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Glow Worm - Compact 80e

1. 7007a Diagram 15 1 Because of our constant endeavour for improvement details may vary slightly from those shown in these instructions 221742D 44
2. M X N 3 N N N y S S V 3 E SS S i x A N N N 2 N N LEADS 3 ECURIN P BURNER SCREW 3 ELECTRICAL CONNECTIONS AIR PRESSURE SECURING SCREW TUBE 2 Diagram 12 2 FLUE y COLLECTOR 221742D Before replacing any of the parts removed during servicing inspect the condition of all seals and joints renewing them as necessary Check the condition of the combustion chamber insulation If renewing refer to Section 4 27 BURNER RETAINING BRACKET Pull bracket forward to remove UN When refitting make sure the bracket is located D in the guide and fitted properly ES SECURING L IP RIGHT HAND SIDE OF BURNER Diagram 12 4 BURNER GUIDE When refitting make sure the burner is located in the burner guide and fitted properly Pull burner forward to remove Diagram 12 5 12 Servicing 12 6 Spark Gap Check that the spark and sensing gaps are as shown in diagram 12 6 12 7 Operational Checks Light the boiler carry out operational checks and any necessary adjustments as described in Commissioning in the Installation Instructions 12 8 Completion Slide the outer case front on secure with the nuts previously removed PRODUCTS PROBE yn Diagram 12 7 IGNITION ELECTRO
3. 15 1 Part Identification The key number in diagram 15 1 and the first column of the list will help identify the spare part 15 2 Ordering When ordering any spare part please quote the part number 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 inner case front see diagram 8 1 Installation Instructions 2 3 4 5 6 7 8 9 DN o 0 o 0 o 0 ec O qo o N O aA A Cc N OC Part No 457077 205769 202639 202638 801179 801199 801166 227106 801189 801194 801203 227004 801192 202226 801182 227070 801186 801208 801181 227060 Description Fan assembly Main injector assembly Spark electrode Assembly Sensing electrode Boiler over heat cut off assy Domestic Hot Water Micro Switch Pressure gauge assembly Control board Pressure Differential Micro Switch Plate to Plate Heat Exchanger Thermistor assembly Domestic Thermistor assembly Heating Pump not illustrated Fuse not illustrated Gas control valve Air pressure switch assy Automatic air vent assembly Safety valve assembly Low water pressure switch Mains switch 43 GC No E27122 E27119 E39443 E39442 E27159 E27185 E26680 E27177 E27161 E27207 E27211 2 8136 E27124 E27166 E27115 E27143 E26675 221742D 15 Spare Parts
4. CENTRAL 1 RETURN FLOW PIPE CO N O N VALVE CLIP OVERHEAT CUTOFF ELECTRICAL CONNECTORS Diagram 14 4 FACSIA RETAINING SECURING BRACKET SCREW 2 PRESSURE GAUGE 33 Diagram 14 6 221742D 14 Replacement of Parts SECURING SCREW SENSING SUPPORT IGNITION LEADS LEAD POSTS 4 Diagram 14 8 MULTI PIN SOCKET SOINS GAS MULTI PIN HEAD CONTROL CONNECTOR CAPSCREW VALVE 8 CAREFULLY BEND THE RETAINING CLIPS FORWARD TO RELEASE MULTI PIN CONNECTORS Diagram 14 7 14 11 Low Water Pressure Switch Before starting refer to Section 11 MANIFOLD GAS SUPPLY Remove the two screws securing the controls cover door and PIPE controls fascia see diagram 9 1 Diagram 14 9 Hinge the assembly open Release the water pressure and drain the central heating circuit of the boiler refer to Section 11 3 and 11 6 TERMINAL Remove the clip to remove the water pressure switch see COVER SCREW diagram 14 11 ELECTRICAL Remove the plastic cover gt ADJUSTER EET NEN e H he electrical loa _ emove the electrical connectors z mrs Refer to wiring diagram 14 29 when fitting OL ZENI PUMP 14 12 Safety Valve j WKS a Before starting refer to Section 11 D Remove the two screws securing the controls cover door and controls fascia see diagram 9 1 gt Hinge the assembly open Remove the case base see diagram 10 3 Release the water pressure a
5. 221742D 12 5 3 Hard Water Areas In areas where the water is hard more than 200mgllitre it is recommended that a proprietary scale reducer is fitted in the cold water supply to the boiler Consult the local water company for additional advice A double check valve assembly must be fitted upstream of the scale reducer Forthe relative position of the scale reducer and pressure reducing valve if required refer to the manufacturer s instructions 6 Installation Preparation and Gas Water Connections The installation requires the following components 1 Plumbing jig Carton 2 Boiler Carton 3 Flue Pack 6 1 Plumbing Jig Remove from the carton the wall template then follow the instructions given on the template Note It is important that the wall hanging bracket and the service cock bracket are fitted to a flat and true wall area for correct alignment with the boiler Where this cannot be achieved itis acceptable to pack out the service cock bracket to obtain the correct alignment with the wall hanging bracket 6 2 Gas Connection Provision is made for the gas supply to be connected from below the boiler see diagrams 1 1 and 6 1 for position Refer also to Gas Supply Section 1 7 Make the gas supply connection to the gas service cock While making the connection do not subject the gas service cock to heat as you may damage the seals 6 3 Water Connections Provision is made for the dom
6. HOUSING TEMP PLATE TO PLATE HEAT EXCHANGER MAIN BURNER AUTOMATIC SAFETY BYPASS VALVE C H SENSOR RETURN D H W GAS HOT OUTLET 221742D COLD FLOW at LAM VALVE DISCHARGE D H W C H EE Diagram 1 3 2 Boiler Position 2 1 Location This boiler must be installed in accordance with the rules in force in the countries of destination This boiler is not suitable for fitting outside Any electrical switch must be positioned so that it cannot be touched by a person using the bath or shower The boiler must be mounted on a flat wall which is sufficiently robust to take its weight refer to Table 1 Data If the location of the boiler or any part of the system is subject to severe cold weather conditions it is recommended that a frost thermostat is fitted Any part of the system that may be vulnerable to freezing must be protected 2 2 Boilers in a compartment Where the installation of the boiler will be in an unusual position the current issue of BS6798 gives detailed guidance on these requirements An existing cupboard or compartment modified for the purpose may be used providing minimum clearances are maintained Details of essential requirements for cupboard or compartment design are given in the current issue of BS6798 The door way opening should be of sufficient size to allow for easy removal of the boiler Where the boiler is
7. INSULATION PADS CERAMIC FIBRE GLASSYARN MINERAL WOOL 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 to the eyes or severe irritation to the skin seek medical attention CONTENTS DESCRIPTION SECTION PAGE No Introduction 3 D ON Clock Settings 4 FOR USE Lighting the Boiler 5 General Data 1 7 INSTALLATION Boiler Position 2 9 Flue and Ventilation 3 10 INSTRUCTIONS Heating System 4 11 Domestic Hot Water System 5 12 Installation Preparation and Gas Water Connections 13 6 Flue Preparation 7 13 Mounting the Boiler 8 16 Electrical Connections 9 20 Commissioning 10 22 General Data 11 25 SERVICING Servicing 12 25 INSTRUCTIONS Fault Finding 13 27 Replacement Parts 14 32 Spare Parts 15 43 221742D 2 Instructions for Use Introduction Please read these instructions and follow them carefully for the safe and economical use of your Combination boiler This boiler must have been installed by a competent person in accordance with the current rules in force in the countries of destination at the time of installation Once the controls are set the boiler is automatic in operation The Co
8. System Commissioning Check that all remote controls and integral clock are calling for heat Fully open all radiator valves Set the heating system in operation and balance the radiators Refer to Section 4 6 and diagram 4 1 Allow the system to reach maximum temperature then switch off isolate the boiler from the electrical supply and drain the system rapidly whilst still hot Remove the inner case front Filland vent the system as described in Section 10 2 Filling the Central Heating Circuit Add inhibitor if applicable refer to Section 4 9 Corrosion Inhibitor Lower the pressure to the initial cold fill design pressure using the external draining tap close to the boiler refer Table 1 and Section 4 10 10 10 Completion Fit the side panels hook into the threaded lugs at the top see diagram 10 4 Fit the case base slide back engage the rear lugs secure with four screws see diagram 10 3 Fit the outer case front by locating it on one side then wrap it around locating it on the opposite side slide down locating on to the threaded lugs at the top and behind the controls cover at the bottom secure with nuts see diagram 10 5 Set the boiler and any remote heating control to the desired settings then close the control cover door EARTH LEAD IGNITION gt AE LEADS 2 QO Q E RE WM i o SENSING LEAD CONTROL BOARD SECURING COVER SCREW 4 CABLE ENTRY COVER 10 11 Instruct
9. and the old mica window Replace with a new mica window see diagram 14 26 Peel off the backing paper and secure with new self adhesive aluminium foil gasket Ensure no air bubbles are trapped underneath the foil Important Make sure that the mica window fully covers the opening and that the hole in the aluminium foil gasket is centred over opening 14 29 Inner Casing Seal Before starting refer to Section 11 Remove the old seal clean out the old adhesive Glue the new seal into place making sure that there are no breaks in it 221742D JI SERRA OA INSULATION OPENING BOILER INNER CASE FRONT PEEL OFF BACKING PAPER Diagram 14 26 SELF ADHESIVE ALUMINIUM FOIL GASKET AIR AIR PRESSURE Ses PRESSURE SWITCH SWITCH TUBE 2 SECURING SCREW 2 i ye RED JA EN jV NT CLEAR ELECTRICAL SNO CONNECTION 2 SN Diagram 14 27 14 Replacement of Parts 14 30 Air Pressure Switch Before starting refer to Section 11 Disconnect the two electrical connectors at the air pressure switch see diagram 14 27 Remove the flexible tubes from the switch Remove the air pressure switch secured with two screws When replacing the tubes to the air pressure switch make sure that the red tube from the fan connects to the upper connection of the switch The polarity of the electrical connections is important refer to diagram 14 29 14 31 Clock Timer ELECTRO MECHANICAL and DIGITAL if
10. carry out functional checks of controls Dispose of all used sealing washers gaskets and O rings when renewing components Use the new ones supplied with the replacement 11 2 Data Label The data label is positioned on the inner case front refer to diagram 1 2 11 3 Isolation of Boiler Before starting any servicing orthe replacement of parts isolate the boiler from the electrical supply at the external isolator When servicing or replacing any cold hot water or heating system components close all water cocks and drain appliance Close the gas service cock see diagram 6 1 BEFORE DRAINING THE BOILER REFER TO SECTION 11 6 11 4 Outer Case Front Removal Remove the two nuts securing the outer case front then lift up unhook the case at the top from the threaded lugs pull it off on one side to release then remove see diagram 10 5 11 5 Inner Case Front Remove the inner case front secured by two clamps at the bottom lift up and unhook at the top see diagram 8 1 11 6 System Pressures and Draining All parts containing water of the central heating circuit within the boiler are under the system pressure Before any parts of this circuit are disconnected reduce the system pressure at the external draining tap turn the central heating isolating valves off and drain at the drain points on the appropriate valves see diagram 6 1 All water containing parts of the domestic hot water circuit of the boiler will be
