulation and bend back securing nibs AIR p PRESSURE tof A W U SWITCH Si Sets AO N J FRONT AIR PRESSURE SWITCH TUBE CLEAR REAR AIR PRESSURE SWITCH TUBE RED Diagram 10 5 a pS a Laki r fe ce re K if A AT y AE se a f 1 me a ae y b P Ok ie Roc Be nea E iNIB SS BURNER INSULATION S PPORT PANEL REAR BRACKET Diagram 10 6 2000225006B 11 Spare Parts 11 1 Part Identification 11 2 Ordering The key number in diagram 11 1 and the first column of the list When ordering any spare part please quote the part number will help identify the spare part Key No Part No 1 2000461752 2 221732 3 2000461994 4 2000461985 5 202635 6 2000461714 7 2000461924 8 221098 9 227030 10 205656 and the description from the list together with the model name and serial number information from the data label The data label is positioned on the heat shield see diagram 6 1 10177 Diagram 11 1 Description GC Part No kkkkkxk Multifunctional control KKKKKK Fan KKKKKK Air pressure switch KKKKKK Electrical thermistor KKKKKK Spark electrode KKKKKK Boiler temperature control
4. Water Connections Fully Pumped Systems Fit suitable fittings into the boiler tappings as required see diagram 4 3 Make sure that all pipes are taken backwards and will clear the casings It is important that all connections are made as shown in diagram 4 3 Fit the water distributor tube into the return connection see diagram 4 2 This tube is packed in the fittings pack Fit plugs into any unused boiler tappings ALTERNATIVE HEATING OR DOMESTIC HOT WATER FLOW ALTERNATIVE HEATING RETURN With distributor tube not shown GRAVITY DOMESTIC RETURN TO i ANY OF THE 3 REMAINING LOWER CONNECTIONS WATER CONNECTIONS GRAVITY DOMESTIC PUMPED HEATING Diagram 4 1 NV MARKER must lie between the two outer NOTCHES E DISTRIBUTOR TUBE must be in pumped return Y MARKER connection DISTRIBUTOR TUBE Diagram 4 2 ALTERNATIVE FLOW POSITIONS PN eer oN RETURN POSITIONS With distributor tube not shown WATER CONNECTIONS FULLY PUMPED SYSTEMS Diagram 4 3 2000225006B 4 Installation 4 4 Pipework When the front tappings are used it is essential that any pipework or fittings do not project more than shown in diagram 4 4 When using a rear tapping with Re 1in BSP fitting for 28mm od pipework it is recommended that a short nipple and an Rc thread BSP to copper elbow is used If the pipework is required to run back to the wall make sure t
5. and circuit water is cold If neon 6 is lit flame failure has occured Reset boiler by turning temperature control to Off waiting 30 seconds and then on If fault persists continue with fault finding below i Is there 230V ac bet agi a all Me Check power supply Lsi and IN Is neon 2 lit Faulty PCB With electrical supply isolated Replace disconnect the 2 way thermistor plug from the PCB Check that there is a resistance Faulty thermistor between 14k 2 5kOhms Replace l With electrical supply isolated remove the boiler access door as Is neon 3 lit described in the relevant parts of section 8 1 to gain access to the Faulty PCB YES air pressure switch Switch on electrical supply Check for 230V ac Replace between N and normally closed contact of air pressure switch Is there 230Vac on fan YES Check for 230V ac between IN and common contact on air Faulty air pressure pressure switch switch Replace Does sparking take place NO Faulty PCB Listen for spark discharge Replace Check for 230V ac YES ae NO between N and brown Faulty PCB Does burner light and between N and black Replace Is the fan turning YES 3 way connector on PCB Is integrity of NO YES Is neon 4 lit electrode and YES HT lead good Check continuity of NO Faulty harness gas valve harness Replace
6. knob kkkkkxk Injector kkkkkxk Fuse kkkkkxk Control board KKKKKK Burner Because of our constant endeavour for improvement details may vary slightly from those shown in these instructions 2000225006B 28
7. lower part of the control box support bracket see diagram 8 6 Undo the wing nut that secures the top of the heat shield and carefully hinge down control box and heat shield see diagram 8 6 Release the two toggle latches that secure the fan access door and remove see diagram 8 7 Note When replacing the fan access door make sure the lip at the top of door fits into and behind the slotted bracket located at the top of the boiler Remove the electrical connections from the fan by pulling the insulation boots only Disconnect the two silicone tubes from the fan taking note of their positions Note To ease removal of the right hand baffle from the heat exchanger remove both silicone tubes from the air pressure switch Remove fan securing screw electrical connections and air pressure tubes then remove fan and flue hood by sliding back to disengage the retaining lugs then lift up Remove the flue hood When replacing the flue hood ensure that it rests on the guides and that the rear of flue hood is located under the pegs at the rear and pushed down and back fully IMPORTANT When re fitting fan check that it fits fully into the flue duct extension piece 2000225006B 20 8 Servicing SECURING SCREWS A a SO i FT ay m 3 Te il Mie ie a Ty OOS ee i BOTTOM PLINTH PANEL Diagram 8 4 OMBUSTION CHAMBER EARTH LEADS COVER Diagram 8 5 8 Servicing 8 2 Boiler Flueways a Remove fl
8. obstructs the ventilation grills or clearances Minimum clearances must be left around the boiler as shown in diagrams 1 6 1 7 amp 1 8 Sheet Metal Parts 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 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 grill on the boiler Do not use the compartment for storage purposes Protection Against Freezing If the 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 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 competent person If this appliance is installed in a rented property there is a duty of care imposed on the owner of th
