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Glow worm Hideaway 80B FF

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1. 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 0 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 there 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 19 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
2. 6 Commissioning 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 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 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 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 diagram 1 2 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 Gas rate Hideaway 808 FF 2 8m h 79
3. 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 A front access clearance should be provided as shown in diagram 1 6 The boiler may be installed in any room although particular attention is drawn to the requirements of BS7671 with respect to the installation of a boiler in a room containing a bath or shower Any electrical switch should be so positioned that it cannot be touched by a person using the bath or shower The electrical provisions of the Building Standards Scotland Regulation
4. 2 THERMISTOR Baram 10 3 10 Replacement of Parts 10 5 Solenoid 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 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 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 with the clear tube from the air pressure switch to the front fan connection as shown in diagram 10 5 and the electrical connections are made as shown in wiring diagram 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 burner from combustion chamber Remove the electrical connections and air pressure tubes from the fan Note Remove the electric
5. NO between N and brown Faulty PCB Does burner light and between N and black Replace YES 3 way connector on PCB NO Is integrity of YES Is neon 4 lit electrode and YES ignition lead good Check continuity of NO Faulty harness gas valve harness Replace YES YES Appliance working Replace 85 Faulty Faulty gas valve satisfactorily necessary PCB Replace ELECTRICAL FAULT FINDING Diagram 9 1 23 221958B 9 Fault Finding 9 1 Electrical Gain access to the control box refer to the relevant paragraph in section 6 1 then remove the control box cover refer to section 5 1 Refer to Boiler Fault Finding see diagram 9 1 Fault Finding Wiring Diagram see diagram 9 3 Pictorial Wiring Diagram see diagram 9 4 9 2 Electrical Supply Failure Failure of the electrical supply will cause the burner to go out Operation will normally resume on the restoration of the electrical supply the burner does not relight after an electrical supply failure and the red neon onthe control panel is lit turn the burner temperature control to 0 wait 30 seconds then fully clockwise to Max see diagram 9 2 221958B 24 BOILER TEMPERATURE CONTROL lowwam Hideaway FF OReset Add Diagram 9 2 MAINS SUPPLY 230v 50112 A AIR PRESSURE SWITCH CONNECTIONS MAIN TERMINAL STRIP CONNECTIONS PRINTED CIRCUIT BOARD CONNECTIONS BLACK r RED BROWN y YELLOW BLUE gy GRE
6. 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 to
7. 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 electrical 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 SECURING lt gt 7 run lt 4 ye TERMINAL BLOCK BOILER TEMPERATURE CONTROL Diagram 10 1 221958B Carefully pull the boiler temperature control knob away from the P C B Discon
8. by fixtures The in fill panel will usually be fitted on the side where there 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 13 NOTE The boiler is assembled at the factory with the control box and heat shield fitted in the lower casing height position SIDE CASING R H SHOWN SPRING CLIP alll L UPPER VIEW SIDE CASING R H SHOWN SPRING CLIP LOWER VIEW Diagram 4 13 221958B 14 4 11 Side Casings Fit the side casings by locating their lugs into the appropriate slot in the boiler plinth see diagram 4 13 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 13 and 4 15 FRONT CASING BRACKET SIDE a CASING R H z MIN LOCATING 2 fe SLOTS os N a NO 8 SCREW 4 SY BOILER PLINTH SIDE CASINGS FITTING Diagram 4 14 UPPER CASING BRACKET Diagram 4 15 4 Installation 4 12 Flue Boiler Connection Remove the three self tapping screws from the lower part of the LOW oe ae control box support bracket see diagram 4 16 eee WING NUT Undo the wing nut that secures the top of the heat shield and carefully hinge down control box and heat shield see diagram HIGH
