Energysaver 60
Contents
1. Glow worm 77 Instructions for Use Installation and Servicing Tobeleftwiththe user 4040 S Energysaver 60 G C No 41 319 71 High Efficiency Boiler C Benchmark PAS010 This is a Cat II Appliance 2H3P Reference in these instructions to British Standards and Statutory Regulations Requirements apply only to the United Kingdom For Ireland the rules in force must be used The instructions consist of three parts User Installation and Servicing Instructions which includes the Guarantee Registration Card The instructions are an integral part of the appliance and must to comply with the current issue of the Gas Safety Installation and Use Regulations be handed to the user on completion of the installation Guarantee Registration Thank you for installing a new Glow worm appliance in your home Glow worm appliances are manufactured to the very highest standard so we are pleased to offer our customers a Comprehensive First Year Guarantee In the center 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 v All replacement parts REGISTER YOUR GLOW WORM APPLIANC2. s instructions for these items On demand the orange light will come on Turn the left hand switch to high flame Turn the control thermostat knob at the right clockwise to any position between MIN and MAX see diagram 1 The maximum setting is about 82 C 180 F The boiler will not light between O and MIN The boiler lighting operation is now automatic as follows The fan operates followed by an ignition spark until the burner lights on low flame after a short period it will go to high flame and the green light will come on The burner will remain alight until switched off by the control thermostat or other remote control If the control thermostat is turned Off by hand wait at least 30 seconds before turning on again When the boiler thermostat is satisfied the burner and green light will go out When the system controls are satisfied the burner orange and green lights will go out The automatic lighting sequence will operate again when heat is required The high low switch should be set to high for winter use but when domestic hot water only is required in the summer it can be turned to low If no light comes on you should contact your installation Servicing company to check the controls although the system may be working To Turn the Boiler Off For short periods turn thermostat control knob anti clockwise until O is againstthe setting point To relig
3. Alternatively the increase in the centre height over a distance X is given by H 0 35X Mark the position of the centre of the flue as in diagram 5 4 LOOSE ITEMS PACK BOILER MOUNTING No 10 x BRACKET SELF TAPPER K M5x10mm il CONTROLS FITTING Note Casing securing screws supplied in loose items pack f Fit in order of numerical sequence Diagram 5 2 SECURING E SCREW 4 Diagram 5 3 221836B 14 5 Preparation 5 3 Flue Hole Cutting Having marked out the flue centre cut a hole for the flue see diagram 5 5 for minimum core drill size for various wall thicknesses This will allow for the 35mm per metre 2 fall towards the boiler Note If required an optional Wall Liner Kit part No 900862 is available complete with fixing instructions 5 4 Wall Mounting Bracket Reposition the template making sure of dimensional alignment with the flue centre lines Mark the boiler securing screws and mounting plate position see diagram 5 6 Drill holes and plug fit the securing screws allowing sufficient clearance to accept the keyhole fixing brackets and secure the boiler mounting bracket to the wall 0248M 115 Minimum hole 125 up to 300mm wall 135 up to 680mm wall REAR FLUE SIDE FLUE Diagram 5 4 See WALL THICKNESS 2 0249M 135 DIAMETER 115 125 DIAMETER DIAMETER See template for centre line po
4. is not suitable for outdoor locations 1 1 Sheet Metal Parts WARNING When installing or servicing the boiler care should be taken when handling sheet metal parts to avoid any possibility of personal injury 1 2 Statutory Requirements The installation ofthe boiler MUST be carried out by a competent person in accordance with the relevant requirements of the current issue of Manufacturer s instructions supplied The Gas Safety Installation and Use Regulations The Building Regulations The Building Standards Scotland Regulations applicable in Scotland local Water Company Bylaws The Health and Safety at Work Act Control of Substances Hazardous to Health The Electricity at Work Regulations and any applicable local regulations 221836B Detailed recommendations are contained in the current issue of the following British Standards and Codes of Practice 854814 BS5440 Part 1 and 2 BS5449 BS5546 BS6700 BS6798 BS6891 and BS7074 Part 1 and 2 BS7478 BS7593 BS7671 We also suggestthat you have to hand a copy ofthe British Gas publication Guidance Notes for the Installation of Domestic Condensing Boilers Manufacturer s notes must not be taken as overriding statutory obligations BSI Certification This boiler certificated to the current issue of P A S 010 for performance and safety It is important that no alteration is made to the boiler without permission in writing from Hepworth Heating Ltd Any
5. of servicing will depend upon the particular installation conditions and usage but in general once a year should be enough It is the Law that any servicing must be carried out by a competent person To obtain service please call your installer or Heatcall Glow worm s own service organisation using the telephone number given on the information plate see diagram 2 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 7891 a RESET BUTTON pc e INSTRUCTION LABEL Diagram 2 221836B Instructions for Use Boiler Clearances If fixtures are positioned close to the boiler space must be left as shown in diagram 3 Enough space must also be left in front of the boiler to allow for servicing Boilers Installed in a Compartment or Cupboard If the boiler is installed in a cupboard or compartment do not obstruct any ventilation openings Do not use the cupboard or compartment for storage Regularly make sure that the air vent openings are clear of obstructions Cleaning WARNING This appliance contains metal parts components and care should be taken when handling and
6. operate the boiler with the bypass closed on minimum load normally central heating only with one radiator operating in the main living area The valve should be opened gradually to achieve the appropriate flow rate as quoted in Section 2 4 If necessary readjust the pump Under NO circumstances should this valve be left in the FULLY Closed position 10 6 Condensate Check After 30 minutes of running turn the boiler off and remove the inner case Check that there are no condensate leaks from the fan outlet flue elbow or fan inlet flue hood joints Also check for leaks from the condensate drainage system 10 7 Operational Checks Adjust the control thermostat and any system controls to their required settings and set high low switch to high Do not attempt to adjust the thermostat calibration screw Operate the boiler again on full service and check that the balancing is satisfactory making further adjustments as necessary to the system radiator valves and bypass There must be no pumping over of water or entry of air at the vent above the feed and expansion cistern If thermostatic radiator valves are fitted care must be taken to make sure that there is an adequate flow rate through the boiler and bypass when the valves are closed For guidance on the use of thermostatic radiator valves refer to the current issue of BS7478 and British Gas Guidance Notes for Installation of Domestic Condensing Boilers To check the
7. operation of the flame supervision device with the burner alight turn gas service cock to Off the burner will go out There will be one attempt to relight indicated by a 5 second ignition phase Wait for 30 seconds Turn the gas cock to ON and the burner should NOT relight Turn the control thermostat knob to OFF and then ON again and the burner WILL now relight Turn high low switch to low and observe low flame then return switch to high Refit the outer case see diagram 5 2 and secure the case with the screws from fittings pack 11 User Information 11 User Information Instruct and demonstrate the efficient and safe operation of the boiler heating system and if fitted the domestic hot water system Advise the user that like all condensing boilers this appliance will produce a plume of condensation from the flue terminal in cool weather This is due to the high efficiency and hence low flue gas temperature of the boiler Show the user the position of Lighting Instructions refer to Instructions for Use Advise the user that for summer use the high low switch can be turned to low Advisethe user ofthe 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 23 Advise the user that to ensure the continued efficient and safe operation of the boiler it is recommende