9. 91 4 10 Condensate Drain Connection If Applicable With reference to Section 3 should your flue be greater than the Dry flue length stated then a condensation drain should be fitted The condensate drain connection is on the chimney flue adapter see diagram 4 15 A22mm plastic overflow pipe should be used to fiton to the drain connection and discharge to a drain The drain pipe should have a fall of at least 2 5 away from the boiler and should incorporate a U trap Condensate should if possible be discharged into the household internal drainage system If this is not practicable discharge can be allowed into the external household drains or by a purpose designed soak away Itis recommended that any external condensate drain is insulated and also preferably of 32mm diameter to prevent freezing in adverse weather conditions FRONT AIR PRESSURE SWITCH TUBE CLEAR FAN ELECTRICAL CONNECTORS AIR PRESSURE TUBE RED REAR AIR PRESSURE SWITCH TUBE RED Diagram 4 14 4 11 Top Casing Refer to diagram 4 16 Fit two plastic pegs one on each side in the holes on the top casing The plastic pegs are a tight fit and are best pushed home with a flat faced tool Secure front of top casing with the two screws provided Diagram 4 15 TOP CASING PLASTIC Diagram 4 16 2000225006B 5 Electrical Wiring CONTROL b BOX MAINS SUPPLY l COVER 530V 50Hz br o SJ g y TERMINAL BLO
10. CK TERMINAL Ls LIVE Switched N NEUTRAL 7 EARTH MAIN ew b BLUE BOILER br BROWN bk BLACK ea RE g y GREEN YELLOW TERMINAL BLOCK CONNECTIONS Diagram 5 1 5 1 Control Box Access Remove control box cover by undoing the four securing screws two on control box two on the heat shield and lift off see diagram 5 1 5 2 Electrical Connections WARNING This boiler must be earthed Take care not to damage any internal wiring Using heat resistant 85 C cable of at least 0 75mm 24 CABLE 0 2mm and of a suitable length route as shown in diagram 5 3 CLAMP Thread through the grommet at the bottom rear of the control SCREW box through the cable clamp and connect to appropriate terminals Tighten cable clamp screws see diagram 5 2 Standard colours are brown live L blue neutral N and green yellow earth Q The mains cable outer insulation must not be cut back external to the cable clamp MAINS INLET Diagram 5 2 Make sure the cable is suitably secured CONNECTOR g When making connections make sure that the earth conductor is made ofa greater length than the current carrying conductors so that if the cable is strained the earth conductor would be the last to become disconnected 5 3 Pump Connection The pump must be connected to the external controls 5 4 Testing Electrical Checks to ensure electrical safety must be carried out by a competent person After installation of
11. EED 1 metre TO INDIRECT MIN CYLINDER 2 metres MAX Heating Circuit DRAIN OFF COCK Distributor tube in pumped return connection FULLY PUMPED SYSTEM DIAGRAMMATIC Diagram 2 2 FLOW RATE GALLON MINUTE 12 3 45 6 7 8 Q N 1074 o O O O io O NO O O INCHES HEAD OF WATER WATER PRESSURE LOSS metre HEAD OF WATER D O WATER PRESSURE LOSS h Hrt 6 12 18 24 30 36 42 FLOW RATE LITRES MINUTE Diagram 2 3 3 Flue and Ventilation Important Notes The flue must be installed in accordance with the rules in force in the countries of destination The flue must be in accordance with the current issue of BS5440 Part 1 The Chimney Flue Adapter Kit Pt No 2000461993 socket is designed to take flue pipes to the current issue of BS567 Ifa flue pipe to BS715 is to be used an adapter must be fitted to the boiler flue socket The flue must be at least equivalent to 1m vertical The maximum flue length must not exceed 15m vertical Due to the Sedbuk D efficiency of the Hideaway FF if the flue length exceeds the following 80C FF 9m then provision must be made to ensure that the condensate products are drained away and that the flue liner is of the appropriate specification We would recommend that one of the following flue liners should be used or an equivalent specification Ritevent Chimflex LW or SB Selkirk Selflex TS or TSE An existing liner must be ch
12. NO YES YES Appliance working Replace as Faulty Faulty gas valve satisfactorily necessary PCB Replace ELECTRICAL FAULT FINDING Diagram 9 1 23 2000225006B 9 Fault Finding 9 2 Electrical Supply Failure MAINS SUPPLY Failure of the electrical supply will cause the burner to go out 230v 50Hz Operation will normally resume on the restoration of the electrical A AIR PRESSURE supply SWITCH CONNECTIONS If the burner does not relight after an electrical supply failure and the reset neon on the control panel is lit turn the burner temperature control to 0 wait 30 seconds then fully clockwise PRINTED CIRCUIT to Max see diagram 9 1 BOARD CONNECTIONS MAIN TERMINAL L STRIP CONNECTIONS BLACK r RED BROWN y YELLOW BLUE gy GREY PURLPLE FUSE TYPE F4A AIR PRESSURE SWITCH SPARK ELECTRODE Diagram 9 3 2000225006B 24 9 Fault Finding NEON KEY see P C B NEON 1 A MAINS ON NEON2 DEMANDON NEON 3 oho FAN RUNNING NEON4 BURNERLIT N74 NEON 5 N SAFETY TEMPERATURE LIMITER NEON 6 X FLAME FAILURE BROWN BLUE GREENYELLOW GREY BLACK PURPLE YELLOW RED THERMISTOR bk bk IK iY N P C B CONTROL BOARD br F4A FUSE Ooo O O NEON 1 NEANS NEON4 NEON6 MAINS SUPPLY 230V 50Hz p g y br TERMINAL BLOCK Ls N l BOILER PILOT FAULT FINDING f 25 AIR PRESSURE GAS CONTROL 9866 L
13. TER YOUR GLOW WORM APPLIANCE 4 All labour charges FOR 1ST YEAR GUARANTEE PROTECTION A All call out charges CALL 0208 247 9857 T Hepworth Heating Ltd Customer Services 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 3 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 production certified by 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 Membe
14. anged if there is any doubt that it will not operate safely throughout the life of any new appliance A drain point is incorporated on the chimney flue adapter to which a drain pipe can be connected refer to section 4 10 3 1 Flue Guidelines The flue should be kept as short as possible Horizontal or very shallow runs of the flue should be avoided as they encourage local cooling Always choose a flue route which will cause the least cooling of the flue There should be a vertical rise of at least 600mm 2ft before using a bend 90 elbows should not be used The existing flue may not be completely sound Therefore to prevent the possibility of leakage additional sealing MUST be carried out between the base of the chimney and the flue liner The end of the flue liner at the chimney top must be adequately sealed and clamped using proprietary fittings suitable for the flue liner used see diagram 3 1 The flue should preferably end above ridge height but at the least above the eaves of a pitched roof Use a certificated terminal If the flue is passed through or near any combustible material it should be installed in accordance with the current issue of BS5440 Part 1 3 If in doubt seek advice from the local gas undertaking or Hepworth Heating Ltd 3 2 Existing Chimney An existing brick chimney must be thoroughly swept and all debris cleared away before lining Remove any damper or register plate Alternatively it may b