11. for the 7 Day Digital Clock Timer This is a 24 hour clock timer that is 1pm is 13 00 and has 8 ON and 8 OFF daily switching actions It is fitted with a lithium battery back up which protects the programme in the event of an electrical failure The battery should have a life of several years IAUTOO ORUN MT W ThF S Su OOOOO DAY HR OR MIN gt Diagram 2 Setting the Clock Diagram 2 1 With both AUTO and RUN switches set to the central position press R reset button the display will flash 2 Set RUN switch to D 221742D 3 Set day of week by pressing button DAY 4 Set time of day by pressing buttons HR and MIN 5 Set RUN switch to the central position colon will flash this indicates the clock is set With the clock set the factory preset programme shown below will operate Setting Timed Programmes With the clock set to the correct time see SETTING THE CLOCK paragraphs 1 4 and then continue as follows 1 Set RUN switch to B the display will indicate MON FRI SAT SUN the 1st ON preset programme and the symbol 7 2 Set day of week to be programmed by pressing the DAY button Note The days can be selected individually or as groups Mon Fri Mon Sat Mon Sun Sat Sun An arrow will be displayed under the day or days selected Set time of day by pressing the buttons HR and MIN Press button P to confirm programmes the display will indicate the 2nd
12. in line with the valve body see diagram 6 1 Open all hot water draw off taps and close them when water flows Check for water soundness of the whole domestic water system and boiler 10 2 Filling the Heating System Open the two central heating isolating valves levers in line with the valve body see diagram 6 1 Flush fill and vent the system refer to Section 4 8 Filling Sealed Systems WARNING SEVERAL COMPONENTS OPERATE ON MAINS VOLTAGE AND WITH THE OUTER CASE REMOVED LIVE COMPONENTS BECOME EXPOSED Make sure that the automatic air vent is operating correctly Take care not to splash any of the electrical components Open the controls cover Refer to diagram 4 Instructions for Use Operate button J between L summer and K winter to ensure that water flows through all parts of the boiler and air is not trapped in the boiler internal bypass Pressurise the system until the pressure is 1 5bar Check the heating system and boiler for water soundness Check the operation of the safety valve by turning the safety valve knob in the direction of the arrow Lower the pressure to the initial cold fill design pressure refer to Table 1 Position the set pointer on the boiler pressure gauge at this pressure also Refit inner case front 10 3 Preparation for Lighting Isolate the boilerfromthe mains electrical supply atthe external isolator Purge gas supply test for soundness Turn on the gas service c
13. side of the hydro block 14 21 Hydro Block Assembly Right hand side see diagram 14 18 Before starting refer to Section 11 Remove the two screws securing the controls cover door and controls fascia see diagram 9 1 Hinge the assembly open Remove the heat exchanger refer to Section 14 26 Remove the diverter switch refer to Section 14 13 Disconnect the domestic hot water micro switch inline electrical connector refer to Section 14 19 Unplug gas control valve multi pin connector x ferr GAS CONTROL VALVE MULTI PIN SECURING PIN 1 RETAINING CLIP DIVERTER SWITCH T ie if 3 SEM y B AG ELECTRICAL PLUG ES PRESSURE ie DIFFERENTIAL MICRO SWITCH ie PIN LOW WATER PRESSURE DOMESTIC HOT WATER THERMISTOR Hemove securing pins 4 5 and 6 see diagram 14 18 Hemove the plate to plate heat exchanger refer to Section 14 23 Remove the bypass tube refer to Section 14 22 Remove the right hand side of the hydro block See inset on diagram 14 18 to remove heating return filter 14 22 Bypass Tube Valve Remove the diverter switch refer to Section14 13 Remove the plate to plate heat exchanger refer to section 14 23 Remove the bypass tube by removing the two securing pins see Diagram 14 19 Remove the bypass valve see diagram 14 20 14 23 Plate to Plate Heat Exchanger Before starting refer to Section 11 Remove the two screws securing the controls cover door and controls
14. the User Instruct and demonstrate the lighting procedure then advise the user of the efficient and safe operation of the boiler Instruct and demonstrate the operation of any heating system controls Advise the user on the use and maintenance of any scale reducer and pass on any relevant instructional documents Advise the user that to ensure the continued efficient and safe operation of the appliance 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 any 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 Heminder Leave these instructions and the Benchmark logbook with the user GAS CONTROL BURNER PRESSURE TEST POINT Diagram 10 1 SECURING SCREW 2 Slacken do not remove CLOCK TIMER COVER PLASTIC PLUG 2 DOMESTIC HOT WATER BURNER PRESSURE POTENTIOMETER HEATING BURNER PRESSURE POTENTIOMETER BURNER PRESSURE ADJUSTING TOOL Diagram 10 2 23
15. the entire system to be drained An additional draining tap MUST be fitted close to the boiler The flow and return isolation valves are provided with drain points for boiler heat exchanger drainage 221742D 4 Heating System DOMESTIC WATER mm BOILER O L COLD SUPPLY ADDITIONAL EXPANSION VESSEL a if required OPTIONAL FILLING KIT AVAILABLE No 457120 FILLING POINT V V HEATING AA CIRCUIT TN Ped FLOW DRAIN CONTROL POINT VALVE Diagram 4 2 ALTERNATIVE METHODS OF FILLING METHOD 1 COMBINED CHECK VALVE HEATING TEMPORARY AND VACUUM SYSTEM R a HOSE SERVICING UNIONS VALVE bi SUPPLY STOP SUPPLY VALVE PIPE METHOD 2 TEMPORARY HOSE HEATING DOUBLE CHECK SYSTEM VALVE ASSEMBLY SERVICING debis VALVE UNIONS ba SUPPLY STOP SUPPLY VALVE PIPE METHOD 3 CISTERN OVERFLOW HEATING PRESSURE SYSTEM SERVICING BEDUCING VALVE DOUBLE CHECK SUPPLY VALVE ASSEMBLY PIPE Diagram 4 3 5 Domestic Hot Water System 5 1 General The domestic hot water service must be in accordance with the rules in force in the countries of destination 5 2 Water Pressure For the minimum and maximum working pressures of the domestic hot water circuit of the boiler refer to diagram 1 2 If the cold water supply pressure exceeds the maximum a governor must be fitted in the supply to the boiler to reduce the pressure to within the limits given
16. thermostats integral clock and the like are switched on programmed and calling for heat Refer to diagram 4 Instructions for Use Set button J to K winter see diagram 4 The pump will circulate water through the boiler and the main burner will light Check that the burner pressure with the heating system cold to prevent any modulation of the gas pressure is within 0 2mbar of 15 01mbar the central heating pressure If the burner pressure is incorrect it may be adjusted to the correct setting by turning the central heating gas pressure adjuster potentiometer located on the control board to gain access remove the two screws securing the controls facia Usingthe burner adjusting tool supplied clockwise to increase see diagram 10 2 Turn the adjuster slowly always making adjustment by reducing below the required pressure then increasing up to the required setting Isolate the boiler from the electrical supply 10 Commissioning Remove the pressure gauge and tighten the test point screw Test for gas soundness around the burner pressure test point with the main burner alight using leak detection fluid Take care not to splash any of electrical components Replace plastic plugs and refit the control fascia 10 8 Temperature Settings The maximum temperature setting for the domestic hot water outlet is 65 C The maximum flow temperature setting for central heating is 80 C 10 9 Heating
17. 221742D 10 Commissioning N WRAP AROUND S Diagram 10 3 SECURING NUT 2 OUTER CASE FRONT SECURING SECURING SCREW 2 SCREW 2 Diagram 10 4 Diagram 10 5 221742D 24 11 General Data 11 1 Servicing or Replacing Parts To ensure the continued efficient and safe operation of the boiler it is 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 The servicing of this boiler must be carried out by a competent person in accordance with the rules in force in the countries of destination NOTE To obtain a products of combustion reading remove the cap from the analyser probe positioned on the top of the boiler see diagram 12 7 Disconnect the analyser tube after use replace the cap Typical values for this boiler at maximum domestic hot water demand is CO 5 8 7 and CO lt 0 006 These are based on a 300mm length rear flue Make sure the appliance does not modulate whilst checking combustion and allow the appliance to warm up for 15 minutes before taking a reading Unless stated otherwise parts removed or renewed during servicing should be fitted in the reverse order to removal After completing any servicing or renewing of gas carrying components ALWAYS test for gas soundness and
18. 569 Important Information Testing and Certification This boiler is tested and certificated for safety and performance It is therefore important that no alteration is made to the boiler without permission in writing from Hepworth Heating Ltd Any alteration not approved by Hepworth Heating Ltd could invalidate the certification boiler warranty and may also infringe the current issue of the Statutory Requirements see Section 1 4 CE Mark This boiler meets the requirements of Statutory Instrument No 3083 The boiler Efficiency Regulations and therefore is deemed to meet the requirements of Directive 92 42 EEC on the efficiency requirements for new hot water boilers fired with liquid or gaseous fuels Type test for purposes of Regulation 5 certified by Notified body 0086 Product 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 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 Substances Hazardous to Health The adhesives and sealants used in this appliance are cured and give no known hazard in this state
19. ALS FROM OPENING DOOR WINDOW IN CAR PORT INTO DWELLING VERTICAL FROM A TERMINAL HORIZONTALLY FROM A TERMINAL mm 25 25 25 25 25 300 600 1200 1200 1500 300 TERMINAL GUARD TYPE K3 SUPPLIED BY Tower Flue Components Ltd Morley Road Tonbridge Kent TN9 1RA Ni n NS tr k RENE AN N CU Mee Diagram 3 1 4 Heating System O CN L E gt O Q D gt D gt C O D c D tc Dt at 80000 btu output Dp M H20 Circuit flow rate l min 4 1 General Notes The boiler is intended for use in a sealed system only 4 2 Safety Valve The safety valve is an integral part of the boiler It cannot be adjusted but has a manual test device 4 3 Pressure Gauge A pressure gauge is incorporated into the boiler to indicate the system pressure The gauge has a cold fill set pointer 4 4 Pump The circulation pump is integral with the boiler The remaining circulating pressure head available from the boiler is shown in diagram 4 1 Glow worm pump 4 5 Expansion Vessel The boiler has an integral expansion vessel with a capacity of 6 Litres If the system water content exceeds the maximum quotedin Table 1 Data an additional vessel should be connected into the system as close as possible to the central heating return connection of the boiler see diagram 4 2 The charge pressure shall not be less that the static head at the poin