8. AND SOIL PIPES 75 F FROM INTERNAL OR EXTERNAL CORNERS 300 G ABOVE ADJACENT GROUND OR BALCONY LEVEL 300 H FROM A SURFACE FACING THE TERMINAL 600 FACING TERMINALS 1200 VERTICAL FROM A TERMINAL 1500 L HORIZONTALLY FROM A TERMINAL 300 626 34 CF 7111 3344433443 1 Ta 11 1111 1 14117714117 117 17 inda 12342 SERE 5 Diagram 4 4 221836B 5 Preparation 5 1 Unpacking diagram 5 1 Open top carton remove top fitting wall template loose items fittings pack and boiler mounting bracket Remove carton wrap and spacing pieces Lift off white outer case front Remove protective packing piece Remove the cover of the inner case see diagram 5 3 5 2 Rear and Side Flue Application Having selected the location and flue application with due regard to the terminal position Take the template and temporarily position it on the wall see diagram 5 4 making sure that the minimum clearances are maintained For a rear flue mark the position of the flue as diagram 5 4 INSTRUCTIONS eS 6289 TOP FITTING WALL TEMPLATE BASE TRAY Diagram 5 1 For a side flue extend the centre line horizontally taking into account the required fall towards the boiler left or right to the corner of the adjacent surface where the flue is required to exit to the outside
9. CREW 2 W SILICONE S SLEEVING SENSING LEAD MM NET a SPARK ELECTRODE l SPARK GAP 3mm to 4mm Diagram 12 9 13 Fault Finding 13 1 Electrical Important On completion of the Service Fault Finding task which has required the breaking and remaking of the electrical connections the earth continuity polarity short circuit and resistance to earth checks must be repeated using a suitable multimeter Refer to Fault Finding Wiring diagram 13 2 and Functional Flow diagram 13 3 Note Failure of an indicator light does not warrant the replacement of an otherwise satisfactory part 13 2 Electrical Supply Failure Failure of the electrical supply will cause the burner to go out Operation will normally resume on restoration of the electrical supply If the boiler does not relight after an electrical supply failure the overheat device may need resetting To reset press the reset button on the underside of the boiler see diagram 13 4 221836B 26 If the cutoff operates at any other time press the reset button and the burner should relight If the fault persists refer to Fault Finding Chart There is a further cutoff mounted on the flue hood see diagram 13 5 which also may need resetting 13 3 Condensate Sensor Refer to fault finding chart The boiler is fitted with a safety device to prevent the boiler from working if the condensate pipe gets blocked Remove the cond
10. D LINK MAY HAVE BEEN 9 GREY REMOVED TO FIT REMOTE CONTROLS GV2 2 from bottom 5548 Diagram 13 3 221836B 32 13 Fault Finding 7891 a RESET BUTTON 5 ae lo on INSTRUCTION LABEL Diagram 13 4 4067 S AU FLUE HOOD OVERHEAT THERMOSTAT Diagram 13 5 14 Replacement of Parts Notes Replacement of parts must be carried out by a competent person Before replacing any parts isolate the boiler from the electrical supply and turn the gas supply off at the gas service cock see diagram 8 1 Unless stated otherwise all parts are replaced in the reverse order to removal After replacing any parts always test for gas soundness and if necessary carry out functional check of controls For the following the front case and inner case cover will need to be removed diagrams 5 2 and 5 3 14 1 Spark Electrode Replace as described in Section 12 4 14 2 Ignition Lead diagram 14 2 Release the control box as Section 9 To disconnect the ignition lead from the control board remove the PCB from the mounting pegs the fronttwo have detachable grips the rear two are plain supports When refitting lead make sure that there is enough length through the gland plate assembly Condensate Sensor diagram 14 2 Refer to the relevant part of Section 14 2 to remove the screw The sensing screw is fitted to a push fit cap which can be levered o
11. E v All labour charges FOR 1ST YEAR GUARANTEE PROTECTION w All call out charges CALL 0208 247 9857 Customer Services Hapworth 9 09 Eda Nottingham Road Belper Derbyshire DE56 1JT Tel 01773 828100 General Sales enquiries One Contact Local Service Fax 01773 828070 Tel 01773 824141 Fax 01773 820569 Important Information TESTING AND CERTIFICATION This boiler istested 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 2 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 Typetestfor purposes of Regulation 5 certified by Notified body 0086 Product productioncertifiedby Notified body 0086 The CE mark on this appliance shows compliance with 1 Directive 90 396 EEC on the approximation of the laws of the Member States relating to appliances burning gaseous fuels 2 Directive 73 23 EEC on the harmonization of the Laws of the Member States
12. MBER VIEWING FRONT PANEL WINDOW SECURING INSULATION SCREW 2 Diagram 14 11 Diagram 14 12 37 221836B 14 Replacement of Parts 14 12 Insulation Rear diagram 14 10 With the heat exchangers and burner assembly removed as Sections 14 10 and 14 11 the rear insulation pad can be removed as shown 14 13 Insulation Combustion Chamber Front Panel diagram 14 11 Remove the two screws from the viewing window then slide the insulation pad out 14 14 Insulation Sides diagram 14 12 Remove the spark electrode refer to Section 12 4 Remove the insulation by sliding it out 14 15 Condensate Sensor diagram 14 13 Refer to the relevant parts of Section 14 2 to remove the screw 14 16 Viewing Window Glass diagram 14 14 Remove the two screws to release the frame and glass When replacing take care not to damage the gasket 14 17 Inner Case Cover Seal When removing seal make sure that all the old adhesive is removed When fitting the new seal make sure that it fits correctly and has not buckled 14 18 Fascia and Lights Assembly Release the control box as Section 9 Refer to the relevant parts of Section 14 5 to remove the fascia and lights bracket 221836B 38 SECURING SCREW 2 GLASS GASKET VIEWING WINDOW INNER CASE FRAME X SECURING GLASS GASKET SCREW 2 VIEWING WINDOW COMBUSTION CHAMBER FRONT PANEL Diagram 14 14 15 Sp
13. N OVERHEAT CUT OFF PHIAL CONTROL OVERHEAT THERMOSTAT LOCKNUT Diagram 14 4 e o HIGH LOW CONTROL 8 5 CONTROLS CONTROL THERMOSTAT S CON NN CONTROLS SCREW 3 ea mem ELECTRICAL CONNECTIONS Z RESET BUTTON FLUE HOOD OVERHEAT THERMOSTAT SECURING Diagram 14 4A SCREW 2 Diagram 14 5 14 5 High Low Control diagram 14 4 and 14 6 Remove the fascia as described in Section 14 4 Remove the four screws securing the lights bracket Remove the locknut to release the High Low control Disconnect the three in line electrical connectors When refitting refer to wiring diagram 13 2 35 14 6 Air Pressure Switch diagram 14 7 Remove the air pressure tubes and electrical connections Remove the two securing screws to release the air pressure switch When fitting the replacement make sure that all the air pressure tubes and electrical connections are made as shown 221836B 14 Replacement of Parts 14 7 Multifunctional Control diagram 8 1 Disconnectthe screws and electrical plugs atthe multifunctional control Support the multifunctional control and remove the four screws from the flanged connection undo the union at the gas service cock and remove the support bracket securing screw Remove the multifunctional control by easing the flange and service cock apart Removetheunion half and refitto the replacement multifunctional valve Use a little join
14. Osma Orcaster If using Marley Terain or Hunter tubing which is slightly larger use the silicone sealant provided in the fittings pack to make a leak proof joint to the drain connection on the boiler The condensate discharge pipe should have a fall of 2 Itis not necessary to provide air breaks or traps in the discharge pipe since the boiler has an integral 50mm trap and siphon The boiler is fitted with a safety device to preventthe boiler from working if the condensate pipe gets blocked by either ice or debris 221836B 16 It is therefore recommended that any external condensate drain pipe is insulated to prevent it freezing up Alternatively a larger diameter pipe can be used and insulated The condensate drain pipe should be checked during any servicing and any debris found removed Refer to the British Gas publication Guidance Notes for the Installation of Domestic Condensing Boiler for advice on the disposal of boiler condensate zm UNION NUT 5 28mm O D COPPER TUBING OLIVE FLUE GAS SAMPLE OIN FLOW RETURN o WATER CONNECTIONS Diagram 6 1 7 Flue Installation 7 1 Rear Flue Mark and cut the air duct terminal assembly see diagram 7 1 and the flue duct diagram 7 2 to the lengths required cutting square and removing any burrs Refer to diagram 7 3 mark through the holes in the flue elbow assembly anddrillthe duct as shown making sure o