15. ce a year should be enough Draw attention if applicable to the current issue of the Gas Safety Installation and Use Regulations Section 35 which imposes a duty of care on all persons who let out any property containing a gas appliance It is the Law that servicing is carried out by a competent person Advise the user of the precautions necessary to prevent damage to the system and building in the event of the heating system being out of use during frost and freezing conditions Reminder Leave these instructions and the Benchmark logbook with the user 8 Servicing f A i REMEMBER When replacing a parton 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 Products of Combustion Check Note To obtain a products of combustion reading remove the SECURING ELECTRICAL front panel and remove the control box as descibed in the PLUG relevant paragraphs of section 4 12 Next remove the cap from the sampling point located on the top of the left hand side of the inner casing see diagram 8 1 Connect the analyser tube on to the nipple WARNING The multifunctional control and fan operate on mains voltage terminals will become live Switch on the electrical supply and gas supply th
16. clearance for servicing should be provided as shown in diagram 1 6 The boiler must not be installed in a room used or intended to be used as sleeping accommodation or a room containing a bath or shower Where the installation of the boiler will be in an unusual location special procedures are necessary the current issue of BS6798 gives detailed guidance on this aspect 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 or compartment 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 however they must not be fitted in a room where the room thermostat is located Note For further information see the current issue of the Building Regulations approved document L1 and the references 1 GIL 59 2000 Central heating system specification CheSS and 2 GPG 302 2001 Controls for domestic central heating system and hot water BRECSU WALL OR FIXTURE FRONT CLEARANCE BOILER Diagram 1 6 2000225006B 2 Water Systems 2 1 Water Pres
17. d When removing and replacing the electrode take care not to damage it When refitting check spark gap see diagram 8 12 10 4 Multifunctional Control Remove front panel to gain access see section 6 8 Remove the electrical plug securing screw and disconnect the plug see diagram 10 4 Disconnect the gas cock on the left hand side Support the multifunctional control remove the four screws 2 long 2 short from the flanged connection at the right hand side Remove and discard the original O ring from the flanged connection and fit the new O ring supplied into recess before fitting the replacement multifunctional control After assembly test for gas soundness and purge in accordance with the current issue of BS6891 ELECTRICAL Diagram 10 2 THERMISTOR Baram 10 3 10 5 Solenoid Remove front panel to gain access see section 6 8 Remove the electrical plug from the multifunctional control and remove the securing screw and then the solenoid assembly see diagram 10 4 10 6 Burner Refer to the relevant paragraphs of the servicing section to remove the burner from combustion chamber 10 7 Injector Refer to the relevant paragraphs of the servicing section to remove the burner from combustion chamber The injector can then be unscrewed from the manifold When replacing use a little jointing compound on the external thread only to ensure a gas tight seal 10 8 Air Pressure Switch Remo
18. d replace as necessary see diagram 8 12 Check the condition of the side and rear insulation panels in the combustion chamber Check the condition of the seals on the boiler access door and the combustion chamber cover Examine the flue hood and terminal to make sure they are clean and clear of obstructions Refit all parts Light the boiler and carry out functional tests as described in section 6 GRAPHITE COATED NUT 2 BURNER INJECTOR Diagram 8 11 l SPARK GAP F f Ff Diagram 8 12 2000225006B 22 9 Fault Finding IMPORTANT On completion of the Fault Finding task which has required the breaking and remaking of the electrical BOILER TEMPERATURE connections the continuity polarity short circuit and resistance CONTROL to earth checks must be repeated using a suitable multimeter WARNING The multifunctional control and fan operate on mains voltage the terminal will be live C low worm 9 1 Electrical Gain access to the control box refer to the relevant paragraph Hideaway FF in section 6 1 then remove the control box cover refer to OReset ddd section 5 1 E Max Refer to Boiler Fault Finding see diagram 9 2 Fault Finding Wiring Diagram see diagram 9 3 Pictorial Wiring Diagram see Diagram 9 2 diagram 9 4 9917 Before carrying out fault finding ensure that gas electricity and water are available at the boiler Ensure that any external controls are calling for heat
19. e locked in the fully open position A flexible flue liner is preferred but a rigid liner may be used with connection to the boiler flue socket made with a short vertical piece of flexible liner see diagram 3 2 The sealing plate also prevents debris falling and gives the flue better insulation reducing the possibility of condensation see diagram 3 1 Check the system efficiency before installing the boiler SEALING AND CLAMPING PLATE 150mm 6in plug of Mineral Wool or similar SEALING PLATE DN Diagram 3 1 m APPROVED SEAL FLEXIBLE LINER BOILER Diagram 3 2 3 3 New Chimney A newly built chimney can be lined with a moisture resistant lining such as salt glazed pipe of an appropriate diameter as specified in the Building Regulations In the case of a salt glazed lined flue it is recommended that a short vertical length of flue pipe preferably flexible metallic be used Fix and seal itto the boiler flue socket and make good with an approved seal If a flue and false chimney breast are to be constructed all openings for pipework to upper floors etc must be sealed If a specially built compartment is constructed for the boiler it must conform to the requirements of the current issue of BS5440 Part 1 and BS5871 2000225006B 3 Flue and Installation 3 4 Timber Frame Buildings If the boiler is to be installed in a timber frame building it should be fitted in accordance with the Inst