9. fit the front panel by hooking under front of top panel locating on the two studs see diagram 6 2 and securing at the bottom on to the bottom plinth panel with two screws see diagram 6 3 SECURING SCREWS BOTTOM PLINTH PANEL Diagram 6 2 LOCATE UNDER LIP p mua Tes LOCATING STUDS FRONT aa pane FRONT PANEL SECURING SCREWS Diagram 6 3 221958B 7 Instructions to the User Instruct and demonstrate the safe and efficient operation of the boiler heating system and domestic hot water system Advise the user that to ensure the continued efficient and safe operation of the boiler it is recommended that it is checked and serviced at regular intervals The frequency of servicing will depend upon the particular installation and usage but in general once a year should be enough Draw attention if applicable to the current issue of the Gas Safety Installation and Use Regulations Section 35 which imposes a duty of care on all persons who let out any property containing a gas appliance It is the Law that servicing is carried out by a competent person Advise the user of the precautions necessary to prevent damage to the system and building in the event of the heating system being out of use during frost and freezing conditions Reminder Leave these instructions and the Benchmark logbook with the user 8 Servicing REMEMBER When replacing a part on this applianc
10. 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 or the earth symbol 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 221958
11. sliding back to disengage the retaining lugs then lift up see diagram 8 7 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 IGNITION AND EARTH LEADS Diagram 8 5 O WING NUT MALA 88 2 ELECTRICAL WIR RE SELF TAPPING SCREWS 3 Diagram 8 6 SECURING SCREWS Se FLUE HOOD 22 SECURING BOTTOM PLINTH SCREW PANEL Diagram 8 4 Diagram 8 7 21 221958B 8 2 Boiler Flueways Remove flueway baffles noting that there are 2 centre and 2 side flueway baffles see diagram 8 8 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 Remove the graphite coated nuts on the supply feed pipe at the rear of the burner to release the burner see diagram 8 10 Clean the burner Use a vacuum cleaner or suitable stiff brush not wire to clean the burner thoroughly making sure that all the b
12. switch off the electrical supply to the boiler To relight follow the lighting sequence given above 221958B BOILER TEMPERATURE CONTROL C25low worm Hideaway FF Reset Add OFF BURNER ON POSITION RESET NEON NEON Diagram 1 1 General Data GAS CONNECTION Re 5 15 in B S P T WATER CONNECTIONS Ret 11 B S P T WATER CONNECTIONS Rc1 reduced with DISTRIBUTOR TUBE to Re 3 4 3 4 in B S P T pumped return NOTE The boiler casing can be set at two heights MAX and MIN GENERAL DIMENSIONS given in millimetres Diagram 1 1 Le ee ee eee 387 700 558 294 364 555 442 3 Max 900 300 194 32 Min 860 Important Notice This boiler is for use only on G20 gas The boiler is delivered in one pack and the flue pack is supplied separately 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 See di
13. 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 REFER TO BS 5546 22mm VENT 15mm COLD FEED INDIRECT CYLINDER Shown with recommended thermostat and valve 2 metres Heating Circuit DRAIN OFF COCK Distributor tube in pumped return connection _ Diagram 2 1 221958B 2 Water Systems 2 3 Gravity Domestic and Pumped Heating It is recommended that a cylinder thermostat is used to prevent lt 22mm VENT the stored water temperature becoming unnecessarily high 15mm when the central heating pump is off 4 COLD FEED The domestic primary flow and return must be 28mm o d The installation must comply with the current issue of BS5546 and 1 metre TO INDIRECT BS6700 see diagram 2 1 MIN CYLINDER If the above conditions cannot be met it is suggested that a fully pumped system be used 2 metres MAX 2 4 Pu