15. S YES NO Is there 240V at the fan Has boiler been NO operating for 10 NO NO seconds yet Is there 240V Replace ignition at PCB YES YES Switch High Low Switch to low Will flue hood Is there a spark at electrode NO thermostat reset Replace flue hood is there 240V at thermostat the fan YES YES f YES Flue hood overheating 2 Does gas ignite blocked secondary heat exchanger clean replace NO Can the low gas NO pressure be set see data tables at test point on gas valve Isolate supply NO Does discharge tube on ignition PCB flash Does gas ignite YES 3 YES Replace PCB Faulty injector Replace Examine electrode and Check continuity of both main coils Coils ok leads Repair replace as necessary Replace ignition PCB Replace as necessary Diagram 13 1 29 221836B 13 Fault Finding NO YES Is condense drain blocked repair Does burner remain alight Is the low gas pressure setting correct see data tables Adjust as necessary Does burner remain alight Will burner remain alight if gas pressure is temporarily increased YES NO Faulty injector Replace Reset pressure Faulty PCB flame detection Replace PCB Reset pressure Boiler satisfactory Does the burner remain alight Is the low gas pressure setting correct see Data Tables at t
16. alteration that is not approved by Hepworth Heating Ltd could invalidate the warranty and could also infringe the current issue of the Statutory Requirements 1 3 Range Rating The boiler is range rated and is factory preset to maximum but may be adjusted to suit individual system requirements refer to Table 2 1 4 General Data The data label is positioned on the inner case visible when the outer case is removed All dimensions on diagrams are given in millimetres except as noted 1 General The Seasonal Efficiency Domestic Boilers UK SEDBUK is 86 9 Thevalueisusedinthe UK Government s StandardAssessment Procedure SAP for energy rating of dwellings The test data from which it has been calculated have been certified by B S I 1 5 Gas Supply The gas installation must be in accordance with the current issue of BS6891 The supply from the governed meter must be of adequate size to provide a steady inlet working pressure of 20mbar 8in wg at the boiler On completion test the gas installation for soundness using the pressure drop method and a suitable leak detection fluid purge in accordance with the above standard 1 6 Electrical Supply WARNING This boiler must be earthed All system components shall be of the approved type and be wired and connected in accordance with the requirements of thecurrentissue of BS7671 and any applicable local regulations Connection of the boiler and system co
17. are Parts 15 Spare Parts When ordering spare parts please quote the appliance name and serial number to be found on the data label visible when the outer casing is removed If ordering from the British Gas also quote the GC number of the part Key No Part No Description GC Part No 1 230530 Multifunctional control 2 800476 Thermostat control 278 094 3 800477 Thermostat over heat cutoff 278 095 4 800466 Overheat Thermostat 278 047 5 450260 High low control 278 276 6 800467 Thermostat control knob 278 049 7 202135 Air pressure switch 313 303 8 203149P Gas manifold assembly 60 Nat 278 099 9 202231 Fuse 10 208302 Sight glass 312 419 208093 Gasket sight glass not shown 312 420 11 800840 Ignition lead E00335 12 202211 Control board PCB 379 239 13 800876 Fan 14 202625 Electrode 278 096 15 202210 Interconnection board 379 238 16 212121 O Ring 136 785 39 221836B 15 Spare Parts 6291 Diagram 15 1 Because of our constan 221836B endeavour for improvement details may vary slightly from those in the instructions 40
18. at all times A compartment used to enclose the boiler must be designed and constructed specifically for this purpose The doorway opening should be of sufficient size to allow for easy removal of the boiler 0157M INCREASE THIS DIMENSION TO 25mm FROM COMBUSTIBLE MATERIAL 51 t PERMANENT SURFACE CLEARANCE OPPOSITE TO FLUE EXIT MUST BE ADEQUATE FOR THE INTERNAL INSTALLATION Diagram 3 1 TABLE 4 Ventilation From Room Energysaver 60 Ventilation From Outside Energysaver 60 221836B 4 Flue NOTE The flue must be installed in accordance with the current issue of BS5440 Part 1 Important The flue must be installed with a fall of 35mm per metre 2 towards the boiler see diagram 4 1 Itis of no advantage to exceed this angle 2 indeed sealing of the fan to flue elbow may become more difficult as the angle is increased The air and flue duct connect to the top of the boiler using an elbow which can be positioned to the side or rear The rear and side flue assemblies are designed for internal installation but if necessary due to insufficient clearances boiler flue terminal location they can be installed from the outside For a wall thickness up to 300mm the flue can be fully installed from the inside For a wall thickness over 300mm the external cut hole will need to be made good from the outside The standard flue is ab
19. ce a plume of condensation in cold weather so special care must be takenin siting the flue terminal so as not to cause a nuisance to adjacent property Where the terminal is fitted within 600mm 24in below plastic guttering an aluminium shield 1500mm 5ft long should be fitted to the underside and immediately beneath the guttering or eaves Where the terminalis fitted within 450mm 18in below eaves or painted guttering an aluminium shield 750mm 2ft6in long should be fitted to the underside and immediately beneath the guttering or eaves 4 2 Terminal Guard A terminal guard is required if persons could come into contact with the terminal or the terminal could be subject to damage If a terminal guard is required it must be positioned to provide aminimum of 50mm clearance from any part of the terminal and be central over the terminal see diagram 4 4 A suitable terminal guard can be obtained from Tower Flue Components Ltd Morley Road Tonbridge Kent TN9 1RA their reference CGD K3 BL may be necessary to increase this dimension to prevent staining of adjacent walls depending on weather conditions 13 z e e s H I _ ie LL MINIMUM SITING DIMENSIONS MINIMUM FOR FANNED FLUE SPACING TERMINALS POSITION in mm A DIRECTLY BELOW AN OPENABLE WINDOW AIR VENT OR ANY OTHER VENTILATION OPENING 300 B BELOW GUTTER DRAIN SOIL PIPE 75 C BELOW EAVES 200 E FROM VERTICAL DRAIN PIPES
20. cleaning with particular regard to edges Clean the casing occasionally by wiping it over with a damp soapy cloth or dry polishing duster Do not use an abrasive cleaner Protection Against Freezing If the boiler is to be out of use for any long period of time during severe weather conditions we recommend that the whole of the System including the boiler be drained off to avoid the risk of freezing up Make sure that if fitted the immersion heater in the cylinder is switched off If you have a sealed water system contact your installation servicing company as draining refilling and pressurising must be carried out by a competent person Boiler Electrical Supply WARNING The boiler must be earthed The boiler must only be connected to a 240V 50Hz supply protected by a 3A fuse All wiring must be in accordance with the current issue of BS7671 The colours of three core flexible cable are Brown live Blue neutral green and yellow earth As the markings on your plug may not correspond with these colours continue as follows The wire coloured blue must be connected to the terminal marked N or Black The wire coloured brown must be connected to the terminal marked R or Red The wire coloured green and yellow must be connected to the terminal marked E Green or the earth symbol 4 Electrical Supply Failure Failure of the electrical supply will cause the burner to go out Shoul
21. d be carried out by a competent person In the event of an electrical fault after installation of the system preliminary electrical system checks as below should be carried out 1 Test insulation resistance to earth of mains cable 2 Test the earth continuity and short circuit of all cables 3 Testthe polarity of the mains The installer is requested to advise and give guidance to the user of the controls scheme used with the boiler 21 MAINS SUPPLY CABLE GROMMET i Wm SS Ni PUMP AND REMOTE CONTROLS GROMMET PUMP CABLE CHASSIS EARTH POST RED LINK SL TO 1 REMOTE CONTROLS 4052 Diagram 9 2 221836B 10 Commissioning Please ensure the Benchmark logbook is completed and left with the user 10 1 Preliminaries All Systems Commissioning should be carried out by a competent person in accordance with current issue of BS6798 Make sure that the system has been thoroughly flushed out with cold water without the pump in place Refit the pump fill the system with water making sure that all the air is properly vented from the system and pump Before operating the boiler check that all external controls are calling for heat 10 2 Sealed Systems Fill the system until the pressure gauge registers 2 7bar 40lbf in Clear any air locks and check for leakage Check the operation of the safety valve preferably by allowing the water pressure to rise until t