20. CE SUPPLY IN OUT COCK Diagram 3 Summer Winter Selector Button Adjust the central heating water temperature control knob N to desired setting Forcentral heating set button J to Winter light K will illuminate The main burner will light The burner ON light D will illuminate When the heating is controlled by a room thermostat and or a time switch button J must be set to Winter light K will illuminate If a hot water tap is opened while the boiler is on for heating priority will be given to hot water Toturnthe heating off for short periods set button J to summer Off light L will illuminate To turn on again set button J to winter On light K will illuminate To Turn the Boiler Off To turn the boiler off set switch B to O To turn on again follow the operating instructions Maintenance and Servicing To ensure the continued efficient and safe operation of the appliance it is 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 If this appliance is installed in a rented property there is a duty of care imposed on the owner of the property by the current issue of the Gas Safety Installation and Use Regulations Section 35 Servicing maintenance should be carried out by a competent person in acc
21. DE SENSING ELECTRODE 1 5mm ANE IGNITION ELECTRODE SPARK GAPS Diagram 12 6 13 Fault Finding 13 1 Initial Checks If the boiler fails to operate first check the following 1 That the electrical supply is available at the boiler and the fuses are in order NOTE THE BOILER CONTROL BOARDS CAN BE DAMAGED BY INCORRECT TESTING OF COMPONENTS AND WIRING WITH THE POWER ON 2 Make sure that the system pressure gauge registers 0 7bar minimum and that the automatic air vent works Refer to Installation Instructions Section 10 2 3 That the gas supply is available at the boiler and purged of air 4 That the boiler is set for the required service 5 With the boiler Summer Winter Button J set to summer L see diagram 4 User Instructions check that the domestic water 27 supply is available and water flows freely from the hot taps Close the taps 6 With the boiler Summer Winter Button J set to Winter K see diagram 4 User Instructions check that all heating system controls if fitted are working correctly and calling for heat If not isolate the boiler from the electrical supply Test for continuity at mains 7 Check Summer Winter Button J is set to Winter see diagram 4 User Instructions In certain circumstances the red neon light may not come on due to no system demand Turn on a domestic hot water draw off tap to create a demand Allow the boile
22. Glowworm 2017420 11 00 Instructions for Use Installation and Servicing Tobeleftwiththe user COMPACT 80e G C No 47 047 O7A Fanned Flue Combination Boiler C 4 benchmark y This is a Cat L Appliance The instructions consist of three parts User Installation and Servicing Instructions which include 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 g All replacement parts REGISTER YOUR GLOW WORM APPLIANCE HY All call out charges CAL L 0208 247 9857 A CALL Tel 01773 828100 Nottingham Road Belper abo DE56 1JT General Sales enquiries One Contact Local Service Fax 01773 828070 Tel 01773 824141 Fax 01773 820
23. L BLOCK Ke 3 AMP EL FUSE T 230V 50Hz urs PERMANENTMAINS BODEN ouste b SUPPLY L POLE N 3k RED LINK ISOLATOR REMOVE WHEN CONNECTING POTENTIAL SYSTEM CONTROLS FREE ROOM STAT NOFROST STAT 7100 INTEGRAL CLOCK TO BOILER ee MEER POTENTIAL FROST STAT JUNCTION BOX IE 230V 50Hz DOUBLE ay PERMANENT MAINS KOLATOR eo 230V 50Hz FROST STAT NO ROOM STAT INTEGRAL CLOCK 10 BOILER 5 WAY TERMINAL BLOCK R1 MAINS 9 POTENTIAL MAINS POTENTIAL JUNCTION ROOM STAT BOX 3K RED LINK REMOVE WHEN CONNECTING 230V 50Hz SYSTEM CONTROLS DOUBLE ey MAINS LI POLE IN SUPP ISOLATOR 230V 50Hz 230V 50Hz FROST STAT ROOM STAT USED AS LINK INTEGRAL CLOCK TO BOILER 5 WAY TERMINAL BLOCK 230V 50Hz POTENTIAL 230V 50Hz POTENTIAL JUNCTION ROOM STAT BOX 3K RED LINK REMOVE WHEN CONNECTING SYSTEM CONTROLS rs rm 230V 50Hz Bo ica cep MAINS N SUPP IBOLATOR 230V 50Hz 230V 50Hz ROOM STAT FROST STAT Diagram 9 3 21 221742D 10 Commissioning Please ensure the Benchmark logbook is completed and left with the user 10 1 Filling Domestic Water Circuit Check that the boiler is isolated from the electrical supply at the external isolator Fully open the domestic water supply stop cock or valve in the supply to the boiler Open the inlet domestic water isolation valve lever
24. L HEATING MAINS WATER ELECTRIC TEMPERATURE M SWITCH B ya KNOB N Ga KEY TO NEON LIGHTS a O1 P m BOILER LOCKOUT m D Sh BURNER IGNITED H ul LOW WATER PRESSURE Other system pipework external to the boiler may require frost protection If the boiler is to be out of use for any long periods during severe weather it is recommended that the whole system including the boiler should be drained to avoid the risk of freezing Make sure that if fitted the immersion heater in the cylinder is switched off Ifin doubt contact you installation servicing company for advice Draining and Filling CAUTION This boiler works in a pressurised system which must only be drained refilled and pressurised by a competent person Note Ifthe pressure gauge indicates aloss of system pressure that is less than 0 7bar YOU MUST CONTACT YOUR INSTALLER Pressure Relief Safety Valve CAUTION A pressure relief safety valve and discharge pipe is fitted to the boiler This valve must not be touched Should there be any discharge from the pipe turn the boiler off isolate from the electrical supply and contact your installation servicing company 221742D E A POWER ON L ga SUMMER SETTING P aa SANITARY DEMAND K ga WINTERSETTING a CENTRAL HEATING DEMAND lt yy Y gt PRESSYDOWN TO OPEN Diagram 4 Cleaning WARNING This appliance contains metal parts components and care shou
25. OFF preset programme and subsequently 3rd 4th 5th 6th 7th 8th 5 Repeat procedures 2 3 and 4 until desired programmes are set Note It is not a requirement to use the 8 on off programmes 6 Set the RUN switch the central position your appliance will now operate at the programmed times General Notes With the AUTO switch in the I position the central heating will operated constantly ON With the AUTO switch in the O position the central heating will not operate Soft Override button indicated by the symbol lt gt this function will override the current central heating programme for the next available ON time programmes are indicated by the symbol 7 To Light the Boiler 1 Check that all four isolating valves are open the levers in line with the valve body see diagram 3 2 Openthe controls cover door and familiarize yourself with the controls see diagram 4 3 CAUTION A sealed pressurised system must be filled and pressurised by a competent person Optional extra filling loop kit No 457120 Only operate the boiler when you are sure that the system has been filled and pressurised Check this by looking at the pressure gauge A it should read 0 7bar minimum Instructions for Use 4 Open a hot water tap check that water flows then close it 5 If you are in any doubt about the boiler being filled with water contact your installation servicing company or the local gas co
26. a A short discharge pipe is supplied loose with the boiler which when fitted to the safety valve will end below the boiler the position is next to the heating return for position see diagram 6 1 This must be extended using not less than 15mm od metal pipe to discharge in a visible position outside the building facing downwards preferably over adrain The pipe must have a continuous fall and be routed to a position so that any discharge of water possibly boiling or steam cannot create any danger to persons damage to property or external electrical components and wiring Note Toeasefuture servicing itis advisableto use a compression type fitting to extend the discharge pipe 221742D 7 Flue Preparation TOP OUTLET FLUE PACK o LO FLUE LENGTH FLUE LENGTH 2 MAX 840mm extd MAX 840mm extd MAX 570mm std MAX 570mm std T 4 Pn samm temm ER ME LE TOP OUTLET SIDE FLUE SCREW amp TAPE TOP OUTLET REAR FLUE RHD SIDE FLUE X plus 254mm FLUE LENGTH LHD SIDE FLUE X plus 10mm FLUE LENGTH Y plus 69mm FLUE LENGTH STD EXTD TOP OUTLET FLUE PACK amp 1 METRE EXTENSION KIT SCREW 2 x 1 metre extension kits may be joined together amp TAPE 15mm di dad B Gg SCHEW amp TAPE VIEW B RHD SIDE FLUE X plus 254mm FLUE LENGTH LHD SIDE FLUE X plus 10mm FLUE LENGTH HEAR FLUE Y plus 69mm FLUE LENGTH REAR OUTLET FLUE PACK REAR OUTLET FLUE PACK a
27. am 8 11 Fit the fan and flue collector the electrical connections and air pressure tubes to the fan Refit the combustion chamber panel Make the outer wall weatherproof A Flue Collar Kit Part No 443286 is available 8 6 Top Outlet Side or Rear Flue Fixing Position the restrictor plate supplied in the loose items pack between the flue elbow and boiler gasket facing upwards Fit the flue elbow to the restrictor plate and top of the boiler using the four screws supplied see diagram 8 7 Tighten the four screws of the flue elbow evenly to ensure a good seal at the gasket Note Itis important the correct restrictor plate is fitted or omitted where instructed For top flue outlet be sure to use the correct restrictor plate all restrictors are supplied with the appliance see restrictor table RESTRICTOR TABLE MAX FLUE FLUE OUTLET LENGTH 1 REAR OM to 0 5M COMP 75E 80E 0 5M MAX 2 REAR 0 5M to 2 5M COMP 75E 80E 0 5m 3 5M 3 TOP OM to 2 5M SECURING SCREW 4 PRODUCTS PROBE USE RESTRICTOR PLATE MARKED COMP 75E 80E 2 5M MAX FLUE ELBOW REAR FLUE SHOWN RESTRICTOR GASKET bv A Diagram 8 7 221742D FITTED TO HYDRO BLOCK GAS SUPPLY lt 7 M 4 e SC 9 T SERVICE COCKS 4 SEALING WASHER 4 INSERT INTO TUBING NUT SAFETY VALVE DISCHARGE Diagram 8 9 8 Mounting the boiler Make sure that the ductings do not slope down towa
28. ch YES Follow B G YES Correct operation Diagram 13 3 221742D 30 13 Fault Finding NB The clock can be by passed by refitting the plug link which should be inside the clock timer cover J Check continuity of clock timer harness ensure an electrical supply is available ensure that remote controls are calling for heat Isolate the boiler from electrical supply remove outer case YES Switch on electrical supply Faulty clock timer is there a display on clock timer Replace YES S Disconnect and insulate the cables from heating common and heating on YE Advance clock timer until a demand is indicated Faulty clock timer Is there now continuity between heating Replace common and heating on YES Clock timer in order if no central heating refer to main fault finding DIGITAL CLOCK TIMER FAULT FINDING Diagram 13 4 NB The clock can be by passed by refitting the plug link which should be inside the clock timer cover Check continuity of clock timer harness ensure an electrical supply is available at the clock ensure that remote controls are calling for heat ensure the override switch if fitted is in overide position Does clock keep time Faulty clock timer Replace YES Isolate electrical supply set clock to an on period Faulty clock timer Is there continuity across common and heating Replace YES Set clock to off period Is there continuity across Faulty clock timer c