14. 0850 with instructions is available see diagram 6 4 If required an optional wall liner kit part no 900862 is available complete with instructions All flue assemblies are designed for internal installation Make sure that the ductings do not slope down towards the boiler 221958B FLUE 8 AIR DUCT LENGTH A 15 3 FLUE MINIMUM MINIMUM MAXIMUM PACKS WALL FLUE FLUE THICKNESS LENGTH LENGTH REAR STD REAR 75 95 510 NOTE IF IT IS NECESSARY TO CUT THE DUCTS TO ACHIEVE THE FLUE LENGTH MAKE SURE THAT THE OVERLAPS ARE AS FOLLOWS THE OVERLAP FOR AIR DUCT 25mm THE OVERLAP FOR FLUE DUCT 50mm Diagram 4 1 4 2 Flue Position and Length Select the boiler location with due regard to the flue length and terminal position see diagrams 3 1 and 4 1 For a wall thickness up to 300mm provided that the optional wall liner kit is used the flue can be fully installed from the inside For a wall thickness of over 300mm the external flue hole will need to be made good from the outside this also applies if you use the flue kit without the optional wall liner kit irrespective of wall thickness BOILER Pra OUTLINE FRONT VIEW Diagram 4 2 4 Installation 4 3 Flue Hole Cutting Mark out the flue centre see diagram 4 2 then cut a hole for the flue using preferably 8 115mm minimum core drill 4 4 Rear Flue Option Kit 425861 if applicable Fitthe wall cover plates as described in t
15. 25 FROM EXTERNAL CORNERS 25 ABOVE ADJACENT GROUND OR BALCONY LEVEL 300 FROM A SURFACE FACING THE TERMINAL 600 FACING TERMINALS 1200 FROM OPENING DOOR WINDOW IN CAR PORT INTO DWELLING 1200 VERTICAL FROM A TERMINAL 1500 HORIZONTALLY FROM A TERMINAL 300 FROM INTERNAL CORNERS 25 Diagram 3 1 COMPARTMENT AIR VENT TABLE COMPARTMENT VENTILATION HIGH LEVEL LOW LEVEL REQUIREMENTS VENT AREA VENT AREA VENTILATION FROM ROOM 2120M 42in 272cm OR SPACE FROM f a i OUTSIDE 136cm 21in 272cm 221958B 4 Installation INCREASE TO 30mm IF A FLUE COLLAR IS ADDED 15mm General Installation Notes The appliance pack contains Boiler Fan connector Casing panels packed seperately Loose items fittings pack see list in pack The flue is supplied seperately NOTE The rear flue option kit Part No 425861 is available which consists of wall cover plates for replacement Hideaway balanced flue appliances Before installation of the boiler make sure that the location selected is in accordance with the requirements of Section 1 7 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 NOTE To make a neat finish to the flue outlet a flue collar kit part No 90
16. 4 16 position Release the two toggle latches that secure the boiler access door and remove see diagram 4 17 Remove the electrical connections from the fan by pulling the insulation boots only LOW 3 SELF Disconnect the two air pressure tubes from the fan taking note position TAPPING of their positions i i SCREWS HIGH for height Remove the fan assembly from the flue hood by removing the position adjustment securing screw pull forward and lift up to release the 3 hooked securing lugs underneath the fan see diagram 4 18 SELF O From the flue pack take the flue spigot the gasket is supplied in TAPPING a i the fittings pack only SCREWS Connect the flue spigot and gasket to the rear flue outlet of the 3 boiler using the self tapping screws provided see diagram 4 3 IMPORTANT With regards to the Manual Handling Operations 1992 Regulations the following operation exceeds the recommended weight for one man lift FAN ACCESS DOOR Place the boiler in position taking care not to damage the casing panels 1 T Diagram 4 16 With access to the flue system through the boiler pull the flue on to the spigot bayonet connection twist anti clockwise to lock into position Take the flue duct extension from the boiler and slide on to the fan duct until it will go no further see diagram 4 19 Fit fan and engage the flue duct extension into the flue duct secure fan replace electrical connections a
17. B 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 anti clockwise 10 off and
18. ER 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 Member
19. TUBE CLEAR CONNECTORS ea 3 3 3 3 3 O AIR PRESSURE TUBE RED FAN SECURING SCREW REAR AIR PRESSURE SWITCH TUBE RED E7 screw 2 Diagram 4 21 16 5 Electrical Wiring SECURING e TERMINAL CONTROL CONTROL b BOX MAINS SUPPLY COVER 530V 50Hz br g y TERMINAL BLOCK LsN b TERMINAL BLOCK CONNECTIONS BOX KEY TO TERMINAL BLOCK RQ OC BOILER TEMPERATURE CONTROL 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 0 2mm and of a suitable length route as shown in diagram 5 3 Thread through the grommet at the bottom rear of the control box through the cable clamp and connect to appropriate terminals Tig
20. Y PURLPLE FUSE TYPE F4A AIR PRESSURE SWITCH SPARK ELECTRODE Diagram 9 3 9 Fault Finding NEON KEY see P C B NEON 1 MAINS ON NEON 2 DEMAND ON 1 NEON 3 oto FAN RUNNING NEON4 BURNERLIT NEON 5 1 NEON 6 SAFETY TEMPERATURE LIMITER X FLAME FAILURE BROWN BLUE GREEN YELLOW GREY BLACK PURPLE YELLOW RED A THERMISTOR ee bk Y L lt P C B CONTROL BOARD F4A FUSE T O NEON 1 NEON 5 b MAINS SUPPLY 230V 50Hz br g y TERMINAL BLOCK Ls N bk BOILER PILOT FAULT FINDING 25 AIR PRESSURE SWITCH GAS CONTROL Ls LIVE Switched N NEUTRAL EARTH MAIN g y L Diagram 9 4 221958B 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 8 2 and isolate the electrical supply to the appliance Unless stated otherwise all parts are replaced in the reverse order to removal After replacing