22. d that it is checked and serviced 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 Draw attention if applicable to the current issue of the Gas Safety Installation and Use Regulations Section 35 which imposes a duty of care on all persons who let out any property containing a gas appliance It is the Law that servicing is a carried out by a competent person Reminder Leave these instructions and the Benchmark logbook with the user 221836B 12 Servicing Notes To ensure the continued efficient and safe operation of the boiler it is recommended that it is checked and serviced at regular intervals The frequency of servicing will depend upon the particular installation and usage but in general once a year should be enough It is the Law that any servicing is carried out by a competent person Note For obtaining a products of combustion reading use the connection on top of the boiler see diagram 6 1 Should the gas pressure need adjusting referto Section 10 4 Isolate the boiler from the electrical supply Before starting a service remove the casing refer to diagram 5 1 Turnthe gas supply off atthe gas service cock see diagram 8 1 Unless stated otherwise parts removed for servicing should be replaced in the reverse order to removal After completing any servicing of gas carrying compon
23. d this happen operation of the boiler will normally resume after the electrical supply is restored If the burner does not relight after an electrical supply failure the overheat device may need resetting press the reset button on the underside of the boiler see diagram 2 221836B INCREASE THIS DIMENSION TO 25mm FROM COMBUSTIBLE MATERIAL 5 i 500 PERMANENT SURFACE CLEARANCE OPPOSITE TO FLUE EXIT MUST BE ADEQUATE FOR THE INTERNAL INSTALLATION Diagram 3 Instructions for Use Overheat Safety Cutoff If the cutoff operates on any other occasion than an electrical failure press the reset button as stated in Electrical Supply Failure If the boiler fails to relight contact your installation servicing company To Turn the Boiler On Sealed Water Systems CAUTION Asealed water system mustbe filled and pressurised by a competent person Only light the boiler when you are sure that the system and boiler have been filled and pressurised The pressure gauge should show at least 0 7bar anything less than this figure could indicate a leak and you MUST contact your installation servicing company If there is any doubt about the boiler and system being full of water consult your installation servicing company All Systems Turn the electrical supply on to the boiler and check that any remote controls are set to your requirements refer to manufacturer
24. densing Boilers for further information 1 8 Heating System Controls The heating system should have installed a programmer and room thermostat controlling the boiler Thermostatic radiator valves may be installed in addition to the room thermostat Note For further information see The Building Regulations 1991 Conservation of fuel and power 1995 edition Appendix G table 4b DATA TABLE 1 TOTAL 48 0 kg WEIGHT 106 Ib LIFT 31 5 kg WEIGHT 69 5 Ib WATER 1 6 Litre CONTENT 0 35 gal cae Re in CONNECTION WATER 28mm copper flow CONNECTION at right return at left l 240V 50HZ fused 3A SUPPLY TABLE 2 Energysaver 60 MAX NOMINAL kW 10 16 16 94 18 64 20 HEAT INPUT uie Bills d iin GROSS Btu h 34 680 57 800 63 584 69 350 NOMINAL kW 8 79 14 65 16 12 17 58 HEAT OUTPUT Btu h 30 000 50 000 55 000 60 000 18 81 NOMINAL kW HEAT 9 40 15 67 17 24 OUTPUT Btu h 32 100 53 500 58 800 64 150 CONDENSING BURNER m bar 45 118 143 17 0 SETTING HOT PRESSURE in wg 18 47 57 6 8 APPROX m h 16 177 1 9 EAS fth 57 625 68 BURNER INJECTOR MARKING 60N 1 9 Anti theft Kits Anti theft kits are available for these appliances contact Hepworth Heating Ltd for further information 221836B 2 Water System Note The boiler has 28mm copper connections which must be used for the Energysaver 60 2 1 Drainin
25. ed and flushed out Important With use a white oxide coating will form on the aluminium parts this should only be removed if the coating is blocking the gaps between the fins When cleaning take care that the water does not overflow the condensate catchment tray Place a sheet of paper over the burner see diagram 12 6 Clean the primary heat exchanger with a suitable soft brush see diagram 12 6 221836B 24 ri SECURING SCREW 2 BYPASS HEAT SHIELD c SECURING SCREW 2 2 4054 Diagram 12 1 AIR 4043 S PRESSUREC TUBES CLEAR TUBES SECURING ELECTRICAL SCREWS 3 CONNECTIONS _ FLUE HOOD Q E lt di FLUE HOOD 4055 S Diagram 12 3 12 Servicing Brush from back to front NOT left to right Do not use a brush with metallic bristles Remove the paper and any debris 12 2 Burner Cleanthe fins of the burner with a suitable soft brush any debris can be allowed to fall into the mixing chamber Do not use a brush with metallic bristles Note The burner is water cooled and a system drain down is required if removing 12 3 Injector Removethe injector by releasing the three screws atthe injector manifold burner box the two screws at the inner case base sealing plate see diagram 12 7 and the four screws at the multifunctional valve see diagram 8 1 Make sure that the O ring i
26. ensate drain cap diagram 14 2 If condensate is backing up to the sensor the drain is blocked and it must be cleared before the boiler will work Inspect external condensate pipe and clear away any debris or ice Release ice blockage by using warm cloths on the pipe 13 Fault Finding PM5 PUMP OVERRUN OPERATION The control thermostat has a pump overrun facility built into it when the control thermostat is set at maximum only the pump overrun will keep the pump running to allow the boiler to cool down after which it will stop providing the remote controls are NOT calling for heat FAULT FINDING Turn boiler control thermostat to maximum with the remote controls calling for heat does the pump continue to run after the appliance has shut down on boiler control thermostat YES E NO Is there 240V on period of time Turn off remote controls does pump stop after a short NO YES Faulty pump overrun Replace control thermostat YES Pump overrun in order Faulty permanent live feed Replace Is there 240V on 9 connection on thermostat YES NO Faulty connections between thermostat and interconnection PCB Repair NO Is there 240V on PL for pump YES or repair as necessary Faulty pum
27. ents ALWAYS test for gas soundness and carry out functional check of controls Also check for condensate leaks at fan outlet flue elbow and fan inlet flue hood joints It should be noted that the burner is water cooled and a system drain down is necessary if the burner is removed 12 1 Heat Exchanger Cleaning Remove the inner case cover see diagram 5 3 Remove the bypass heat shield see diagram 12 1 Note The flue hood top will spring up Disconnect the fan air pressure tubes combustion sampling tube electrical connections and remove the three fan securing screws fan and the flue hood Note On reassembly it is suggested that the two top securing screws for the bypass heat shield and the flue hood be partially engaged before fitting of the bypass heat shield see diagram 12 3 Carefully remove the combustion chamber front panel see diagram 12 4 Remove the loose baffle from the condensing section see diagram 12 5 When replacing note that it is marked Front Place a container under condense drain trap see diagram 12 8 and remove red cap Flush loose debris from secondary heat exchanger with water poured from above and allow the water to drain through the flexible condensate tube at the right hand side of the heat exchanger into the container Check that this tube is not partially blocked and the water runs freely If there is any build up of debris in the condensate trap the trap should be remov