20. e property by the currentissue of the Gas Safety Installation and Use Regulations Section JD To obtain service please call your installer or Heatcall Glow worm s own service organisation using the telephone number given on the inside of 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 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 L or Red The Green and yellow cable must be connected to the terminal marked E or Green
21. en operate the boiler On completion of the test switch off the electrical supply and gas supply remove analyser tube and replace sampling point cap Servicing Before servicing turn off the gas and isolate the electrical supply to the boiler After completing a service always test for gas soundness make electrical checks and carry out functional check on controls Unless stated otherwise all parts are replaced in the reverse order to removal ELECTRICAL WIR RE SAMPLE POINT CLIR Diagram 8 1 19 2000225006B 8 1 Access Remove the boiler front casing panel refer to section 6 8 Remove the bottom plinth panel by unscrewing the two dog point screws securing the panel to the boiler plinth see diagram 8 4 Disconnect gas valve from gas cock and unplug electrical plug from gas valve firstly removing electrical plug securing screw see diagram 8 2 Unclip electrical wires from control box support bracket see diagram 8 3 Undo the four self tapping screws that secure the combustion chamber front and carefully withdraw it together with the burner and gas valve assembly taking care not to strain the ignition and earth wire see diagram 8 5 Note When replacing burner in combustion chamber make sure it fits correctly on the guides Disconnect the ignition and earth leads from the burner and remove by drawing the leads though the grommet see diagram 8 5 Remove the three self tapping screws from the
22. ere is no pumping over of water or entry of air at the open vent above the feed and expansion cistern 6 7 Adjustment Fully Pumped Open Vented System When commissioning the system the boiler should first be fired on full service that is central heating and domestic hot water Adjust the pump to the system design setting then balance the system making adjustments as necessary 2000225006B 18 6 Commissioning 6 8 Completion Adjust the boiler temperature control and any system controls to their required settings Fit the bottom plinth panel and secure with two dog point screws see diagram 6 2 Finally fit the front panel by hooking under front of top panel locating on the two studs and securing at the bottom on to the bottom plinth panel with two screws see diagram 6 3 SECURING SCREWS i P Tia 2i e gt int e gt ar Sl g BOTTOM PLINTH PANEL Diagram 6 2 OCATE UNDER LIP I u LOCATING STUDS FRONT __ n FRONT PANEL SECURING SCREWS Diagram 6 3 7 Instructions to the User f A 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 on
23. hat it will clear the boiler air duct and if working to minimum clearance does not project too far from the boiler see diagram 4 5 Do not route any pipework water or gas across the front of the combustion chamber cover The gas pipework must be along the left hand side of the boiler 4 5 Casing Brackets Fit the two upper and two front casing brackets shown in diagram 4 6 using the No 8 screws provided NOTE The screws will already be fitted Push the captive nuts supplied loose on to the casing brackets as shown in diagram 4 6 le 2174 in PIPEWORK CASING CLEARANCES Diagram 4 4 57 MAX 21 4 in FOR MINIMUM na REAR CONNECTION PIPEWORK 28mm Diagram 4 5 2000225006B UPPER CASING BRACKET No 8 SCREW CAPTIVE NUT No 8 SCREW FRONT 4 CASING BRACKET CASING BRACKETS FITTING Diagram 4 6 FRONT CASING BRACKET SIDE a CASING R H 3 MIN LOCATING Tyo a SLOTS aie No 8 x MAA BA SCREW BOILER P PLINTH SIDE CASINGS FITTING Diagram 4 7 4 Installation 4 6 Side Casings Fit the side casings by locating their lugs into the appropriate slot in the boiler plinth see diagram 4 7 depending on the required height there are two options see section 1 7 Secure the casing sides to the front and rear upper casing brackets with self tapping screws supplied see diagrams 4 7 and 4 8
24. he waterway see diagram 2 2 2 5 Circulation Pump Normally the pump should be setto give atemperature difference of 11 C 20 F across the boiler Atthe appropriate pumped flow rate the pressure loss through the boiler can be found from the graph diagram 2 3 Use a pump with integral valves or fit isolating valves as close to the pump as possible 2 6 Cylinder For all systems supplying domestic hot water the cylinder must be indirect 2 7 Safety Valve A safety valve need not be fitted to an open vented system 2 8 Draining Tap A draining tap must be provided at the lowest points of the system which will allow the draining of the entire system including the boiler and hot water cylinder Draining taps should be to the current issue of BS2879 2 9 Thermostatic Radiator Valves If thermostatic radiator valves are fitted care must be taken to ensure that there is an adequate flow rate through the boiler when they close refer to the current issue of BS7478 for guidance If fitted to all radiators ensure a bypass is fitted and adjust to achieve a temperature difference no greater than 20 C between flow and return with the thermostatic valves closed 2000225006B REFER TO BS 5546 lt 22mm VENT 15mm COLD FEED INDIRECT CYLINDER Shown with recommended thermostat and valve 2 metres Heating Circuit DRAIN OFF Distributor tube in COCK pumped return connection Diagram 2 1 VENT 15mm COLD F
25. ill remain alight until switched off either by the boiler temperature control programmer if fitted or any remote system control To make sure that the flame supervision device is working correctly the following should be done With the burner alight turn the gas service cock Off see diagram 6 1 After a short period the burner will go out A CONTROL BOX B PHIAL POCKET C GAS SERVICE COCK QA D BURNER ON NEON D J E RESET NEON F TEMPERATURE CONTROL G BURNER PRESSURE TEST POINT H GAS PRESSURE ADJUSTMENT SCREW J DATA LABEL Diagram 6 1 2000225006B The correct working of the flame supervision is shown by the Burner On neon going out and the ignition sequence starting up After a short period the boiler will shut down If the lighting sequence described fails refer to fault finding section 9 To carry on turn the gas service cock On see diagram 6 1 To re start the lighting sequence turn the burner temperature control to 0 then fully clockwise to Max During normal operation when the boiler switches Off the burner will go out The automatic lighting sequence will work again when heat is required If the reset neon lights turn the boiler temperature control to 0 off wait 30 seconds then repeat the lighting instructions 6 4 Testing Gas With the boiler on proceed as follows Test for gas soundness around the boiler gas components using a suitable