21. agrams 1 1 amp 1 2 All dimensions are given in millimetres except as noted Approximate weight of complete boiler 131 5kg 29015 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 The Seasonal Efficiency Domestic Boilers UK SEDBUk is D 78 6 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 1 1 2 Range Rating See diagram 1 2 F HEPWORTH HEATING LTD ulowsworm BELPER DERBYS DE56 1JT HIDEAWAY 80B FF 2000461940 Electrical Supply 230V 50Hz 49W Fused at 3A For use on 12 G20 20mbar This boiler is intended exclusivel to be installed on a gas supply with a governed meter HEATING CIRCUIT PMS 2 5 bar INJECTOR 4 4mm PART No 2000461924 11887 HEAT INPUT NETT Q kW Btu h 25 94 88 507 HEAT OUTPUT P kW Btu h 23 45 80 000 SERIAL No Diagram 1 2 221958B 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 Water Company Bye laws The Building Sta
22. al connections by pulling insulation boots only Undo the screw securing the fan to the flue hood and disengage fan from flue hood 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 SOLENOID SECURING SECURING SCREW SCREW ELECTRICAL PLUG GAS SOLENOID ASSEMBLY Diagram 10 4 10 10 Insulation Refer to the relevant paragraphs of the servicing section to remove the burner from combustion chamber 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 FRONT AIR PRESSURE SWITCH TUBE CLEAR AIR PRESSURE TP SWITCH ELECTRICAL CONNECTORS REAR AIR PRESSURE SWITCH TUBES RED Diagram 10 5 221958B 11 Spare Parts 11 1 Part Identification The key number in diagram 11 1 and the first column of the list will help identify the spare part Key No Part No 2000461752 227132 2000461994 2000461985 202635 2000461714 2000461924 227098 227030 205656 Description 11 2 Ordering When ordering any spare part please quote the part number and the description from the list togethe
23. alve 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 221958B 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 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 boiler access door and remove see diagram 8 7 SAMPLE POINT E Diagram 8 1 SECURING SCREW ELECTRICAL PLUG GAS SERVI COCK UNION Diagram 8 2 8 Servicing 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 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 by
24. d 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 supply 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 programmer control is fitted make sure it is in the ON mode Make sure that any remote controls are calling for heat BOILER COMPONENTS 221958B 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 t
25. diagram 4 6 Make sure that the ductings do not slope down towards the boiler Make good around the flue outside after installation of the boiler Important If the wall liner kitis used the self adhesive foam seal included in the wall liner kit must be used in place of the one supplied with the flue pack see diagram 4 6 for position of self adhesive seal Push the flue assembly into and through the hole such that it is within the wall and does not stick out into the room Do not push the flue assembly too far into the hole as it has to be pulled back into the boiler and secured If the boiler is not to be fitted for some time cover the hole in the wall Diagram 4 4 STANDARD 510mm REAR FLUE TERMINAL CLAMPING BRACKET A is ay RESTRICTOR CLAMPING BRACKET NIB TERMINAL RESTRICTOR SHOWN FITTED Diagram 4 5 221958B 4 Installation 4 6 Water Connections Gravity Domestic and Pumped Heating Fit suitable fittings into the boiler tappings see diagram 4 7 Make sure that all pipes are taken backwards and will clear the casings see diagram 1 1 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 8 This tube is in the fittings pack Dome
26. e 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 front panel and remove the control box as descibed in the 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 then 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 8 1 Access Remove the boiler front casing panel refer to paragraph 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 v