28. ff for easy access Note The condensate flexible tube is a push fit and can be removed from the condensate drain trap to improve access to the screw When replacing the cap make sure that it is firmly in place and that the ring tag is pointing away from the casing side 33 SECURING CONDENSATE FLEXIBLE SCREW 2 TUBE 5549 SENSING LEAD Diagram 14 2 221836B 14 Replacement of Parts 14 3 Printed Circuit Boards PCBs diagram 14 3 Release the control box as Section 9 Control PCB diagram 14 3 top Disconnect the electrical plug on the board Release from its two support post and carefully pull the board away noting that the ignition lead is still connected It may be necessary to hold some of the wires above the PCB clear with an electrical screwdriver on removal or refitting Release and carefully pull the board away from its supports noting that the ignition lead is still connected Disconnect the ignition lead Interconnecting PCB ICB diagram 14 3 bottom Disconnect the electrical plugs and cables from the terminal strip Release and carefully pull the board away from its supports When refitting refer to wiring diagram 13 2 14 4 Control Thermostat and Overheat Cutoff Release the control box see Section 9 Control Thermostat diagram 14 4A and 14 4 Pull off the control thermostat and High Low knobs Remove the three fascia securing screws and fascia Remove t
29. flexible hose to the replacement SECURING SCREW 2 AIR PRESSURE SWITCH ELECTRICAL CONNECTIONS 3 GREY BROWN l CLEAR RED AIR PRESSURE H TUBE gt Diagram 14 7 L UNION CONNECTIONS SECURING SS Mm UN up 289 gt srank SPARK PAN ELECTRODE CONDENSATE TUBE INJECTOR MANIFOLD Diagram 14 8 14 Replacement of Parts Heat Exchanger Primary diagram 14 10 Disconnect the three union connections 14 11 Burner diagram 14 9 Note To carryout the following operations it will be found more convenient if the whole of the heat exchanger and burner are removed as a unit Follow the relevant parts of Servicing Section and remove the bypass heat shield fan flue hood combustion chamber front panel heat exchanger baffle spark electrode injector and thermostat phials Release the flexible tube from the condense drain trap this is a push fit Release union connections and the six securing screws then remove the complete assembly Remove the insulation as Section 14 14 and retain for use in the replacement part Disconnect the two union connections Fit the insulation REAR INSULATION Diagram 14 10 SECONDARY HEAT EXCHANGER PRIMARY HEAT EXCHANGER UNION JJ d f M hk Diagram 14 9 COMBUSTION PILOT CHA
30. fthe correct alignment of the Top 7 2 Side Flue Mark and cut the air duct terminal assembly see diagram 7 4 and flue duct diagram 7 5 to the lengths required cutting square and removing any burrs Refer to diagram 7 3 mark through the holes in the flue elbow assembly and drill the flue duct as shown making sure of the correct alignment of the Top 7 3 Internal Flue Assembly If access to the outside wall is not practical the flue system can be installed from inside Use of the optional wall liner kit required Apply sealant to the flue duct locate into the air duct terminal see diagram 7 6 Apply sealant to the flue elbow spigot and then locate the flue and air duct terminal assembly to the flue elbow as shown in diagram 7 3 making sure of the alignment of the Top Secure the air duct terminal assembly to the flue elbow and flue duct assembly with the two self tapping screws supplied in the loose items pack and then seal with the tape provided Place the flue assembly into the flue hole Make sure that the flue terminal is correctly positioned and projecting the correct distance from the outside wall face see diagram 7 9 7 4 External Flue Installation Locate the air duct terminal assembly into the flue elbow assembly as shown in diagram 7 3 making sure of correct terminal alignment of the TOP Mark the position of the air duct terminal assembly securing holes and drill two 2 8mm diameter holes thr
31. g Tap The boiler is provided with a draining point atthe lower left hand side of the burner manifold to be used for draining the boiler see diagram 2 1 A draining tap must be provided at the lowest points of the system which will allow the entire system and hot water cylinder to be drained Draining taps shall be to the current issue of BS2879 2 2 Safety Valve A safety valve need not be fitted to an open vented system 2 3 Pump The pump should be fitted in the flow pipe from the boiler and have isolating valves each side integral if possible A variable duty pump should be set to give a temperature difference of 11 C 20 F between the flow and return with the thermostat set at MAX which is about 82 C 180 F to give a design flow rate as shown in Table 3 See chart for pressure drop of the boiler diagram 2 2 High resistance microbore systems may require a higher duty pump 2 4 Bypass A BYPASS MUST BE FITTED see diagram 2 3 for a suitable position The flow rate through the boiler must not be allowed to fall below that given in Table 3 Where the water system can allow the boiler and pump to operate on bypass only the bypass must be placed at least 1 5m away from the boiler 2 5 Inhibitor Attention is drawn to the current issue of BS5449 and BS7593 on the use of inhibitors in central heating systems If an inhibitor is to be used contact an inhibitor manufacturer for their recommendations as
32. gram 7 1 221836B 7 Flue Installation 6863 Diagram 7 2 6864 LONG FLUE TERMINAL Diagram 7 4 3mm DRILL SIZE amp Q AIR DUCT TERMINAL AND FLUE DUCT ASSEMBLY _ SEAL WITH TAPE SUPPLIED FLUE ELBOW ASSEMBLY FLUE DUCT ASSEMBLY 4079 a DUCT SEALANT TERMINAL AND Diagram 7 3 6885 N minus 42mm BOILER CENTRE LINE T o Diagram 7 5 221836B 18 7 Flue Installation 6867 FLUE DUCT FOAM SEAL SEALANT AIR DUCT TERMINAL FLUE DUCT ASSEMBLY Diagram 7 6 Diagram 7 8 6866 6868 STD FLUE TERMINAL 63 LONG FLUE TERMINAL 61 FOAM SEAL FLUE Y TERMINAL FLUE DUCT Diagram 7 9 7 6 Wall Liner If a wall liner is used fit self adhesive seal as follows For wall thicknesses up to 300mm fit the self adhesive seal to the air duct see diagram 7 7 make sure the joint is on top For wall thicknesses over 300mm see diagram 7 8 Diagram 7 7 19 221836B 8 Gas Connection Make the gas connection to the gas service cock see diagram 8 1 MULTI FUNCTIONAL Sea hee SCREW SUPPORT BRACKET S GAS SERVICE E COCK SHOWN SCREWS Vu 4 BURNER SECURING PRESSURE SCREW UNION TEST POINT CONNECTOR SECURING SCREW Diagram 8 1 9 Electrical Con
33. he electrical connections from the control thermostat body Remove the two control thermostat securing screws Release the gland plate assembly see diagram 14 2 Release and remove the control thermostat phial from the pocket Withdraw the capillary through the gland plate and controls box grommet Slide control thermostat body away from control box On replacement smear the phials with the heat sink compound supplied before replacing in the phial pocket When refitting refer to wiring diagram 13 2 Overheat Cutoff diagram 14 4A and 14 4 Remove the electrical connections Remove the locking nut Release the gland plate assembly Release and remove the overheat cutoff phial from the pocket Withdraw the capillary through the gland plate and controls box grommet On replacement smear the phials with the heat sink compound supplied before replacing in the phial pocket When refitting refer to wiring diagram 13 2 Neatly secure any surplus capillary Flue Hood Overheat Cutoff diagram 14 5 Remove electrical connections and unfasten the screws to release Note the polarity of the connections is not important 221836B 34 ELECTRIC PLUG IGNITION LEAD TERMINAL STRIP SUPPORT POST 2 4065 CONTROL P C B ELECTRICAL PLUG 5 Diagram 14 3 14 Replacement of Parts CONTROL THERMOSTAT SECURING SCREW 2 ELECTRICAL CONNECTION 5 4078 RETAINING PI
34. he test point on the gas valve Turn High Low switch to High Check and adjust High gas pressure see data tables Is gas pressure OK NO YES Does High neon light Isolate supply Check continuity between 4 and 1 on High Low switch Switch ok Replace High Low switch Replace gas valve PM5 Adjust gas pressure Diagram 13 1 221836B Co o Fault Finding HIGH LOW FLAME SWITCH REMOTE SWITCH KEY b BLUE bk BLACK br BROWN g y GREEN YELLOW g GREY REMOVE RED LINK IF REMOTE SWITCH IS TO BE FITTED j BOILER CONTROL THERMOSTAT 9024 AIR PRESSURE SWITCH Diagram 13 2 31 221836B 13 Fault Finding RED LINK CONTROL THERMOSTAT OVERHEAT DEMAND NEON THERMOSTAT i P C B 2 Stat 1 FUSE P C B 1 TYPE F2A b Pius V I 10 PLASTIC I IGNITION pan pk CM1 2 I P C B 6 07 OF N AIR PRESSURE I 90 SWITCH I 5Q I 7Q I GV1 2 I LOW FLAME NEON Amp Con e Lamp N 2 1 Pig I W Vrs HIGH LOW DH aie E SWITCH W wi HIGH FLAME Y Lamp CONDENSE NEON N 1 CUT OFF br b GV2 1 KEY r RED W C P C B CONNECTIONS ie STAT Pin No br BROWN p PURPLE MAIN TERMINAL STRIP CONNECTIONS b BLUE CONTROL THERMOSTAT CONNECTIONS bk BLACK y YELLOW PRINTED CIRCUIT BOARD CONNECTIONS w WHITE RE