26. itute of Gas Engineers document GE UP 7 1998 If in doubt seek advice from the local gas undertaking or Hepworth Heating Ltd 3 5 Ventilation for Boiler Installed in a Room or Space If the boiler is to be installed in a room or space a purpose designed permanent ventilation opening to supply air for combustion must be provided on an outside wall to external air refer to the current issue of BS5440 Part 2 for details The opening may be directly into the room or the space containing the boiler or an outside wall of an adjacent room or space which has an internal permanent air vent of the same size into the room or space containing the boiler Do not ventilate through a bedroom bedsitting room private garage or a room containing a bath or shower When the boiler is installed in a room or internal space already containing other fuel burning appliances then the air supply of such appliances must be taken into account The ventilation opening areas are givenin Air Vent Table The figures quoted refer to the minimum acceptable effective area 3 6 Ventilation for Boilers Installed in a Compartment When the boiler is fitted in a compartment high and low level purpose designed permanent openings must be provided to supply air for combustion and compartment ventilation The cupboard containing the boiler must have the door removed for ventilation reasons The air vents must have minimum areas see Compartment Air Vent
27. leak detection fluid in accordance with the current issue of BS6891 Check the burner gas pressure at least 10 minutes after boiler has lit refer to Data Label see diagrams 1 2 1 3 amp 1 4 If necessary adjust the gas pressure to obtain the required setting turning screw clockwise to decrease pressure see diagram 6 1 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 The gas rates Hideaway 80C FF 2 8m h 87ft h is for guidance only dependent on the heat setting Turn the boiler temperature control fully anti clockwise to 0 Isolate from the electrical supply Remove the pressure gauge from the test point and refit screw making sure a gas tight seal is made When the boiler temperature control is turned to the O position by hand wait at least 30 seconds before turning On again 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 time 6 5 Testing All Water Systems Allow the system to reach maximum working temperature and examine for water leaks There should be no undue noise in the system The boiler should then be turned off and the system drained off as rapidly as possible whilst still hot Refill system 6 6 Open Vented System Ensure th
28. low worm 2000225006B 03 02 Quality through design Instructions for Use Installation and Servicing Tobeleftwiththe user Hideaway 80C FF G C No 41 047 41 Chimney Fanned Flue Boiler C 4 Chenchmark The mark of quality for domestic heating This is a Cat I Appliance Reference in these instructions to British Standards and Statutory Regulations Requirements apply only to the United Kingdom For Ireland the rules in force must be used The instructions consist of three parts User Installation and Servicing Instructions which includes the Guarantee Registration Card The instructions are an integral part of the appliance and must to comply with the current issue of the Gas Safety Installation and Use Regulations be handed to the user on completion of the installation Guarantee Registration Thank you for installing a new Glow worm appliance in your home Glow worm appliances are manufactured to the very highest standard so we are pleased to offer our customers a Comprehensive First Year Guarantee In the centre pages are to be found your Guarantee Registration Card which we recommend you complete and return as soon as possible If this card is missing you can obtain a copy or record your registration by telephoning the Heatcall Customer Service number 01773 828100 Our Guarantee gives you peace of mind plus valuable protection against breakdown by covering the cost of 4 All replacement parts REGIS
29. ly Turn the gas service cock On see diagram 6 1 Purge in accordance with the current issue of BS6891 WARNING The multifunctional control and fan operate on mains voltage terminals will become live If programmer control is fitted make sure it is in the ON mode Make sure that any remote controls are calling for heat BOILER COMPONENTS Turn the boiler 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 boiler temperature control to O then fully clockwise to Max Max is approximately 82 C 180 F After the burner has lit the Burner on neon on the control panel will come on Isolate the boiler from the electrical supply Loosen the burner pressure test point screw and connect a suitable pressure gauge see diagram 6 1 Switch on the electrical supply to the boiler WARNING The multifunctional control and fan operate on mains voltage terminals will become live 6 3 Testing Electrical Turn the boiler temperature control fully clockwise to the maximum setting The lighting sequence is automatic as follows The fan operates and after a short period of time the spark ignition operates the solenoid opens then the burner will light shown by the Burner On neon on the control panel lighting up The burner w
30. nsions are given in millimetres except as noted Approximate weight of complete boiler 131 5kg 290lb 5 76 litre 1 27gallons Re in BSPT Re1 1in BSPT 230V 50Hz fused 3A Aeromatic Water content Gas connection Water connection Electrical supply Burner jo ae fe The Seasonal Efficiency Domestic Boilers UK SEDBUk is D 78 4 The value is usedin 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 See diagrams 1 2 for boiler ratings HEPWORTH HEATING LTD BELPER DERBYS DE56 1JT 2000463352 GC No 41 047 41 Glow worm HIDEAWAY 80C FF Electrical Supply 230V 50Hz 49W Fused at 3A For use on Izu G20 20mbar This boiler is intended exclusively to be installed on a gas supply CE 0086 with a governed meter GB IE HEATING CIRCUIT PMS 2 5 bar 0086 AP 041 INJECTOR 4 4mm PART No 2000461924 11 8 4 7 HEATINPUTNETT Q kW Btu h 25 94 88 507 23 45 80 000 SERIAL No Diagram 1 2 2000225006B 1 General Data 1 3 Statutory Requirements The installation of this appliance must be carried out by a competent person and must be in accordance with the relevant requirements of the current issue of Manufacturer s instructions supplied The Gas Safety Installation and Use Regulations Building Regulations Local Wate