27. e multimeter WARNING The multifunctional control and fan operate on mains voltage the terminal will be live Before carrying out fault finding ensure that gas electricity and water are available at the boiler Ensure that any external controls are calling for heat and circuit water is cold D 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 5 neon 1 lit Is there 230V ac between NO Check power supply Esl andi Check power supply Is neon 2 lit With electrical supply isolated 56 PCB disconnect the 2 way thermistor plug from the PCB Check that there is a resistance Faulty thermistor between 14k 2 5kOhms Replace With electrical supply isolated remove the fan 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 YES Check for 230V ac Is the fan turning Is there 230V ac between N and common on fan contact on air Faulty air pressure NO pressure switch switch Replace YES Faulty Does sparking take place NO Faulty PCB Listen for spark discharge Replace Check for 230V ac YES oe
28. he instructions supplied with the kit 4 5 Flue Preparation Note If the flue collar kit see diagram 4 4 is to be used increase the 15mm projection to 30mm Extend the telescopic flue to the required length making sure thatthe minimum overlap is no less than 25mm and thatthe flue terminal projects 15mm minimum beyond wall face see diagram 4 1 If it is necessary to cut the flue ensure that the overlap is as stated in diagram 4 1 Carefully drill though air duct pilot hole and secure with self tapping screw provided in fittings pack see diagram 4 3 Seal the joint with the tape provided Note Should any one of the flue sections require cutting to obtain desired flue system length make sure that the overlaps are as follows The overlap for air duct 25mm The overlap for flue duct 50mm Take the terminal restrictor and position the clamping bracket making sure the clamping bracket nib protrudes in the slot of the terminal restrictor and secure with locking screw but do not tighten see diagram 4 5 Engage the terminal restrictor on the flue terminal by hooking it over the terminal end and engaging the clamping bracket behind the inner ring of the terminal securing it by tightening the locking screw see diagram 4 5 GASKET SCREW 4 SPIGOT BAYONET CONNECTION SCREW AND TAPE Diagram 4 3 Fit the self adhesive foam seal provided in the flue pack around the air duct at the position shown in
29. he 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 onthe 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 will 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 D BURNER ON NEON E RESET NEON F TEMPERATURE CONTROL G BURNER PRESSURE TEST POINT H GAS PRESSURE ADJUSTMENT SCREW J DATA LABEL Diagram 6 1
30. hten 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 Make sure the cable is suitably secured When making connections make sure that the earth conductor is made of a greater length than the current carrying conductors 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 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 Ls LIVE Switched N NEUTRAL EARTH MAIN b BLUE br BROWN bk BLACK g y GREEN YELLOW CABLE CLAMP SCREW MAINS INLET CONNECTOR 17 Diagram 5 1 Diagram 5 2 Diagram 5 3 221958B 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 complete
31. ilding it should be fitted in accordance with the Institute of Gas Engineers document IGE UP 7 1998 If in doubt seek advice from the local gas undertaking or Hepworth Heating Ltd 3 3 Terminal Guard A terminal guard is required if persons come into contact with the terminal or the terminal could be subject to damage If a terminal guard is required it must be positioned to provide a minimum of 50mm clearance from any part of the terminal and be central over the terminal A suitable guard reference Type K3 can be obtained from Tower Flue Components Ltd Morley Road Tonbridge Kent TN9 1RA 3 4 Room Ventilation The boiler is room sealed and does not require the room or space containing it to have permanent air vents 3 5 Compartment Ventilation Where the boiler is fitted in a compartment the high and low level permanent air vents must have effective areas see Compartment Air Vent Table Both the high and level air vents must communicate with the same room or must both be on the same wall to outside air Under Car Port etc MINIMUM SITING DIMENSIONS FOR MINIMUM FANNED FLUE TERMINALS POSITION SPACING in mm A B C D E F G H DIRECTLY BELOW ABOVE OR HORIZONTALLY TO AN OPENING AIR BRICK OPENING WINDOWS AIR VENT OR ANY OTHER VENTILATION OPENING BELOW GUTTER DRAIN SOIL PIPE 25 BELOW EAVES 25 BELOW A BALCONY OR CAR PORT 25 FROM VERTICAL DRAIN PIPES AND SOIL PIPES