29. ctions by pulling the boots not the wires and air pressure switch tubes see diagram 12 2 Remove the fan Remove flue collector assembly by pulling it forward see diagram 12 3 Disconnectthe three electrode leads see diagram 12 1 White lead sensing electrode Remove the burner retaining bracket by sliding it out see diagram 12 4 Carefully pull the burner forward to remove see diagram 12 5 Take care not to damage the combustion chamber insulation 12 2 Cleaning Heat Exchanger Place a sheet of paper or similar in the combustion chamber to act as a collector for deposits removed Brush the heat exchanger with a suitable brush remove paper together with any debris Take care not to damage the insulation Do not use a brush with metallic bristles 221742D 12 Servicing 12 3 Cleaning Main Burner Use a vacuum cleaner or suitable brush to clean the burner thoroughly making sure that all burner ports are clear and unobstructed Do not use a brush with metallic bristles 12 4 Service Checks Inspect the spark and sensing electrodes Clean or renew if necessary refer to Sections 14 4 and 14 5 Check the main injector cleaning or renewing as necessary refer to Section 14 3 IGNITION ELECTRODE IGNITION SENSING ELECTRODE ELECTRODE RIT PTD I PLEA AN N SILICONE SLEEVE 3 Diagram 12 1 Y V Y N P NS CN S Y A b x SN N N
30. d Disconnect the electrical connections unclip to remove the thermistor see diagram 14 4 14 17 Flow Regulator Filter Before starting refer to Section 11 Drain domestic hot water Remove outer case front as section 11 4 Remove the two screws securing the controls cover door and controls fascia see diagram 9 1 Hinge the assembly open Release the water pressure and drain the domestic hot water circuit of the boiler refer to Section 11 3 and 11 6 Remove the flow regulator filter see diagram 14 15 RETAINING CLIP 1 LOW WATER PRESSURE SWITCH LEFT HAND HYDO BLOCK RETAINING CLIP Diagram 14 11 14 18 Pressure Differential Micro Switch Before starting refer to Section 11 Drain central heating water Remove outer case front as section 11 4 Remove the two screws securing the controls cover door and controls facia see diagram 9 1 Hinge the assembly open Disconnect the inline connector to the pressure differential micro switch Remove the micro switch securing clip ease the micro switch from its housing see diagram 14 16 14 19 Domestic Hot Water Micro Switch Before starting refer to Section 11 Drain domestic hot water Remove outer case front as section 11 4 Remove the two screws securing the controls cover door and controls fascia see diagram 9 1 Hinge the assembly open Disconnect the inline connector to the hot water micro switch Remove the micro switch securing clip eas
31. e the micro switch from its housing see diagram 14 17 221742D 14 Replacement of Parts DIVERTER SWITCH RETAINING CLIP ELECTRICAL PLUG DIVERTER VALVE Diagram 14 12 RETAINING Make sure spindle is located DIVERTER VALVE SECURING PIN Diagram 14 13 O RING ELECTRICAL CONNECTOR THERMISTOR DOMESTIC HOT WATER SECURING PIN Diagram 14 14 221742D 36 WATER INLET FILTER O RING WE e JQ NES SECURING REGULATOR PIN Diagram 14 15 SECURING CLIP PRESSURE DIFFERENTIAL KO MICRO SWITCH Lg Diagram 14 16 DOMESTIC SECURING CLIP HOT WATER 7 MICRO SWITCH Yj P j T z Sy aaae Diagram 14 17 14 Replacement of Parts 14 20 Hydro Block Assembly Left hand side see diagram 14 18 Before starting refer to Section 11 Remove the two screws securing the controls cover door and controls fascia see diagram 9 1 Hinge the assembly open Remove the heat exchanger refer to Section 14 26 Remove the diverter switch refer to Section 14 13 Remove low water pressure switch refer to Section 14 11 Disconnect the pressure differential micro switch inline electrical connector refer to Section 14 18 Unplug gas control valve multi pin connector Hemove securing pins 1 2 and 3 see diagram 14 18 Remove the plate to plate heat exchanger referto Section14 23 Remove the bypass tube refer to Section 14 22 Remove the left hand
32. emoved test for 230v at the fan connectors Fan failure with the power off and the supply leads to the fan disconnected pull the boots only the resistance across the fan coil should not be greater than 500 Pump With the power off unplug the connector from the pump Restore the power and check that there is 230V between live red and neutral black or live and the appliance earth Air pressure switch With the power off and the front cover removed pull one of the supply cables from the fan and ensure itis electrially safe Restore the power establish a demand check that there is 230v at one of the APS cables but not at the other Turn the power off refit the fan cable restore the power and check that there is now 230V at both the APS connectors Caution the appliance will light unless the spark leads are temporarily unplugged from the electrodes and laid where they cannot spark and ignite the gas and are electrically safe This indicates that the APS changes state when the fan is run The three way valve Seperate the cable connector from the motor noting its orientation and the connector numbering marked on the motor housing Check that with a DHW demand there is 230V across sockets 2 and 1 and with a CH demand there is 230V across sockets 2 and 3 or ground and 1 ground and 3 respectively 29 221742D 13 Fault Finding Check appliance installation and that it is mechanically correct 7402 YES Check fil
33. en fitting the new main injector fit the new copper sealing washer supplied to ensure gas soundness see diagram 14 2 14 4 Spark Electrodes and Sensing Electrode Before starting refer to Section 11 General Data Isolate the boiler from the electrical supply Remove the outer case front and the inner case front refer to Sections 11 4 and 11 5 Remove the spark electrode lead and silicone sleeve remove the securing screw and electrode see diagram 12 1 14 5 Ignition Leads and Sensing Lead Before starting refer to Section 11 Disconnect the silicone sleeve and lead at the electrode see diagram 12 1 White to sensing electrode Important Note If replacing one of the ignition leads it will be necessary to disconnect both from their electrodes and untwist them from one another and the earth lead Make sure when replacing the two ignition leads that they are tightly twisted together again and the earth lead is twisted round the pair see diagrams 10 2 and 12 1 Disconnect leads from the two retaining clips at the side of case Remove the two screws securing the controls facia see diagram 9 1 Hinge the control fascia open Hemove the control board cover see diagram 10 2 Remove the lead on the control board and withdraw from grommet see diagram 14 8 221742D 32 14 6 Boiler Overheat Cutoff Before starting refer to Section 11 Disconnect the electrical connections unclip to remove the overheat cutoff see diag
34. essure then increasing up to the required setting Close the hot water draw off If the maximum pressure cannot be obtained check thatthe gas supply of adequate size refer to Section 1 7 10 5 Gas Rate Modulation The burner pressures are factory preset and no adjustment should be required When checked if they are not consistant with the information in table 1 the following steps should be taken Fully open a domestic hot watertap ensure there is no modulation Turn the domestic burner pressure potentiometer to minimum by turnining anticlockwise with the tool supplied do not force it see diagram 10 2 Carefully turn the minimum stop screw on the gas control valve When the correct setting is achieved adjust the potentiometer on the control board PCB until the maximum is achieved If it is not possible to abtain the maximum required turn the potentiometer fully clockwise do not force it Removing the cover screw onthe main gas control valve and turn the adjustment screw until a pressure of 1mbar above the maximum stated in table 1 is achieved Refit the cover and adjust the potentiometer to give the stated maximum setting by turning below the setting then slowly increasing upwards 10 6 Domestic Water Flow Rate This is factory preset and can not be adjusted 10 7 Burner Pressure Heating The burner pressure is factory preset and no adjustment should be required Check that all remote heating system controls room
35. estic cold water inlet to be connected from below or through an internal wall at the rear of the boiler see diagram 1 1 and 6 1 for position Refer also to Section 5 Domestic Hot Water System Provision is made for the water connections to be connected from below or from above passing down either side of the boiler Take care that any pipework connected from above will clear the expansion vessel Refer to the wall template If connecting from above a vertical piping kit 457160 is available and is recommended NOTE Top rear flue outlet is not possible with a vertical piping kit If necessary temporarily fit the boiler Flush out the domestic water and heating system before connecting the boiler Make the connections to the domestic hot water outlet and the heating system by means of the isolating valves see diagram 6 1 While making the connections Do not subject any of the isolating valves to heat as you may damage the seals Make sure that the drain and operating screw heads on the isolating valves are accessible SAFETY DISCHARGE PIPE ROUTING POSITION i PAA H EOK O bet ay sf pA HOT GAS COLD HEATING WATER WATER SERVICE FLOW OUT COCK SUPPLY IN RETURN SLOT OPEN GAS SERVICE COCK LEVERS OPEN HEATING FLOW RETURN LEVERS OPEN COLD WATER SUPPLY IN OUT Diagram 6 1 6 4 Safety Valve Discharge WARNING It must not discharge above an entrance or window or any type of public access are
36. fascia see diagram 9 1 Hinge the assembly open Remove the securing screws to release the plate to plate heat exchanger see diagram 14 21 Remove the diverter switch refer to Section1 4 22 Push it out tilt and remove see diagram 14 21 When re fitting it will only fit one way HYDRO BLOCK SECURING ASSEMBLY PIN 6 DOMESTIC HOT WATER MICRO SWITCH SECURING PIN 4 and 5 FILTER Diagram 14 18 221742D 14 Replacement of Parts 14 24 Expansion Vessel Before starting refer to Section 11 Renewal of the expansion vessel requires the boiler to be removed from the wall As an alternative a separate expansion vessel of the same specification may be connected as close as possible to the boiler leaving the original in position refer to the Installation Instructions Disconnect the boiler water connection union nuts at the front of the isolating valves see 6 1 Disconnect the gas service cock union Disconnect the safety valve discharge pipe from the boiler Disconnect the mains supply cable at the connector block on the back of the controls fascia Remove the two screws at the service cock bracket Pull the boiler from the isolating valves Unhook the boiler at the top easing the boiler from the flue outlet and lift off Carefully lay the boiler down on its side for access to the expansion vessel Disconnect the union nut connection see diagram 14 22 and discard the sealing washer for the ne