31. nti clockwise to 0 off and switch off the electrical supply to the boiler To relight follow the lighting sequence given above 2000225006B BOILER TEMPERATURE CONTROL C25low worm Hideaway FF Reset Add OFF BURNER ON POSITION RESET NEON NEON Diagram 1 1 General Data NOTE The boiler casing can be set at two heights MAX and MIN WATER CONNECTIONS Rei reduced with DISTRIBUTOR TUBE to Re 3 4 in B S P T pumped return GENERAL DIMENSIONS given in millimetres k GAS CONNECTION Re 17 5 1 5 in B S P T WATER CONNECTIONS Rei 1in B S P T INSIDE DIAMETER OF ADAPTOR FOR 125mm sin NOMINAL DIAMETER FLUE TO BS567 Diagram 1 1 ee ee ee eae mm 387 145 558 294 364 555 442 3 Max 900 Min 860 Important Notice This boiler is for use only on G20 gas Wherever possible all materials appliances and components to be 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 Refer to Manual Handling Operations 1992 Regulations Sheet Metal Parts WARNING When installing or servicing this boiler care should be taken to avoid any possibility of personal injury when handling the edges of sheet metal parts 1 1 Technical Data Refer to diagrams 1 1 1 2 1 3 and 1 4 All dime
32. o the wing nut that secures the top of the heat shield and sia ACCESS carefully hinge down control box and heat shield see diagram i DOOR 4 10 Release the toggle latches that secure the fan access door and remove see diagram 4 11 Remove the electrical connections from the fan by pulling the insulation boots only Disconnect the air pressure tubes from the fan taking note of their positions Remove the fan assembly from the flue hood by removing the securing screw pull forward and lift up to release the 3 hooked securing lugs underneath the fan see diagram 4 12 M From the Chimney Flue Adapter Kit take the flue spigot the gasket is supplied in the fittings pack TOGGLE LATCHES Connect the flue spigot and gasket to the top flue outlet of the Diagram 4 11 boiler using the self tapping screws provided see diagram 4 15 From the Chimney Flue Adapter Kit take the chimney flue adapter and remove restrictor securing screw select and fit appropriate restrictor Marked C then secure in place with the previously removed screw To remove plastic end stop depress the collet Slide the Chimney Flue Adapter into the flue spigot until it engages in the bayonet connection and flue duct bend extension piece then twist clockwise to lock see diagram 4 15 Engage the flue duct extension on to the flue duct secure fan replace electrical connection and air pressure tubes The polarity of the electrical connections i
33. o use a mechanical handling aid Take care to avoid trip hazards slippery or wet surfaces CONTENTS DESCRIPTION SECTION PAGE No INSTRUCTIONS Introduction 3 FOR USE Lighting the Boiler 4 General Data 1 5 INSTALLATION da o E s o Flue amp Ventilation 3 9 INSTRUCTIONS Installation 4 10 Electrical Wiring 5 17 Commissioning 6 18 Instructions to User i 20 Servicing 8 20 SERVICING Fault Finding 9 23 INSTRUCTIONS Replacement Parts 10 26 Spare Parts 11 28 2000225006B 2 Instructions for Use Introduction Please read these instructions and follow them carefully for the safe and economical use of your boiler The Glow worm Hideaway C FF series are fanned flue boilers with a chimney flue adapter They provide heating and if required an indirect domestic hot water supply The boiler is automatic in operation having only one user control the boiler temperature control Gas Safety Installation and Use Regulations In your own interests and that of safety itis the law that ALL gas appliances are installed by a competent person in accordance with the current issue of the above regulations WARNINGS 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 Clearances Make sure that nothing
34. on Notes The appliance pack contains Boiler Casing panels packed seperately Loose items fittings pack see list in pack The chimney flue adapter with flue extension is supplied seperately Before installation of the boiler make sure that the location selected is in accordance with the requirements of Section 1 8 4 1 Unpacking The boiler casing panels are packed separately within the main carton and are designed to enable gas and water connections to be made before fitting the casing panels The casing brackets flue restrictor distributor tube and other loose items are in the fittings pack IMPORTANT With regards to the Manual Handling Operations 1992 Regulations the following operation exceeds the recommended weight for one man lift 4 2 Water Connections Gravity Domestic and Pumped Heating Fit suitable fittings into the boiler tappings see diagram 4 1 Make sure that all pipes are taken backwards and will clear the casings Heating flow Any one of the four upper connections may be used Domestic flow Any one of the three remaining upper connections may be used Heating return The water distributor tube must be fitted into either of the front lower connections on all installations see diagram 4 2 This tube is in the fittings pack Domestic return Any one of the three remaining lower connections may be used for the gravity domestic hot water return Fit plugs into any unused boiler tappings 4 3
35. r Company Bye laws The Building Standards Scotland Regulations applicable in Scotland 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 BS6891 BS5440 Part 1 and 2 BS6798 BS5449 BS5546 BS6700 BS7478 BS7593 BS7671 Manufacturer s instructions must not be taken as overriding statutory requirements 1 4 B S I Certification This boiler is certificated by B S I for safety and performance It is therefore important that no alteration is made to the boiler unless agreed in writing by Hepworth Heating Ltd Any alteration not approved by Hepworth Heating Ltd could invalidate the B S I certification boiler warranty and could infringe the current issue of the Statutory Requirements 1 5 Gas Supply The gas installation should be fitted 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 6 Electrical WARNING This boiler must be earthed The electrical installation must be carried out by a competent person All e