32. lls or clearances Minimum clearances must be left around the boiler as shown in diagrams 1 4 1 5 amp 1 6 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 8 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 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 this appliance is installed in a rented property there is a duty of care imposed on the owner of the 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
33. low worm 221958B 03 02 Quality through design Instructions for Use Installation and Servicing Tobeleftwiththe user Hideaway 80B FF G C No 41 047 35 Balanced Fanned Flue Boiler C 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 REGIST
34. mped Heating and Hot Water Where a single flow and return is taken from the boiler a minimum static head of 1metre 3ft3in must be provided Heating between the water line of the feed tank and the centre of the Circuit waterway see diagram 2 2 2 5 Circulation Pump at Distributor tube in l pumped return Normally the pump should be setto give atemperature difference connection of 11 C 20 F across the boiler Atthe appropriate pumped flow FULLY PUMPED SYSTEM rate the pressure loss through the boiler can be found from the DIAGRAMMATIC Diagram 2 2 graph diagram 2 3 Use a pump with integral valves or fit isolating valves as close to the pump as possible FLOW RATE GALLON MINUTE 2 6 Cylinder 123453678 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 1 1074 O O O 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 3 O NO O INCHES HEAD OF WATER Draining taps should be to the current issue of BS2879 a a LL 2 9 Thermostatic Radiator Valves A I r 0 8 12 18 24 30 36 42 when they close refer to the current issue of BS7478 for FLOW RATE LITRES MINUTE guidance If fitted to all radiators ensure a bypass is fi
35. nd air pressure tubes The polarity of the electrical connections is not important Make sure that the air pressure tubes are fitted as before see diagram 4 20 and that the fan duct engages fully into the flue duct extension piece TOGGLE LATCHES Diagram 4 17 SECURING LUGS Diagram 4 18 15 221958B 4 Installation 4 13 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 BS6891 4 14 Top Casing Refer to diagram 4 21 Fit two plastic pegs one on each side in the holes on the top casing The plastic pegs are atight fit and are best pushed home with a flat faced tool Secure front of top casing with the screws provided 221958B FLUE DUCT EXTENSION PIECE Diagram 4 19 FRONT AIR PRESSURE FAN ELECTRICAL WITCH
36. ndards 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 5 5 Certification This boiler is certificated by 8 5 1 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 8 5 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 external components shall be of the ap
37. nect the electrical plugs from the control board PCB slightly bending back the retaining latches to allow withdrawal see diagram 10 2 Disconnect 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 Refer to the relevant paragraphs of the servicing section to remove the burner from combustion chamber To remove the electrode unscrew from the retaining bracket see diagram 8 12 Take the electrode out from below and remove the ignition lead 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 securing screw and disconnect the electrical 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
38. proved 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 851363 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 221958B 10 floor level MAX 900 MIN 860 BOILER CASING ALTERNATIVE HEIGHT 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 10 CUPBOARD CUPBOARD MINIMUM CLEARANCES UNDER WORKTOP FIXTURES Diagram 1 5 1 General Data 1 7 Boiler Location This 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
39. r 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 gt 5 Ue oor Multifunctional control Fan Air pressure switch Electrical thermistor Spark electrode Boiler temperature control knob Injector Fuse Control board Burner 1 E S Lit 10177 Diagram 11 1 GC Part No kkkkkxk kkkkkxk kkkkkxk kkkkkxk KKKKKK KKKKKK KKKKKK kkkkkxk kkkkkxk KKKKKK Because of our constant endeavour for improvement details may vary slightly from those shown in these instructions 221958B 28
40. s apply to such installations in Scotland 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 8 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 BOILER WALL OR FIXTURE FRONT CLEARANCE Diagram 1 6 2 Water Systems 2 1 Water Pressure 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 90 which has an open vent in the