35. he valve lifts This should be within 0 3bar 4 3lbf in2 of the preset pressure Where this is not possible a manual check should be carried out Release the cold water to initial design pressure 10 3 Initial Lighting Testing and Adjustment WARNING The multifunctional control fan and control box operate on MAINS voltage terminals will become live Check that the mains electrical supply to the boiler is switched off and that the control thermostat is turned to O see diagram 10 1 For future reference stick the self adhesive arrow indicator from the loose items pack to the data label against the rating that the boiler is going to be set to Turn on the supply at the gas service cock Loosen the burner pressure test point screw and fit a suitable pressure gauge see diagram 8 1 Turn the electrical supply on to the boiler and check that all remote controls are calling for heat The orange demand light will come on see diagram 10 1 Turn the left hand switch to High flame Turn the control thermostat knob at the right clockwise to any position between MIN and MAX see diagram 10 1 The maximum setting is about 82 C 180 F The boiler will not light between O and MIN The boiler lighting operation is now automatic The fan operates followed by an ignition spark until the burner lights on Low flame after a short period it will go to High flame the green light is on The burner will rema
36. his is quite normal and it will disappear after a short period of time Refit the electrical controls box GREEN LIGHT 5 FOR HIGH HIGH LOW CONTROL 5 FLAME CONTROL THERMOSTAT KNOB KNOB Z Ff a nD bd S GREEN LIGHT FOR LOW FLAME ORANGE DEMAND LIGHT Diagram 10 1 As ti 9023 O HIGH SETTING ADJUSTMENT BRASS NUT EG QS sy LOWER SETTING ADJUSTMENT INNER SCREW Diagram 10 2 10 Commissioning 10 5 Heating System Check that all remote controls are calling for heat Allow the system to reach maximum temperature and examine for water leaks The boiler should then be turned off and the system drained off as rapidly as possible whilst still hot Refill the system vent and again check for water soundness For sealed water systems adjust to initial design pressure The setpointer on the pressure gauge should be setto coincide with the indicating pointer The overrun thermostat will keep the pump running when the boiler shuts down so long as the temperature within the boiler is above a predetermined level When commissioning the system the boiler should be fired with the bypass fully closed on full service that is central heating and domestic hot water The system should then be balanced adjusting the pump and lockshield valves as necessary to achieve flow rates refer to Section 2 4 Having achieved a satisfactory condition
37. ht the main burner turnthe thermostat knob clockwise to any setting between MIN and MAX For longer periods turn the thermostat control knob anti clockwise until O is against the setting point and switch off the electrical supply to the boiler To relight follow the sequence given above Note If the burner goes out for any reason wait 30 seconds before relighting Condensation Pluming Like all condensing boilers this appliance will produce a plume of condensation from the flue terminal in cool weather This is due to the high efficiency and hence low flue gas temperature of the boiler 221836B 1 General 0156M FLUE TERMINAL DETAIL i e 35mm fall per metre of flue length 2 CONDENSATE DRAIN WATER CONNECTIONS GAS CONNECTION DRAIN CONNECTION CAPPED OFF 22 Diagram 1 1 Important Notice This boiler is for use only on G20 gas but may be converted for use on G31 gas L P G with an available conversion kit Energysaver 60 Kit No 444509 The boiler is delivered in one pack Wherever possible all materials and components to be used shall comply with the requirements of applicable British Standards Where no British Standard exists materials and equipment should be fit for their purpose and of suitable quality and workmanship This boiler must have fully pumped circuits but is suitable for use with open vented or sealed water systems This boiler
38. in alight until switched off by the control thermostat or other remote control The automatic lighting sequence will operate again when heat is required 10 4 Testing Gas With the boiler on proceed as follows Test for gas soundness around the boiler gas components using a suitable leak detection fluid in accordance with the current issue of BS6891 Check the burner pressure at least 10 minutes after the burner has lit refer to Data label If the main burner pressure requires adjustment see diagram 10 2 The brass nut controls the main high burner pressure 221836B 22 The centre plastic posidrive screw controls the Low burner pressure The centre plastic posidrive screw must be held in position whilst adjusting the main high burner pressure brass nut After adjustment the low pressure must be checked by turning the high low to low setting Should any doubt exist aboutthe gas rate check it using the gas meter test dial and a stop watch at least 10 minutes after the burner has lit make sure that all other gas burning appliances are off The rates are as shown in Table 2 Turnthe control thermostat knob to Off Remove the pressure gauge from the test point and refit the screw making sure that a gas tight seal is made When the control thermostat is turned to Off by hand wait at least 30 seconds before turning On again There may beaninitial smell given off from the boiler when new t
39. ing at a gauge pressure of 0 35bar above the safety valve setting 2 14 Water Makeup Provision should be made for replacing water loss from the System using a make up bottle or filling loop mounted in a position higher than the top point of the system connected through a non return valve to the return side of either the heating circuit or the hot water cylinder Alternatively provision for make up can be made using a filling loop 2 15 Filling a Sealed Water System Provision for filling the system at low level must be made Three methods are shownin diagram 2 5 There mustbe no permanent connection to the mains water supply even through a non return valve 221836B 10 METHOD 1 COMBINED om CHECK VALVE HEATING AND VACUUM SYSTEM 7 i ae SERVICING UNIONS VALVE SUPPLY STOP SUPPLY VALVE PIPE METHOD 2 TEMPORARY HOSE HEATING DOUBLE CHECK SYSTEM VALVE ASSEMBLY f SERVICING VALVE s x HOSE UNIONS ha SUPPLY STOP SUPPLY VALVE PIPE METHOD 3 CISTERN OVERFLOW HEATING PRESSURE SYSTEM SERVICING PRESSURE VALVE DOUBLE CHECK VALVE ASSEMBLY SUPPLY PIPE Diagram 2 5 3 Boiler Location NOTE The boiler may be installed in any room although particular attention is drawn to the requirements of the current issue of BS7671 with respect to the installation of a boiler in a room containing a bath or shower Any electrical switch or boiler control using
40. le to provide the duct lengths as shown in diagram 4 2 for a rear flue and diagram 4 3 for a side flue If a longer flue duct is required do not extend the ductings A 1 2 or 3metre long flue system and terminal can be supplied Make sure flue slopes 2 down towards the boiler that is 35mm fall per metre of flue length 2 0158M w REAR FLUE 10 5mm SIDE VIEW 35mm Make sure flue slopes 2 down towards the boiler that is 35mm fall per metre of flue length 2 t SIDE FLUE f FRONT VIEW Diagram 4 1 n P 221836B 12 6860 REAR FLUE LENGTHS R Wall Thickness 75mm to 442mm STD Flue pack 1m Flue pack 75mm to 953mm 2m Flue pack 75mm to 1953mm 3m Flue pack 75mm to 2933mm Diagram 4 2 6861 SIDE FLUE LENGTHS S External wall face to boiler casing STD Flue pack 80mm to 331mm 1m Flue pack 80mm to 841mm 2m Flue pack 80mm to 1841mm 80mm to 2821mm 3m Flue pack Diagram 4 3 4 Flue 4 1 Terminal Position The minimum acceptable spacings from the terminal to obstructions and ventilation openings are as shown in diagram 4 4 The boiler must be installed so that the terminal is exposed to the external air It is important that the position of the terminal allows the free passage of air across it at all times Note The flue will produ
41. llation must comply with the Building Regulations and local Water Company bylaws see also the current issue of BS5546 and BS6700 If fitting to an existing system the local authority should be informed 2 9 Sealed Water Systems The installation must comply with the appropriate requirements of the current issue of 854814 855449 BS6759 BS6798 and BS7074 Part 1 and 2 See diagram 2 4 for a suggested layout 2 Water System 2 10 Safety Valve Open vented system _ A safety valve must be fitted to a sealed system Recommended D It shall be preset nonadjustable with a lift pressure of 3bar relationship between incorporating seating of a resilient material a test device and a 450mm pump cold feed and connection for drain MIN vent The drain from the safety valve must be routed clear of any HEIGHT 22mm MIN VENT electrical fittings and positioned so that any discharge can be seen m FEED AND Lt EXPANSION 2 11 Expansion Vessel CISTERN A diaphragm type expansion vessel conforming to the current 15mm MINIMUM issue of BS4814 see also BS7074 Part 1 and 2 must be COLD FEED connected at a point close to the inlet side of the circulating pump see the diagrammatic layout diagram 2 4 unless laid 15mm MINIMUM down differently by the manufacturer BY PASS WITH The expansion vessel volume depends on the total water LOCKSHIELD VALVE system volume and the initial system design pressu