36. r 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 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 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 MANUAL HANDLING GUIDANCE During the appliance installation and the replacement of the heat exchanger it will be necessary to employ caution and assistance whilst lifting as the appliance or component exceeds the recommended weight for a one man lift In certain situations it may be required t
37. s LIVE Switched N NEUTRAL EARTH MAIN Diagram 9 4 2000225006B d 10 Replacement of Parts Important notes 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 Replacement of parts must only be carried out by a competent person Before removing or replacing any parts turn off the gas supply at the gas service cock see diagram 10 2 and isolate the electrical supply to the appliance 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 carry out functional check of controls 10 1 Electrical Thermistor Remove front panel to gain access see section 6 8 Remove control box cover by undoing the four securing screws two on control box two on the heat shield and lift off see diagram 10 1 Remove thermistor lead from retaining clip located on the control box support bracket see diagram 8 3 Release strain relief grommet securing thermistor lead at the side of control box Disconnect the thermistor electrical plug from the control board P C B slightly bending back the retaining latch to allow withdrawal see diagram 10 2 Remove the retaining wire and withdraw the elec
38. s boiler is not suitable for outside installation The boiler casing can be fitted at two heights Refer to diagram 1 3 The boiler is assembled at the factory with the control box and heat shield fitted in the lower position The boiler must stand on a level floor conforming with local authority requirements and building regulations The base temperature is within the requirements of the current issue of BS5258 The boiler may stand on a wooden floor but a metal base plate is required to protect plastic tiles and similar floor coverings Suitable installation 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 When the boiler is to be installed level with work surfaces and the like minimum clearances should be provided as shown in diagram 1 4 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 should be positioned to provide minimum clearances as shown in diagram 1 5 To facilitate minimum clearances it may be necessary to modify kitchen units and fixtures Combustible material must not be 25mm 1in away from flue components see diagram 1 5 A front access
39. s not important Make sure that the air pressure tubes are fitted as before see diagram 4 14 and that the fan duct engages fully into the flue duct extension piece IMPORTANT With regards to the Manual Handling Operations SECURING 1992 Regulations the following operation exceeds the LUGS recommended weight for one man lift Place the boiler in position taking care not to damage the casing panels Diagram 4 12 Flue Connection NOTE Fix and seal the flue to the hood of the chimney flue FLUE DUCT adapter in accordance with normal practice EXTENSION The flue should be 125mm 5in nominal diameter refer to PIECE section 3 Diagram 4 13 2000225006B 14 4 Installation 4 9 Water amp Gas connections Replace fan access door heat shield and control box Note When replacing the fan access door make sure the lip at the top of door fits into and behind the slotted bracket located at the top of the boiler As there are two casing height options the control box height and the heat shield may have to be adjusted to suit your requirements Complete the water connections to the boiler Fill vent and flush the system Check for any water leaks and put right Make the gas connection to the service cock at the lower left hand side of the boiler see diagram 1 1 The whole of the gas installation including the meter should be inspected tested for soundness and purged in accordance with the current issue of BS68
40. sure Head The boiler shall only be connected to a cistern water supply with a minimum head of 1metre 3ft3in and a maximum head of 27metres 90ft which has an open vent in the system The working pressure must be within the range 0 1bar to 2 7bar 1 3 to 39lbftin 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 the inhibitor manufacturers so that they can recommend their most suitable product When using in an existing system take special care to drain the entire system including the radiators then thoroughly clean 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 when the central heating pump is off The domestic primary flow and return must be 28mm o d 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 2 4 Pumped Heating and Hot Water Where a single flow and return is taken from the boiler a minimum static head of imetre 3ft3in must be provided between the water line of the feed tank and the centre of t
41. table The figures quoted refer to the minimum acceptable effective area Both the high and low level openings must communicate with the same room or must both be on the same wall to outside air If air vent grilles are fitted to a cavity wall the opening through the wall must be ducted Where ventilation air to a compartment is taken from a room or space then the room or space must be fitted with a ventilation opening as specified in Air Vent Table For information regarding compartment requirements refer to the appropriate section of the current issue of BS6798 3 7 Extract Fans If an extract fan is fitted in the premises there is a possibility that if adequate inlet openings are not provided spillage of the products from the boiler could occur When openings are fitted in accordance with the current issue of BS5440 Part 2 and this section extract fans should not cause down draught but where such fan installations are found a spillage test must be carried out in accordance with the current issue of BS5440 Part 1 and any corrective work done 2000225006B 10 AIR VENT TABLE FOR ROOM SPACE INSTALLATIONS EFFECTIVE AREA OF VENT COMPARTMENT AIR VENT TABLE COMPARTMENT VENTILATION REQUIREMENTS HIGH LEVEL LOW LEVEL VENT AREA VENT AREA FROM ROOM 205cm 32in 409cm 64in2 OR SPACE FROM o lan OUTSIDE 103cm 16in 205cm 32in VENTILATION 4 Installation General Installati