41. stic 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 7 Water Connections Fully Pumped Systems Fit suitable fittings into the boiler tappings as required see diagram 4 9 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 9 Fit the water distributor tube into the return connection see diagram 4 8 This tube is in the fittings pack Fit plugs into any unused boiler tappings WITH WALL LINER KIT ONLY WALL THICKNESS UP TO 300mm FOAM SEAL WALL THICKNESS OVER 300mm Diagram 4 6 221958B ALTERNATIVE HEATING OR DOMESTIC HOT WATER ALTERNATIVE HEATING RETURN With distributor tube not shown GRAVITY DOMESTIC RETURN TO ANY OF THE 3 REMAINING LOWER CONNECTIONS WATER CONNECTIONS GRAVITY DOMESTIC PUMPED HEATING Diagram 4 7 N UPPER MARKER must lie between the two outer NOTCHES Vai DY a TUBE must be in pumped return a MARKER connection DISTRIBUTOR TUBE Diagram 4 8 ALTERNATIVE lt ALTERNATIVE SPN RETURN POSITIONS With distributor tube not shown WATER CONNECTIONS FULLY PUMPED SYSTEMS Diagram 4 9 4 Installation 4 8 Pipework When the front tappings are used it is essential that any pipework or fittings do no
42. t project more than shown in diagram 4 10 When using a rear tapping with Rc 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 that it will clear the boiler air duct and if working to minimum clearance does not project too far from the boiler see diagram 4 11 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 Pe Vas PIPEWORK CASING A CLEARANCES Diagram 4 10 57 MAX 1a in FOR MINIMUM REAR CONNECTION PIPEWORK 28mm Diagram 4 11 4 9 Casing Brackets Fit the two upper and two front casing brackets shown in diagram 4 12 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 12 UPPER CASING BRACKET No 8 SCREW P gl CAPTIVE NUT FRONT 4 CASING BRACKET CASING BRACKETS FITTING Diagram 4 12 221958B 4 Installation 4 10 Side In fill Panel if required A side in fill panel is supplied with the boiler which can be fitted at the rear of the left or 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
43. tted and Diagram 2 3 adjust to achieve a temperature difference no greater than 20 C between flow and return with the thermostatic valves closed WATER PRESSURE LOSS metre HEAD OF WATER D O WATER PRESSURE LOSS lt 221958B 8 3 Flue and Ventilation The flue must be installed in accordance with the rules in force in the countries of destination 3 1 Terminal Position The minimum acceptable siting dimensions for the terminal from obstruction other terminals and ventilation openings are shown in diagram 3 1 The terminal must be exposed to the external air the position allowing free passage of air across it at all times Car ports or similar extensions of a roof only or a roof and one wall require special consideration with respect to any openings doors vents or windows under the roof Care is required to protect the roof if it is made of plastic sheeting If the car port consists of a roof and two or more walls seek advice from the local gas company before installing the boiler the terminal is fitted within 600mm below plastic guttering or painted soffit an aluminium shield 1500mm long should be fitted immediately beneath the guttering or eaves If the terminal is fitted within 450mm below painted eaves or a painted gutter an aluminium shield 750mm long should be fitted immediately beneath the guttering or eaves 3 2 Timber Frame Buildings the boiler is to be installed in a timber frame bu
44. urner ports are clear and unobstructed 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 FLUEWAY BAFFLE EXCHANGER SIDE FLUEWAY BAFFLE HEAT EXCHANGER Diagram 8 8 221958B 22 8 Servicing 8 4 Service Checks Inspectthe spark electrode andclean and 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 Diagram 8 9 S GRAPHITE A 8 Servicing _ SPARK GAP me 3 6 1 1 F GRAPHITE COATED NUT 2 BURNER INJECTOR Diagram 8 11 ELECTRODE fMi 9 Fault Finding IMPORTANT On completion of the Fault Finding task which has required the breaking and remaking of the electrical connections the continuity polarity short circuit and resistance to earth checks must be repeated using a suitabl
45. 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 al o i 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 221958B 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 B FF series are balanced fanned flue boilers 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 obstructs the ventilation gri

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