37. fitted Before starting refer to Section 1 General Data Isolate the boiler from the electrical supply Remove outer case front as section 11 4 Remove the two screws securing the controls cover door and controls facia see diagram 9 1 Hinge the assembly forward Remove the clock timer cover see diagram 10 2 Disconnect the clock timer wiring harness plug remove the clock timer and electrical connections see diagram 14 28 41 ELECTRICAL CONNECTION 4 SECURING SCREW 4 BLUE BROWN ORANGE PURPLE an L eS e VLD L N E Alz O IN O Diagram 14 28 221742D 14 Replacement of Parts D AIR PRESSURE SWITCH WHITE GREY BLUE ORANGE BLACK RED BROWN YELLOW GREEN PURPLE YELLOW REGE THERMISTOR T2 CENTRAL Ta HEATING MERE II BOYER sow gr E MICRO SWITCH E bk y PRESSURE DIFFERENTIAL MICRO SWITCH 230V 50Hz PERMANENT MAINS SUPPLY FUSED AT 3A WATER ELECTRODE CLOCK TIMER ETE ROOM STAT y NOTE 2 2 Plug C W link to be removed when clock timer is used The removed plug to be left inside the clock timer cover Diagram 14 29 NOTE 1 Red link to be removed when external room stat is used 221742D 42 MAINS SWITCH 7671a PRESSURE SWITCH g y IGNITION g y ELECTRODE sail ue ju en i CHASSIS EARTH SENSING 15 Spare Parts
38. fitted in a cupboard or compartment permanent ventillation is not required Any existing compartment air vents must not be removed or blocked off 2 3 Clearances The boiler should be positioned so that at least the minimum operational and servicing clearances are provided see diagram 2 1 Additional clearances may be required around the boiler for installation 2 4 Timber Frame Buildings If the boiler is to be installed in a timber frame building it should be fitted in accordance with the Institute of Gas Engineers document IGE UP 7 1998 Ifin doubt seek advice from the local gas undertaking or Hepworth Heating Ltd 25 ABOVE THE TOP OF THE BOILER CASE OR THE FLUE ELBOW IF FITTED f 450 B 150 To achieve minimum Installation clearance of 5mm The side panels will have to be fitted prior to boiler mounting DIMENSIONS IN MILLIMETRES Diagram 2 1 221742D 3 Flue and Ventilation 3 1 General The flue must be installed in accordance with the rules in force in the countries of destination 3 2 Terminal Position The minimum acceptable siting dimensions for the terminal from obstructions 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 port or similar extensions of a roof only or roof and one wall require special consideration with respect to any open
39. flue inside and 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 7 3 for position of self adhesive seal 7 6 Flue Positioning 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 COLLAR Diagram 7 2 WITH WALL LINER KIT ONLY WALL THICKNESS UP TO 300mm FOAM SEAL d En e t 15 4 FOAM SEAL aa WALL THICKNESS DWN OVER 300mm Diagram 7 3 221742D 8 Mounting the boiler 8 1 Boiler Mounting COMBUSTION Remove the inner case front secured by two clamps at the CHAMBER PANEL bottom lift up and unhook from the threaded lugs at the top see RETAINING diagram 8 1 LUG 4 Remove the combustion chamber panel transit screws see diagram 8 2 It will not be necessary to refit these Slide the combustion chamber panel upwards to disengage from the retaining lugs pull forward to remove see diagram 8 2 Remove the fan electrical connections by pulling the plastic boots not the wires Remove the tubes from fan noting the colour tubes positions see diagram 8 3 Remove the fan and flue collector assembly by pulling it forward see diagram 8 3 Re
40. g procedures see diagram 13 2 13 3 and for clock timer fault finding diagram 13 4 and 13 5 On completion of a fault finding task that has required the disconnection and making of electrical connections then checks for earth continuity polarity and resistance to earth must be carried out TO TEST FOR COMPONENT OPERATION FAILURE Power to the appliance Test for 230V across live brown and earth yellow and green 230V across live and neutral blue and zero potential across neutral and earth Thermistors With the power off unplug the connector and test resistance is 10k ohms at 25 C Differential pressure switch With the power off seperate the in line connector and test for continuity across male end restore the power and with demand off open circuit demand on closed circuit Domestic Hot Water demand switch With the power off seperate in line connector and test for continuity across male end Tap open continuity between black and white cables black and red are open circuit With demand off there is continuity between black and red and that black and white are open circuit Overheat thermostat With the power off unplug the connectors and test for continuity zero resistance Power to the gas control valve With a demand on test for voltages of 24 to 50V across the black and white cable connectors and 130V across the red and blue cable connectors Power to the fan With a demand on and the front cover r
41. h an external isolator which must also isolate any heating system controls see diagram 9 2 Any heating system controls must not interrupt the permanent mains supply to the boiler Using PVC cable of a suitable length and rating as stated in Section 1 8 Electrical Supply route the mains supply cable and connect to the appropriate terminals of the connector block restrain with the cable clamp supplied see diagram 9 2 Standard colours are Brown Live Blue Neutral Green and Yellow Earth Make the earth cable of a greater length so that if the cable is strained the earth would be the last to become disconnected CAUTION It is ESSENTIAL to make sure that the polarity is correct 9 2 Heating System Controls All external controls and wiring are required to provide a minimum of reinforced insulation at 250Vrms between the parts of those devices operating at mains hazardous voltage and the user accessible parts af those devices Note For further information see The Building Regulations 1991 Conservation of fuel and power 1995 edition Appendix G table 4b If electrical controls are not to be used to regulate the heating system do not remove the red link cable When any form of external electrical control is being used to regulate the heating system remove the red link cable and connect heating system controls in series The mains cable outer insulation must not be cut back external to the plug 9 3 Clock
42. ings doors vents or windows under the roof Care is required to protect the roof if made of plastic sheeting If the car port comprises of a roof and two or more walls seek advice from the local gas undertaking before installing the boiler If the terminal is fitted within 600mm below plastic guttering 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 3 Flue Options There are various flue systems to choose from as follows Standard Top Outlet Flue Pack Pt No 230483 Standard Rear Outlet Flue Pack Pt No 230482 Extended Top Outlet Flue Pack Pt No 230487 1 Metre Extension Kit Pt No 230484 Optional Wall Liner Kit No 900862 A Flue Bend Kit or Vertical Flue Kit can be supplied see Hepworth Heating Flue Options Guide for configurations available 45 Flue Bend Pack Pt No 230485 90 Flue Bend Pack Pt No 230486 In Line Flue Adapter Kit Pt No 230488 Vertical Flue Kit No 458115 3 4 Internal Access Flue All flue assemblies are designed for internal installation given that there is sufficient clearances opposite to the flue for the installation of the flue If there is insufficient clearance the flue can be installed from outside For a wall thickness up to 300mm provided that there is
43. inner case front see diagram 1 2 1 6 Data See table 1 and diagrams 1 1 1 2 amp 1 3 The Seasonal Efficiency Domestic Boilers UK SEDBUK is 77 1 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 l e e eim a u o w 5 142 18 65 Optional flue kits are available Horizontal top outlet and Vertical 22mm COMPRESSION CENTRAL HEATING CQ g15mm COMPRESSION DOMESTIC WATER 15mm COMPRESSION GAS CONNECTION Diagram 1 1 P N 135 110 138 85 103 TABLE 1 Lift Weight 31 7kg 69 89b Total Weight 41 1kg 90 611b Gas connection 15mm compression Heating and return 22mm compression Domestic hot water 15mm compression Safety valve Preset 3bar 43 5lbf in Safety valve discharge 15mm copper Water content 1 42 litres 0 31 gallon E Expansion vessel capacity 6 litres 1 32 gallons 0 7bar 10 1 lbf in Heating cold fill pressure minimum D H W working pressure 0 8 to 10bar 60 litres E Maximum Heating 13 2 gallons system water content usin with a cold fitted expansion fill pressure vessel of 0 7bar 230V 50Hz 150W fused 3A 1 Type T2A Electrical supply Electrical rating Internal Fuse rating Boiler starts at an inlet pressure of O 5bar but requires 0 8bar for maximum output M For larger systems use an additional expansion ve
44. ld be taken when handling and cleaning with particular regard to edges The boiler casing can be cleaned using a mild liquid detergent with a damp cloth then a dry cloth to polish Do not use any form of abrasive or solvent cleaner as you may damage the paint work Boiler Casing CAUTION Do not remove or adjust the casing in any way as incorrect fitting may result in incorrect operation or failure to operate at all If in doubt seek advice from the local gas company or your installation servicing company Replacement Parts If replacement parts are required apply to your local supplier or British Gas Please quote the name of the appliance 1 General Data NNNNNNNNNS A Bic 1 1 Installation Materials and equipment should be fit for their purpose and of suitable quality and workmanship 1 2 Important Notice This boiler is for use only on natural gas G20 1 3 Sheet Metal Parts WARNING When installing or servicing this boiler care should be taken when handling the edges of sheet metal parts to avoid any possibility of personal injury 1 4 Requirements The installation of this boiler must be carried out by a competent person in accordance with the current rules in force in the countries of destination at the time of installtion Manufacturer s instructions supplied Manufacturer s instructions must not be taken as overriding statutory requirements 1 5 Data Label The data label is on the
45. lectrical Preliminary electrical system checks as outlined ina Multimeter Instruction book are the first checks to be carried out during a fault finding procedure Isolate the boiler from the electrical supply refer to Section 11 3 Gain access to the boiler controls by removing the outer case Before replacing any part please read points below Heplacement of parts must only be carried out by a competent person 1 Refer to Section 11 1 2 Always isolate the boiler from the electrical supply and as required the gas supply as Section 11 3 3 On completion make good any water loss and pressurise the front refer to diagram 10 5 system to initial design pressure refer to Commissioning in Remove the two screws securing the controls facia see diagram the Installation Instructions 9 1 Hinge the control facia forward Before starting refer to Section 11 1 Isolate the boiler from the electrical supply refer to Section Remove the controls board cover by slackening the cable entry 11 3 cover screws see diagram 10 2 Remove the covers Ease the cover up and clear Check that all cables multipin connectors and connectors are secure on the board Testthefuse onthe main control board and renew as necessary Fuse 1 type 2AT If a fuse fails repeatedly or the initial fault finding checks described in Section 13 1 indicate a boiler fault check the boiler electrical circuits and follow the fault findin