42. mains electricity should be so situated that it cannot be touched by a person using the bath or shower The electrical provisions of the Building Standards Scotland Regulations are applicable to such installations in Scotland The boiler must be mounted on a flat wall which is sufficiently robust to take its total weight see Data Table 1 3 1 Boiler Clearances The boiler must be positioned so that at least the minimum operational and servicing clearances are as shown in diagram 3 1 Additional clearances may be required around the boiler for installation purposes dependent upon site conditions 3 2 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 3 3 Room Ventilation The boiler is room sealed so when installed in a room or space a permanent air vent is not required 3 4 Cupboard or Compartment Ventilation Where the boiler is fitted in a cupboard or compartment permanent high and low level ventilation must be provided The ventilation areas required are given in Table 4 Where the installation of the boiler will be in an unusual location special procedures are necessary refer to the current issue of 856798 for guidance Make sure that the cupboard or compartment air vents are positioned to be clear of obstructions
43. n then seek medical attention FLUE SEALANT This contains cyclohexylaminosilane It may cause irritation of skin of sensitive persons Wash contact area with soap and water if irritation occurs seek medical advice It will cause irritation on contact with eyes If so wash eye with large amounts of fresh water for at least 15 minutes If irritation occurs seek medical advice If swallowed drink plenty of milk and seek medical advice CONTENTS DESCRIPTION SECTION PAGE No INSTRUCTIONS Introduction 3 FOR USE Lighting the Boiler 5 General Data 1 6 Water System 2 8 Boiler Location 3 11 INSTALLATION Flue 4 12 INSTRUCTIONS Preparation 5 14 Water and Condensate Connections 6 16 Flue Installation 7 17 Gas Connection 8 20 Electrical Connection 9 20 Commissioning 10 22 User Information 11 23 Servicing 12 24 SERVICING Fault Finding 13 26 INSTRUCTIONS Replacement Parts 14 33 Spare Parts 15 39 221836B Instructions for Use GREEN LIGHT FOR HIGH FLAME gt o 0 GREEN o LIGHT FOR LOW FLAME HIGH LOW CONTROL KNOB Qj N CONTROL THERMOSTAT KNOB min f TN max ene ORANGE DEMAND LIGHT Introduction Please read these instructions and follow them for the safe and economical use of your boiler This boiler is designed to provide central heating from a fully pumped open vented or sealed water system with a fully indirect cylinder The boiler is fully automatic in operation having
44. nection WARNING This boiler must be earthed Remove the screws as diagram 9 1 io Pull the control box forwards to release from the rear slot allow i to pivot and place into position as shown in diagram 9 1 Using PVC insulated cable to the current issue of BS6500 Table 16 and of a suitable length thread the cable through the small cable clamp and connect to the appropriate terminals see diagram 9 2 Standard colours are brown live L blue neutral N green yellow earth E The mains cable outer insulation must not be cut back external to the cable clamp When making connections make sure that the earth conductor SECURING is made of agreater length thanthe current carrying conductors SCREW 2 so that if the cable is strained the earth conductor would be the CONTROL last to become disconnected BOX It is essential that the polarity is correct LOCATING C SLOTS y p Q SS oC BS PULL 4 SLIGHTLY XA FORWARD AND UP Diagram 9 1 221836B 20 9 Electrical Connection 9 1 Pump and External Controls Connection The pump must be connected directly to the control box as shown in diagram 9 2 Any external controls must only be connected to interrupt the Red Link between terminals 1 and SL Thread the cable s through the large cable clamp in the side of the control box 9 2 Testing Electrical Checks to ensure electrical safety shoul
45. ntrols to the mains supply must be through a common isolator and must be fused 3A maximum This method of connection should be preferably by a double pole isolating switch provided it has a minimum contact separation of 3mm on both poles This should be readily accessible and preferably adjacent to the appliance It should supply the appliance only and be easily identifiable as so doing Alternatively an unswitched shuttered socket outlet and 3A fused 3 pin plug both to the current issue of BS1363 may be used provided that they are not used in a room containing a bath or shower Wiring to the boiler must be PVC insulated type to the current issue of BS6500 Table 16 1 7 Condensate The boiler condensate should if possible be discharged into the household internal draining system that is sink or washing machine drain If this is not practicable discharge can be external into the household drainage system or a purpose designed soakaway The boiler is fitted with a safety device to prevent the boiler from working if the condensate pipe gets blocked by either ice or debris It is therefore recommended that any external condensate drain pipe is insulated to prevent it freezing up Alternatively a larger diameter pipe can be used and insulated The condensate drain pipe should be checked during any servicing and any debris found removed Refer to the British Gas publication Guidance Note for the Installation of Domestic Con
46. ough the air duct terminal assembly Apply sealant to the flue duct and locate into air duct terminal see diagram 7 6 From outside place the air duct terminal assembly and flue duct into the flue hole Make sure that the flue terminal is correctly positioned and projecting the correct distance from the outside wall face see diagram 7 9 Apply sealant to the flue elbow spigot and then locate the flue and air duct terminal assembly as shown in diagram 7 3 make sure of the correct alignment of the Top Secure the air duct terminal to the flue elbow with the two self tapping screws supplied in the loose items pack then seal with the tape provided 7 5 Flue Elbow Fit the flue elbow gasket from the fittings pack to the casing top The two fan bracket securing screws should be loosened but not removed before slackening the three fan securing screws After locating the flue elbow into the outlet of the fan secure the flue elbow onto the top panel with the four M4x14 screws provided Then push fan upward making sure that the flue elbow spigot engages inside the fan outlet and compresses the gasket 17 Complete assembly by fully tightening the two fan bracket securing screws Finally tighten the three fan securing screws Fit the inner case door FAN BRACKET SECURING SCREW 2 4444 FAN SECURING SCREW 3 6862 STANDARD FLUE TERMINAL Q plus 67mm Dia
47. p wiring Replace Faulty connections between thermostat and interconnection PCB Repair 27 221836B 13 Fault Finding Before detailed checking of electrical components ensure that remote controls are calling for heat Check that the gas supply is free of obstructions and purged of air Check the overheat thermostat and fluehood thermostat have not operated Isolate the electrical supply and physically check ALL cables connections and the printed circuit board PCB fuse Check the air tubes to air pressure switch Is there 240V between L PM5 YES Is thermostat neon on YES Isolate supply NO Correct power T A T AI I rhIT supply problem NO a Isolate supply Check continuity of overheat thermostat Thermostat ok YES NO Replace overheat thermostat Check continuity of control thermostat between 3 and gt ok NO Replace control thermostat YES Check wiring and IC PCB stat plug for defects Repair or replace wiring PCB if necessary Is there continuity between and on APS YES NO I ms Replace APS Diagram 13 1 221836B 28 13 Fault Finding D Reconnect supply NO YE