42. 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 3 Test the polarity of the mains The installer is requested to advise and give guidance to the user of the controls scheme used with the boiler Replace the control box cover Diagram 5 3 2000225006B 16 6 Commissioning IMPORTANT NOTE The WARNING NOTICE attached to the front casing must only be removed by the user Please ensure the Benchmark logbook is completed and left with the user and the magnetic lighting instruction label is placed on the surface of the boiler casing 6 1 All Systems Commissioning should be carried out by a competent person in accordance with the current issue of BS6798 UNDER ALL CIRCUMTANCES 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 Initial Lighting and Testing CAUTION This work must be carried out by a competent person in accordance with the current issue of BS6798 Make sure that all naked lights and cigarettes are extinguished Refer to Instructions for Use and identify the controls Check that the boiler is isolated from the electrical supp
43. trical thermistor from its phial see diagram 10 3 Draw the thermistor lead followed by the thermistor out though the control box case Re assembly note When fitting the thermistor make sure it is fully inserted into the phial see diagram 10 3 Take care when re threading retaining wire so as not to damage thermistor 10 2 Control Board P C B Remove front panel to gain access see section 6 8 Remove control box lid by undoing the four securing screws two on control box two on the heat shield and lift off see diagram 10 1 Carefully pull the boiler temperature control knob away from the P C B SECURING ZO 7 run lt 4 x TERMINAL BOILER TEMPERATURE CONTROL Diagram 10 1 2000225006B Disconnect the electrical plugs from the control board PCB slightly bending back the retaining latches to allow withdrawal see diagram 10 2 Disconnect the ignition lead Carefully pull the board away from its supports bending back slightly the retaining latches When refitting refer to wiring diagram 9 4 Take care when replacing the burner temperature control knob by supporting the potentiometer on the P C B 10 3 Electrode Remove front panel to gain access see section 6 8 Refer to the relevant paragraphs of the servicing section to remove the burner from combustion chamber To remove the electrode unscrew the retaining bracket see diagram 8 12 Take the electrode out from below and remove the ignition lea
44. ueway baffles noting that there are 2 centre and 2 aa NUT side flueway baffles see diagram 8 8 SZ Fol Place a sheet of paper in the combustion chamber to catch any flue debris Thoroughly clean boiler flueways and fins with a suitable stiff brush Replace in reverse order after completing the relevant instructions in sections 8 3 and 8 4 8 3 Burner and Injector Remove the two screws and nuts securing the burner support bracket to the combustion chamber cover see diagram 8 9 SELF Remove the graphite coated nuts on the supply feed pipe at the eae rear of the burner to release the burner see diagram 8 10 TAPPING SCREWS Clean the burner Use a vacuum cleaner or suitable stiff brush 3 not wire to clean the burner thoroughly making sure that all the burner ports are clear and unobstructed Diagram 8 6 Check the burner injector for blockage or damage and replace if necessary see diagram 8 11 With the burner removed the injector can be inspected and cleaned as necessary For cleaning do not use a wire or sharp instrument on the hole If removed use a little suitable sealant on the external thread when refitting to make sure a gas tight seal is made BOTTOM PLINTH PANEL PANEL Diagram 8 7 SIDE FLUEWAY BAFFLE FLUEWAY BAFFLE HEAT EXCHAN a EXCHANGER Diagram 8 8 21 2000225006B 8 Servicing 8 4 Service Checks Inspect the spark electrode and clean an
45. ve front panel to gain access see section 6 8 Refer to the relevant paragraphs of the servicing section to remove the fan access door Remove the air pressure tubes and electrical connections from the switch release the securing screws and remove the switch see diagram 10 5 When fitting the replacement make sure that the air pressure tubes are fitted as shown in diagram 10 5 and the electrical connections are made as shown in wiring diagram 9 4 10 9 Fan Remove front panel to gain access see section 6 8 Refer to the relevant paragraphs of the servicing section to remove the fan access door Remove the electrical connections and air pressure tubes from the fan Note Remove the electrical connections by pulling insulation boots only Undo the screw securing the fan to the flue hood and disengage fan from flue hood see diagram 10 5 When re assembling make sure that the air pressure tubes are fitted as before and that the fan duct engages fully into the flue duct extension piece The polarity of the electrical connections is not important ELECTRICAL SOLENOID SECURING PL SECURING SCREW a SCREW GAS SER A COCK a ia Eh we _ UNION F j is F ty gt Lo ed Wi i i J i E PEt lt SOLENOID ASSEMBLY Diagram 10 4 10 Replacement of Parts ee f ee 10 10 Insulation Refer to the relevant paragraphs of the servicing section to remove the burner from combustion chamber
46. xternal 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 through an unswitched shuttered socket outlet and 3A fused 3 pin plug both to the current issue of BS1363 Alternatively a 3A fused double pole isolating switch may be used having a minimum double pole contact separation of 3mm serving only the boiler and system controls Heat resistant cable of at least 0 75mm 24 0 20mm to the current issue of BS6500 Table 16 must be used for all connections within the boiler casing to the control box pump etc 1 7 Condensate Drain A plastic drain pipe may need to be fitted to allow discharge of condensate to a drain Condensate should if possible be discharged into the internal household draining system If this is not practical discharge can be made externally into the household drainage system or a purpose designed soak away see section 4 10 for more details 2000225006B MAX 900 MIN 860 POSITIONS FLOOR LEVEL BOILER CASING HEIGHT S Diagram 1 3 WORKTOP 407 MIN BOILER BOILER CUPBOARDS MINIMUM CLEARANCES LEVEL WITH WORKTOP Diagram 1 4 WORKTOP OR FIXTURE j CUPBOARD CUPBOARD MINIMUM CLEARANCES UNDER WORKTOP FIXTURES Diagram 1 5 1 General Data 1 8 Boiler Location Thi
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