46. move the rear outlet restrictor plate and retain if using the fi NS rear flue outlet see diagram 8 4 REAR FLUE ONLY Fitthe flue spigot supplied seperately see TRANSIT diagram 8 5 SCREW 2 TOP FLUE ONLY Remove the blanking plate from the top of the boiler and use to blank the hole where the rear restrictor plate discard was fitted Note Should the side clearances be less than 30mm It will be necessary to fit the side panels before mounting the boiler Refer to Section 10 10 for fitting Remove the protective caps from the boiler water pipes Fit the sealing washers supplied in the fittings pack to the boiler water pipes by inserting them into the tubing nuts the nipples on the washers will hold them in position see diagram 8 8 ELECTRICAL Lift the boiler into position on the top mounting brackets use CONE hand holes provided see diagram 8 6 SECURING RETAINING LIP CLAMP 2 AT REAR gt lt INNER CASE FRONT f N S P OP ATE c umm THREADED LUG 2 Diagram 8 1 Diagram 8 3 221742D 16 8 Mounting the boiler 8 2 Water and Gas Connections Locate the boiler water pipes and gas supply pipe making sure the washers are retained in the tubing nuts onto the isolation valves fully push the boiler back see diagram 8 8 Ensure the bottom boiler bracket is sitting on top of the service cock bracket see diagram 8 6 Secure all the tubing nuts finger tight pl
47. mp 1 METRE EXTENSION KIT FLUE LENGTH 2 x 1 metre extension kits may be joined together 510mm MAX 15mm SCREW tomi L LL EE 1 Po FW SCREW n SCREW amp TAPE amp TAPE Y plus 95mm FLUE LENGTH Y plus 95mm FLUE LENGTH MAXIMUM DISTANCE FROM NOTE MINIMUM MINIMUM See Fe T IF IT IS NECESSARY TO CUT THE DUCTS BOILER MOUNTING FACE BOILERCASINGTO TO ACHIEVE THE FLUE LENGTH MAKE SURE THICKNESS c SU CENGTE THAT THE OVERLAPS ARE AS FOLLOWS THE OVERLAP FOR AIR DUCT 25mm TOP STD THE OVERLAP FOR FLUE DUCT 50mm REAR SIDE R H THE MAXIMUM LENGTHS CAN BE INCREASED SIDE L H BY AN ADDITIONAL 2 METRES WITH THE USE OF THE 1 METRE EXTENSION KITS NOTE THIS APPLIES TO STANDARD KITS ONLY 7639 TOP EXTD 144 REAR A SIDE R H SIDE L H REAR STD REAR Diagram 7 1 221742D 14 7 Flue Preparation 7 1 Flue Position and Length Determine flue application length and terminal position before starting refer to diagram 7 1 Note The Standard Top Outlet Flue Pack and the Extended Top Outlet Flue Pack contains a flue duct extension piece complete with O rings this should be discarded If you are using a Flue Bend or a Vertical Flue Kit please follow the instructions supplied with the kit To make a neat finish to the flue outlet a flue collar kit part No 443286 with instructions is available see diagram 7 2 Note If required an optional wall liner kit part n
48. mpact combination boiler is able to provide room heating as part of a central heating system and domestic hot water direct from the cold water supply without the need for secondary storage The boiler can be fitted with one of two makes of clock which look like this Clock Timers IAUTOO GRUN MT W Th F S Su DAY HR MIN gt OR Digital timer Electro mechanical clock timer IMPORTANT NOTICE This boiler is for use only on G20 gas Gas Leak or Fault If a gas leak or fault exists oris suspected turn the boiler off and consult your local gas company or your local installation servicing company Mains Water Temperature NOTE The mains incoming water temperature in the winter is lower than in summer To achieve the same outlet water temperature in the winter it will be necessary to reduce the water flow rate using the hot water tap Boilers Installed in Compartments If the boiler has been fitted into a compartment or cupboard do not obstruct the compartment air supply vents Do not use the compartment for storage Electrical Supply WARNING The boiler must be earthed The boiler must be connected to a 230V 50Hz permanent supply Connection of the whole electrical system of the boiler and any heating system controls to the electrical supply mustbe through one common isolator Isolation should preferably be by a double pole switched fused spur box The fused spur box should be readily acce
49. mpany 6 Check that the electrical supply to the boiler is ON at the external isolator 7 Check lockout light refer to boiler safety cutoff reset button 8 Set the switch B to 1 situated on the control fascia 9 Set the summer winter button J light L or K will illuminate 10 Set C clock timer if fitted and any remote controls as required 11 Check the lights D and E are illuminated on the control fascia Close the controls cover door In certain circumstances a surge in water pressure may cause the appliance to operate momentarily this will be indicated by the pump starting and the fan speed increasing This is quite normal Domestic Hot Water Temperature The sanitary water temperature control knob M see diagram 4 will control the desired temperature of the water until the flow exceeds the capability of the boiler to give the required temperature rise Thenthe temperature is determined by controlling the hot water flow from the tap ie reduce flow increase temperature increase flow reduce temperature NOTE The mains incoming water temperature in the winter is lower than in the summer SAFETY VALVE DISCHARGE PIPE POSITION Dae N NC Ir 9 Wu JD WOW Ci g on pa sor oas coo BEATING WATER SERVICE WATER OUT COCK SUPPLY IN HEATING FLOW LEVER OPEN HEATING FLOW RETURN LEVER OPEN SLOT OPEN COLD WATER GAS SERVI
50. nd drain the central heating circuit SECURING of the boiler refer to Section 11 3 and 11 6 SCREW 4 SPINDLE Disconnect the union nut and clip to release the safety valve Diagram 14 10 see diagram 14 5 221742D 34 14 Replacement of Parts 14 13 Diverter Switch Before starting refer to Section 11 Isolate the boiler from the electrical supply Remove outer case front as section 11 4 Remove the two screws securing the controls cover door and controls fascia see diagram 9 1 Hinge the assembly open Remove the electrical plug the retaining clip ease the switch from the diverter valve see diagram 14 12 14 14 Diverter Valve Before starting refer to Section 11 Remove the diverter switch as section 14 13 Remove the diverter valve securing pin ease the diverter valve from its housing see diagram 14 13 14 15 Thermistor Domestic Hot Water Before starting refer to Section 11 Drain domestic hot water Remove outer case front as section 11 4 Remove the two screws securing the controls cover door and controls fascia see diagram 9 1 Hinge the assembly open Remove the electrical connection securing pin ease the thermistor from its housing see diagram 14 14 14 16 Thermistor Central Heating Before starting refer to Section 11 Remove outer case front as section 11 4 Remove the two screws securing the controls cover door and controls facia see diagram 9 1 Hinge the assembly forwar
51. o 900862 is available complete with instructions 7 2 Flue Assembly Extend the telescopic flue to the required length making sure thatthe minimum overlap is no less than 25mm and thatthe flue terminal projects 15mm minmum beyond wall face see diagram 7 1 Carefully drill though air duct pilot hole and secure with self tapping screw provided in fittings pack see diagram 7 1 Seal the joint with the tape provided If the flue system requires the addition of flue extension kits drill seal and secure them with the self tapping screw and tape provided Note Should any one of the flue sections require cutting to obtain desired flue system length cut at the end opposite the expanded end If the boiler is not to be fitted for some time cover the hole in the wall 7 3 Internal Access Flue If access to the outside wall is not practical the flue system can be installed from inside Use of the optional wall liner kit is required 7 4 Rear Outlet Flue Fixing Fit the self adhesive foam seal provided in the flue pack around the air duct at the position shown in diagram 7 1 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 7 3 for position of self adhesive seal 7 5 Top Outlet Side or Rear Flue Fixing Make good the area around the
52. ock slot in line with the length of the cock Loosen the burner pressure test point screw and connect a suitable pressure gauge see diagram 10 1 10 4 Burner Pressure Hot Water Connect the electrical supply the pump will operate for about 30 seconds then the pump will stop Fully open the largest hot water draw off tap whereby the main burner will light the flames gradually increasing to the maximum Check the soundness of the boiler gas joints with the main burner on using a leak detection fluid Take care not to splash any of the electrical components To achieve this flow rate a water pressure of at least O 8bar is required during commissioning although subsequently the appliance will work at a minimum pressure of O 5bar This flow rate should prevent any modulation of the gas pressure 221742D 22 The burner pressure is factory preset and no adjustment should be required Check the burner pressure is within 0 2mbar of 15 01mbar If this is incorrect the burner pressure may be adjusted to the correct setting by turning the hot water gas pressure adjuster potentiometer located on the control board To gain access remove the two screws securing the controls facia see diagram 9 1 Hinge the control facia forward Remove the plastic plugs Using the burner adjusting tool supplied clockwise to increase see diagram 10 2 Turn the adjuster slowly always making adjustment by reducing below the required pr
53. ommon and heating on Replace ias EXTERNAL Clock timer in order if no central heating CONTROLS refer to main fault finding G YELLOW YELLOW 2 ORANGE PURPLE ELECTRO MECHANICAL CLOCK TIMER FAULT FINDING PLUG FROM CLOCK TIMER Diagram 13 5 31 221742D 14 Replacement of Parts 14 1 Fan Before starting refer to Section 11 Disconnect the two electrical connectors at the fan by pulling the boots not the wires see diagram 14 1 Remove the two flexible tubes from the fan see diagram 14 1 Note When replacing the tubes from the air pressure switch ensure the lower red tube from the fan connects to the upper connection of the switch Remove the fan secured with a screw at the front ease the fan outlet from the flue duct and retaining lip atthe rear see diagram 14 1 Note To fit the fan locate it into the flue duct and rear retaining lip push fully up to ensure a good seal then secure the fan with the screw see diagram 14 1 The polarity of the two electrical connectors is not important 14 2 Main Burner Before starting refer to Section 11 Remove as described in Servicing Section 12 Remove the spark electrode assemblies from the burner secured by three screws see diagram 12 1 Fit spark electrode assemblies to new burner Taking care fit new burner 14 3 Main Injector Before starting refer to Section 11 Remove as described in Servicing Section 12 Unscrew the main injector Wh