48. re For any system an accurate calculation of vessel size is given in the 1150mm current issue of 887074 Part 1 MIN Ed Example For an initial system design pressure of 0 7bar the e minimum total vessel volume required is 0 063xTotal System gt ET volume e Note A higher initial design pressure requires a larger volume expansion vessel Guidance on vessel sizing is also given in the current issue of BS5449 and BS7074 Part 1 The charge pressure must not be less than the static head of the H H system that is the height of the highest point of the system U BOILER above the expansion vessel MAX The water content of the boiler is given in the Data Table 1 Diagram 2 3 2 3 LITRES 0 66 gals AIR 6 MAKE UP BOTTLE V RELEASE if required POINT AUTO I AIR NON RETURN VENT VALVE X22mm min shiu I BY PASS WITH S LOCKSHIELD Say mR SSE F OW VALVE SAFETY 2 VALVE 5 lt PRESSURE IO GAUGE RETURN Make up alternatives BOILER EXPANSION VESSEL Diagram 2 4 9 221836B 2 Water Sytem 2 12 Pressure Gauge A pressure gauge with a set pointer and covering at least 0 to 4bar 0 to 60lb in shall be fitted permanently to the system is a position where it can be seen when filling the system 2 13 Domestic Hot Water Cylinder SINGLE FEED INDIRECT CYLINDERS ARE NOT SUITABLE The hot water cylinder must be of the indirect coil type It must be suitable for work
49. relating to the electrical equipment designed for use within certain voltage limits 3 Directive 89 336 EEC on the approximation of the Laws of the Member States relating to electromagnetic compatibility INFORMATION FOR THE INSTALLER AND SERVICE ENGINEER Under Section 6 of The Health and Safety at Work Act 1974 we are required to provide information on substances hazardous to health CERAMIC FIBRE INSULATION PADS GLASSYARN These can cause irritation to skin eyes and the respiratory tract If you have a history of skin complaint you may be susceptible to irritation High dust levels are usual only if the material is broken Normal handling should not cause discomfort but follow normal good hygiene and wash your hands before eating drinking or going to the lavatory If you do suffer irritation of the eyes or severe irritation to the skin seek medical attention THERMOSTATS These contain very small amounts of xylene in the sealed phial and capillary If broken under normal circumstances the fluid does not cause a problem but in case of skin contact wash with cold water If swallowed drink plenty of water and seek medical attention CUT OFF DEVICES Cut off devices with copper phial bulb only Bulb contains activated charcoal and very small amounts of chloroddifludromethane in the sealed phial and capillary If broken under normal circumstances the fluid does not cause a problem If there is irritation to the eyes or ski
50. s in place in the flanged connection when refitting Clean the holes by blowing through Do not use a wire or sharp instrument on the holes 12 4 Spark Electrode Remove the silicone sleeving and disconnectthe ignition lead see diagram 12 9 Remove the two securing screws Withdraw the electrode taking care notto damage the insulation material Inspect and clean taking care not to damage the ceramic body When replacing make sure that the spark gap is as shown 12 5 Condensate Drain Remove the cap at the base of the condensate drain trap see diagram 12 8 and carefully flush through from the condensate collecting tray diagram 12 6 taking care not to allow any water to overflow the tray When refitting the cap make sure a water tight seal is made 4056 SECURING SCREW 2 Diagram d 12 6 Operational Checks After completing a service before fitting the casing check the inner case seal to ensure that it is in good condition renew if necessary 2 BAFFLE S O 1 Diagram 12 5 SECONDARY HEAT 9 EXCHANGER 3 PRIMARY HEAT EXCHANGER BURNER Diagram 12 6 221836B 12 Servicing o INJECTOR 2 MANIFOLD SECURING SCREW 3 SECURING SCREW 2 Diagram 12 7 GASKET g SECURING SCREW 3 CONDENSE DRAIN TRAP WASTE OUTLET Diagram 12 8 CAP SECURING S
51. sitions Diagram 5 5 15 221836B 5 Preparation BOILER TOP Sud ans FIXING POINTS 0170 7dia gas NO 16dia PLUG 12x2in 7dia gasas 3 16dia PLUG NO 12x2in 5mm 3 MOUNTING I BRACKET FIXING POINT S 9 BOILER MOUNTING BRACKET ET Diagram 5 6 O AR F m e PRESSURE 7 Vi IT TUBES CLEAR RED TUBE TUBES 4043 S exp SECURING SCREWS 3 ELECTRICAL CONNECTIONS Diagram 5 7 5 5 Boiler Preparation Lift the boiler into position above the boiler mounting bracket lowering the boiler into position at the same time locating the key hole slots of the boiler on to the securing screws when located secure the screws see diagram 5 6 6 Water and Condensate Connections 6 Water Connections Make the water connection to the heating system see diagram 6 1 The boiler has compression connections with nuts and olives supplied loose in the fittings pack to accept 28mm outside diameter copper tubing to BS2871 The 28mm connections must be used for the Energysaver 60 The right hand connection is the flow from the boiler 6 1 Condensate Connection The condensate drain connection is at the bottom right of the boiler The drain ends in a spigot which is suitable for push fit 22mm in plastic overflow pipe for example Hepworth Polypipe Uponor
52. ting compound on the external thread only to ensure gas soundness Make sure that the new O ring is in place in the flanged connection is replaced It will be necessary to purge the pipework and multifunctional control before relighting and checking the pressure refer to Commissioning 14 8 Fan Refer to Section 12 1 Heat Exchanger Cleaning Make sure that the earth connection is remade onto the replacement fan The polarity of the electrical connections is not important 14 9 Injector Refer to Servicing Section 12 3 Fit new injector as shown Note The replacement injector is supplied complete with the gas supply pipe manifold 14 10 Heat Exchanger diagram 14 8 Note To carryout the following operations it will be found more convenient if the whole of the heat exchanger and burner are removed as a unit Follow the relevant parts of Servicing Section and remove the bypass heat shield fan flue hood combustion chamber front panel heat exchanger baffle spark electrode injector and thermostat phials SECURING SCREW 4 BRACKET Fini nT 7 A Sr ES LOCKNUT HIGH LOW CONTROL Diagram 14 6 221836B Release the flexible tube from the condense drain trap this is a push fit Release union connections and the six securing screws then remove the complete assembly Heat Exchanger Secondary diagram 14 9 Disconnect the union connector Remove and fit the
53. to the best product to use Note This boiler has a totally copper water system and does not require a special inhibitor normally associated with other types of high efficiency condensing boilers If an existing system is to be reused take special care to drain the entire system including the radiators then thoroughly cleaning out before fitting the boiler whether or not adding an inhibitor 2 6 Open Vented Water System The boiler must be supplied from an unrestricted water supply taken from a feed and expansion cistern situated ata maximum height of 27metres 90ft above the boiler The cold feed must be 15mm minimum size The vent must rise continuously and be unrestricted It is important that the relative positions of the pump cold feed and open vent are as shown in diagram 2 3 221836B 3 E BOILER DRAIN POINT Diagram 2 1 Flow rate gallons minute z c 012 3 4 5 6 7 8 5 o E e T 5 Be of of 58 58 qc aoc oo 8 8 os z 0 5 10 15 20 25 30 35 40 Flow rate litres minute Diagram 2 2 TABLE 3 Design Minimum Flow Rate Flow Rate Energysaver 60 23L min 17L m 2 7 Domestic Hot Water Cylinder The domestic hot water cylinder must be of the double feed fully indirect type Not the single feed self priming type 2 8 Domestic Hot Water System Unvented Where a storage system will not have a vent to atmosphere the insta
54. two user controls high low control on the left and the control thermostat on the right see diagram 1 The high low control can set to Low during the summer months Important Notice This boiler is for use on natural gas G20 as distributed in the United Kingdom and Ireland but may be converted for use on L P G Propane G31 with the use of a conversion kit i e Energysaver 60 Kit No 444509 If your boiler has been converted to use L P G Propane the following note applys Propane cylinders are under pressure and should never be stored or used indoors residentially They should only be kept outside Under no circumstances should LPG Propane cylinders be fitted or stored in basement areas or boiler house Gas Safety Installation and Use Regulations In your interest and that of gas safety it is the Law that ALL gas appliances are installed by a competent person in accordance with the current issue of the above regulations Gas Leak or Fault If a gas leak or fault exists or is suspected the BOILER MUST BE TURNED OFF including the electrical supply and MUST NOT BE USED UNTIL THE FAULT HAS BEEN PUT RIGHT Advice help should be obtained from your installation servicing company or the local gas undertaking Diagram 1 Maintenance Servicing 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
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