54. ontrolling the boiler Thermostatic radiator valves may be installed however they must not be fitted in a room where the room thermostat is located Note All systems must have at least one radiator not fitted with a thermostatic valve Note For further information see The Building Regulations 1991 Conservation of fuel and power 1995 edition Appendix G table 4b uw HEPWORTHHEATINGLTD Glow worm BELPER DERBYSDE561JT COMPACT 80E 457101 930V 50Hz 150W Fused at 3A For use on 544 G20 20 mbar This boiler is intended exclusively to be installed on a gas supply C 0086 GB IE with a governed meter 86 AU 587 SPECIFIC WATER RATE 11 22 l min DOMESTIC CIRCUIT PMW 10 bar HEATINGCIRCUITPMS 2 5bar HOT BURNER PRESSURE mbar 15 01 15 01 HEAT INPUTNETTQ kW 25 92 25 92 10 85 HEAT OUTPUT P kW 23 45 23 45 8 79 SERIALNo INJECTOR 4 2mm 205769 The appliance flue type is a C and C This refers to a concentric flue where the fan is downstream of the heat exchanger The C is a horizontal flue termination and the C is a vertical flue termination Diagram 1 2 EXPANSION VESSEL OVERHEAT an CUT OFF i LOW WATER PRESSURE SWITCH PRESSURE DIFFERENTIAL MICRO SWITCH GAS VALVE CJ E TEMP SENSOR MOTORISED 3 WAY VALVE
55. ordance with the rules in force in the countries of destination To obtain service please call your installer or Heatcall Glow worm s own service organisation using the telephone number behind the controls cover door 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 Clearances The boiler requires a clearance in front below and at the sides ofthe casing for safety servicing and maintenance access see diagram 2 1 Protection Against Freezing The boiler has a 2 stage built in frost protection Provided power and gas are available and there is adequate pressure in the system ifthe watertemperature within the appliance falls below 10 C approx the pump only will come on If the water temp continues to fall to 6 C approx the main burner will fire at min rate until the water in the appliance is greater than 15 C approx This is a separate function to any remote frost protection fitted 221742D Instructions for Use CONTROLS FASCIA PRESSURE GAUGE A RAVE O CO SANITARY WATER SUMMER WINTER TEMPERATURE BUTTON J CONTROL KNOB M p CLOCK TIMER CENTRA
56. pieces Remove the securing clips on the inlet and outlet pipes Remove the combustion chamber main panel securing screws Remove the heat exchanger combustion chamber assembly WA Remove heat exchanger front retaining clips GK o NS A SA Remove the heat exchanger from its retaining tabs positioned at the rear by easing it forward and up Replace heat exchanger making sure that it is correctly PUMP engaged on the retaining lugs at the back of the combustion chamber carefully refit the pipe securing clips and front retaining clips HEAT EXCHANGER SS BAFFLE M SIDE PES ip INSULATION 2 S PAPAE E j in em B W N CHAMBER MAIN PANEL d e SECURING SCREW 4 P j Y BEADING PIPE SECURING 7 CLIP 2 O RING Diagram 14 24 39 221742D 14 Replacement of Parts COMBUSTION CHAMBER REAR INSULATION FRONT PANEL NA 2 INSULATION 14 27 Combustion Chamber Insulation Remove outer case front as section 11 4 Remove the inner case front as Section 11 5 Unhook the combustion chamber front see diagram 8 2 Remove the burner see section 14 2 Remove the front insulation piece see diagram 14 25 Slide out both side insulation pieces Pull the lower rear insulation forwards then slide the upper rear insulation down from behind the heat exchanger 14 28 Viewing Window Before starting refer to Section 11 Remove the old self adhesive aluminium foil gasket
57. r and system to cool down waiting at least a minimum of four minutes before pressing Summer Winter Button J to set to Winter K If this is satisfactory proceed with the detailed fault finding as Section 13 3 221742D 13 Fault Finding 13 2 Clock Timer PERMANENT TERMINAL ON OFF oO If the clock has failed it can be bypassed by disconnecting the MAINSS DUESOHZ BLOCK SWITCH ne plug and reconnecting the link see diagram 13 1 Gain access by removing the two screws securing the controls facia see diagram 9 1 TK Hinge the control facia forward ELECT EUDES PUMP re Remove the clock timer cover see diagram 10 2 uM O AIR Disconnect the clock wiring harness plug and connect the link PRESSURE SWITCH This is a temporary measure and the clock should be repaired M or replaced as soon as possible grey FAN brown oxo blue O OVERHEAT E CUTOFF x yellow a back F white T PRESSURE DIFFERENTIAL Z brown Q WATER 0 DIVERTER VALVE yellow CLOCK TIMER PLUG blue N ia MAINS FUNCTIONAL FLOW orange orange o X CH THERMISTOR sui purple e DHW THERMISTOR me white O DHW E FLOW black O CLOCK TIMER SWITCH es F black Z WATER e e PRESSURE SWITCH e grey EXTERNAL i L AX CLOCK TIMER CONTROLS EE E orange CLOCK TIMER PLUG LOW VOLTAGE FUNCTIONAL FLOW Diagram 13 1 Diagram 13 2 221742D 28 13 Fault Finding 13 3 E
58. ram 14 4 14 7 Pressure Gauge Before starting refer to Section 11 Hemove case base see diagram 10 3 Open the controls cover door Remove the two screws securing the controls facia see diagram 9 1 Hinge the control fascia open Release the water pressure and drain the central heating circuit of the boiler refer to Section 11 3 and 11 6 Disconnect the pressure gauge connection from the safety valve discard the washer see diagram 14 5 CLEAR AIR PRESSURE decus A LL ELECTRICAL CONNECTION 27 RETAINING LIP SECURING SCREW Diagram 14 1 COPPER SEALING WASHER INJECTOR MANIFOLD Diagram 14 2 14 Replacement of Parts Remove the pressure gauge see diagram 14 6 Locate the supplied washer under the pressure gauge connection when refitted to the safety valve 14 8 Control Board Before starting refer to Section 11 Remove the two screws securing the controls facia see diagram 9 1 Hinge the control fascia open Remove the cable entry covers see diagram 10 2 Disconnect the multi pin connectors retained by clips see diagram 14 7 Remove the controls board cover see diagram 10 2 Disconnect the remaining multi pin connector retained by a clip Remove the control board securing screw and the control board from the support posts see diagram 14 8 THE MAIN CONTROL BOARD MUST BE KEPT IN THE ANTI STATIC HOLDER UNTIL IMMEDIATE REQUIREMENT When replacing the main cont
59. rds the boiler Remove the fan from the flue collector secured with a screw and retaining lip Fit the flue connecting sleeve onto the fan see diagram 8 12 Fit the fan to the flue ducting Holding it up in position fit the flue collector see diagram 8 13 Secure the fan to the flue collector with the securing screw and retaining lip see diagram 8 14 Fit the electrical connections and air pressure tubes to the fan Refit the combustion chamber panel Make the outer wall weatherproof A Flue Collar Kit Part No 443286 is available CONNECTING SLEEVE Diagram 8 12 FLUE RETAINING DUCTING LIP FLUE CONNECTING EF gt SLEEVE lag FAN Push up P 1 to fit SS SPIGOT CUTOUT 2 FLUE Diagram 8 10 COLLECTOR Diagram 8 13 FLUE FLUE FLUE CONNECTING SUCTING DUCTING CLEAR ELECTRICAL SLEEVE CONNECTIONS PRESSURE FAN RETAINING CONNECTING SECURING LIP Diagram 8 11 SLEEVE SCREW Diagram 8 14 19 221742D 9 Electrical Connections 9 1 Supply Cable Connection CAUTION To prevent an induced current from switching the central heating on when not required it is important that the heating system control cables are separated from the other mains supply cables Open the controls cover door Remove the two screws securing the controls facia see diagram 9 1 Hinge the control fascia open The boiler requires a permanant mains supply throug
60. rol board check and if necessary adjust the main burner gas pressure in both the hot water and central heating modes Refer to Commissioning in the Installation Instructions 14 9 Gas Control Valve Before starting refer to Section 11 Remove the two screws securing the controls cover door and controls fascia see diagram 9 1 Hinge the assembly open Disconnect multi pin connector Support the gas control valve remove the eight socket head capscrews at the sides of the gas control valve see diagram 14 9 Separate the valve from the pipes noting the fitted position Discard the O rings and fit the new ones supplied Check and adjust the main burner gas pressure in the hot water and central heating modes refer to Commissioning in the Installation Instructions 14 10 Pump Before starting refer to Section 11 Remove the two screws securing the controls facia see diagram 9 1 Hinge the assembly open Release the water pressure and drain the central heating circuit of the boiler refer to Section 11 3 and 11 6 Remove the electrical plug at the pump see diagram 14 10 Remove the four cap head screws see diagram 14 10 Make sure that the pump is fitted in the correct orientation The pump adjuster on the new pump should be set to that of the original refer also to Section 4 4 The flow rate should be controlled by means of a valve in the heating flow refer to Section 4 6 THERMISTOR GAS CONTROL
61. ssel see Section 4 Approximate gas rate at max input 2 47m3 h 87 17ft9 h 221742D 1 General Data 1 7 Gas Supply The gas installation shall be in accordance with the rules in force in the countries of destination 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 With all other appliances operating 1 8 Electrical Supply WARNING This boiler must be earthed All system components shall be of an approved type The electrical installation shall be in accordance with the current rules in force in the countries of destination at the time of installation Connection of the whole electrical system of the boiler and any heating system controls to the electrical supply mustbe through one common isolator Isolation should be by a double pole switched fused spur box having a minimum contact separation of 3mm in each pole The fused spur box should be readily accessible and preferably adjacent to the appliance It should be identified as to its use Alternatively a fused 3A 3pin plug and unswitched socket may be used provided they are not used in a room containing a bath or shower The mains supply cable and other cables connected to the boiler must be the PVC flexible type of at least 0 75mmv 24 0 20mm FANNED FLUE 1 9 Heating System Controls The heating system should have installed a timer and room thermostat c
62. ssible and preferably adjacent to the appliance It should be identified as to its use Alternatively a fused 3A 3 pin plug and shuttered unswitched Socket may be used Thecolours ofthree core flexible cable are blue neutral brown live green and yellow earth As the markings on your plug may not correspond with these colours continue as follows The wire coloured blue must be connected to the terminal marked N or Black The wire coloured brown must be connected to the terminal marked L or Red The wire coloured green and yellow must be connected to the terminal marked E or Green or the earth symbol L PVC flexible cable having a conductor size of 0 75mm 24 0 20mm must be used within the boiler casing to connect to the boiler Electrical Supply Failure The boiler will not work without an electrical supply Normal operation ofthe boiler should resume when the electrical supply is restored Note The boiler safety cutoff may have operated please refer to the following section to reset Heset any external controls to resume normal operation of the central heating The digital timer has a lithium battery back up and will not need resetting Unless it is without power for a considerable period Boiler Safety Cutoff Reset Button The boiler is fitted with a safety cutoff device to prevent damage through overheating Should the main burner go out during a demand the red lockout ligh
63. sufficient space and the optional wall liner kit is used the flue can be 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 3 5 Terminal Guard A terminal guard is required if persons could come into contact with the terminal or the terminal could be subject to damage If a terminal guard is required it must be positioned to provide a minimum of 50mm clearance from any part of the terminal and be central over the terminal The guard should be similar to that shown in diagram 3 1 221742D 10 3 6 Room Ventilation Ventilation must be provided in accordance with the rules in force in the countries of destination The boiler is room sealed so where the boiler is fitted in a room or space a permanent air vent is not required 3 7 Cupboard Compartment Ventilation If the boiler is to be fitted in a cupboard or compartment Refer to Section 2 2 MINIMUM SPACING MINIMUM SITING DIMENSIONS FOR FANNED FLUE TERMINALS POSITION A DIRECTLY BELOW AN OPENABLE WINDOW AIR VENT OR ANY OTHER VENTILATION OPENING BELOW GUTTER DRAIN SOIL PIPE BELOW EAVES BELOW A BALCONY OR CAR PORT FROM VERTICAL DRAIN PIPES AND SOIL PIPES FROM INTERNAL OR EXTERNAL CORNERS ABOVE ADJACENT GROUND OR BALCONY LEVEL FROM SURFACE FACING THE TERMINAL FACING TERMIN
64. t F will illuminate on the control fascia situated above the Reset Button G see diagram 4 The red light will not illuminate if there is no system demand Allow the boiler and system to cool down waiting at least a minimum of four minutes before pressing the Reset button G The boiler will take a few seconds to reset after the button is pressed If the problem persists turn the boiler off and consult your installation servicing company The Gas Safety Installation amp Use Regulations In your interests and that of safety it is the law that ALL gas appliances are installed by competent persons in accordance with the current issue of the above regulations 221742D Instructions for Use Setting Instructions for Electro mechanical Clock if fitted This clock has a twenty four hour dial that is 1pm is 13 To set the time turn the whole face clockwise until the pointer is against the time of day To set any Off time push the tappets outwards To set any On time push the tappets inwards Time can be set either On or Off in fifteen minute segments Note The clock supplied could be fitted with an override device see diagram 1 which switches the clock programme On or Off permanently The switch will need to be repositioned to resume programmed working OVERRIDE CLOCK FACE of POINTER 0 CONSTANT OFF PROGRAMMED I CONSTANT ON Diagram 1 Setting Instructions
65. t of connection that is the height of the top point of the system above the expansion vessel 4 6 Flow Rate A valve must be incorporated in the main flow or return of the system valve A shown in the flow diagram 4 2 This valve must be lockable and positioned so that inadvertent closure or unauthorisedinterference is not possible The design differential can be between 11 C 20 F and 17 C 30 F dependent upon the system resistance and the available pump head Diagram 4 1 4 7 Bypass The bypass is an integral part of the boiler 4 8 Filling Sealed Systems An optional extra filling loop is available Part No 457120 Provision for filling the system at a low level must be made Three methods of filling are shown in diagram 4 3 There must be no permanent connection to the mains water supply even through a non return valve NOTE Itis important that fittings used for connection to potable water comply with the water undertakers requirements 4 9 Corrosion Inhibitor If an inhibitor is to be used in the system contact the inhibitor manufacturer so that they can recommend their most suitable product When fitting the boiler into an existing system special care should be taken to drain the entire system including radiators then thoroughly cleaning out before fitting the boiler whether or not adding an inhibitor 4 10 Draining A draining tap must be provided at the lowest points of the system which will allow
66. ters are clean and allow adequate water flow YES NO Is mains L E D illuminated Check fuses and power supply YES Open a tap to create demand YES If lockout L E D is illuminated press reset NO YES A NO Demand L E D illuminated Check flow switch operation YES B NO Pump starts Check 230V supply to pump Check the pump is not mechanically stuck YES C NO Check 230V Check air pressure Check thermistor Unplug fan and check an starts supply to fan switch operation coil resistance YES 2 n Check primary circui Check ai itch stat Start spark Check spark electrodes eck primary circuit eck air pressure switch status and cables overheat continuity and operation YES E NO sie ee ee ke at ew oe control a control Check vent nend g valve cables valve voltage connecting tubes YES F Burner pressure increases NO Check sensing electrode Check burner for YES G Turn control thermostat or flow jn Is heating circuit Check 3 way rate down to induce modulation getting hot valve operation YES Domestic hot water operates Manually push brass splindle in diverter valve Does domestic hot water get hot Unclip motor Turn domestic hot water YES when pushed in and central heating Off and On Does pin move in and out water get hot when released Switch to central heating demand YES NO Heplace motor If domestic hot water demand is still illuminated Demand L E D illuminates l Faulty domestic hot water swit
67. timer Kit if applicable Fit the clock timer kit following the appropriate sections of the instructions supplied with it 9 4 Frost Thermostat If the installation requires protection by a frost thermostat connect a single pole type to the appropriate terminals of the connector Keep all cables away from hot surfaces 9 5 Electrical Test Carry out preliminary electrical system checks as below 1 Test insulation resistance to earth of mains cables 2 Test earth continuity and short circuit of all cables 3 Test the polarity of the mains Refit the control fascia 221742D SECURING CONTROLS SCREW 2 MA Diagram 9 1 RED CABLE CONNECTION jinx CLAMP BLOCK GROMMET Ol lOi Lb SCREW 2 YEAS Diagram 9 2 9 Electrical Connections EXTERNAL CLOCK 3K RED LINK REMOVE WHEN CONNECTING ANY HEATING SYSTEM CONTROLS TO BOILER 5 WAY TERMINAL BLOCK SWITCH CONTACTS Q ME CONTROL a 18 IT I 3 AMP Il FUSE DOUBLE 9 0 POLE ISOLATOR 230V 50Hz PERMANENT MAINS SUPPLY L N ELECTRICITY SUPPLY CONNECTIONS ROOM THERMOSTAT FROST THERMOSTAT INTEGRAL CLOCK TO BOILER 5 WAY TERMINAL BLOCK MAINS POTENTIAL JUNCTION ROOM STAT BOX 3 RED LINK d i REMOVE WHEN ELE es es 230V 50Hz CONNECTING DOUBLE PERMANENT MAINS SYSTEM CONTROLS POLE SUPPLY ISOLATOR 230V 50Hz ROOM STAT NO FROST STAT INTEGRAL CLOCK TO BOILER 5 WAY TERMINA
68. under the supply water pressure Before any parts of this circuit are disconnected turn the domestic cold water isolating valve off open the hot water taps to reduce the water pressure in the boiler close the hot water isolating valve and drain the boiler at the valves see diagram 6 1 After replacing any water containing part of the central heating circuit make up the water loss vent all air and pressurise the system Refer to Commissioning in the Installation Instructions Check for water soundness and that the safety valve seats without leaking 12 Servicing 12 1 Isolation and Access REAR FLUE ONLY Before commencing refer to Section 11 Remove the combustion chamber panel unhook and lift off see diagram 8 2 Remove the fan electrical connections by pulling the boots not the wires and air pressure switch tubes see diagram 8 3 Remove the fan and flue collector assembly by pulling it forward see diagram 8 3 Disconnectthe three electrode leads see diagram 12 1 White lead sensing electrode Remove the burner retaining bracket by sliding it out see diagram 12 4 Carefully pull the burner forward to remove see diagram 12 5 Take care not to damage the combustion chamber insulation 12 2 Isolation and Access HORIZONTAL TOP FLUE OUTLET ONLY Before commencing refer to Section 11 Remove the combustion chamber panel unhook and lift off see diagram 8 2 25 Remove the fan electrical conne
69. us turn maximum Connect the gas pipe to the isolation valve ensuring that the sealing washer supplied fitted is in position 8 3 Boiler Securing Secure the boiler to the service cock bracket with the screws provided in the fittings pack see diagram 8 6 An anti theft kit is available Kit No 457110 8 4 Discharge Pipe Fit the short discharge pipe to the safety valve using the nut and sealing washer supplied in the fittings pack see diagram 8 9 Extend the discharge pipe using only a compression type fitting to join the discharge extension refer also to Section 6 4 Safety Valve Discharge AIR PRESSURE RESTRICTOR SWITCH PLATE SECURING SCREW 3 Diagram 8 4 FLUE SPIGOT SECURING SCREW 3 Diagram 8 5 RETAINING LUG BOILER 6955 MSS TOP MOUNTING BRACKET S PL HAND HOLES On Top SECURING SCREW BOILER ui SERVICE COCK BRACKET Diagram 8 6 221742D 8 Mounting the boiler 8 5 Rear Outlet Flue Fixing Make sure that the ductings do not slope down towards the boiler Fit the air duct into the flue spigot by pulling the air duct into the flue spigot locating cutouts Turn the air duct anti clockwise to lock into the cutouts see diagram 8 10 Note Itis important the correct restrictor plate is fitted or refitted see restrictor table Fit the flue connecting sleeve onto the fan see diagram 8 11 Fit the fan to the flue ducting see diagr
70. w one supplied Remove the expansion vessel secured with two clamping screws Connect the union nut when fitting the expansion vessel before clamping it REAR OF THE BOILER SECURING PIN 2 Diagram 14 19 SECURING PIN O RING BYPASS VALVE Diagram 14 20 221742D 38 Remove securing screws and push back to release LIK SS Ma J a IN A Aa A 7 CRN AP w i m REG Tilt and pull out between pump and SECURING gas supply pine SCREW 2 d ER d N BP OR pur Lh 1E VW d U ic 0000499 _ Ue A SEALING WASHER 4 Be sure to fit sealing washers PLATE TO when refitting PLATE HEAT EXCHANGER Diagram 14 21 UNION NUT CONNECTION p e E D T SY lt p A AN SECURING SCREW 2 EXPANSION VESSEL Diagram 14 22 14 Replacement of Parts 14 25 Automatic Air Vent Before starting refer to Section 11 AIR VENT AUTOMATIC AIR VENT Remove the automatic air vent see diagram 14 23 CAP x SEN CLIP SLACKEN THE SMALL CAP ON THE AIR VENT THIS MUST NOT BE RE TIGHTENED 14 26 Heat Exchanger Before starting refer to Section 11 Ne Unhook the combustion chamber front see diagram 8 2 a Remove the fan and flue collector refer to Section 14 1 Remove the burner see Section 14 2 Refer to diagram 14 24 and remove the two side insulation

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