Glow-worm 120CF User Manual

Instructions for Use

Installation and Servicing

T o be left with the user

Hideaway 120

G.C. No. 41 313 29

Open Flue Boiler

221758A.10.00

1369

BS 6332
BS 5258

This is a Cat I2H Appliance

Reference in these instructions to British Standards and Statutory

Regulations/Requirements apply only to the United Kingdom.

The instructions consist of three parts, User, Installation and Servicing Instructions, which includes the Guarantee Registration

For Ireland the rules in force must be used.

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

In the center pages are to be found your Guarantee Registration Card, which we recommend you complete and

If this card is missing you can obtain a copy or record your registration by telephoning the Heatcall Customer

Our Guarantee gives you peace of mind plus valuable protection against breakdown by covering the cost of:

✔

All replacement parts

❏

✔

All labour charges

❏

All call-out charges

✔

❏

to offer our customers' a Comprehensive First Year Guarantee.

return as soon as possible.

Service number 01773 828100.

REGISTER YOUR GLOW-WORM APPLIANCE

FOR 1ST YEAR GUARANTEE PROTECTION

CALL 0208 247 9857

One Contact Local Service

Customer Services:
Tel: [phone]
Fax: [phone]

Hepworth Heating Ltd.,

Nottingham Road, Belper, Derbyshire. DE56 1JT

General/Sales enquiries:

Tel: [phone] Fax: [phone]

Important Information

Notes and General Information

Please read these instructions and follow them carefully for the
safe and economical use of your boiler.

The boiler is automatic in operation, once the pilot is lit and the
controls have been set.

Glow-worm Hideaways’ are central heating boilers, to provide
heating and if required an indirect domestic hot water supply.

Gas Safety (Installation and Use) Regulations

In your own interests and that of 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.

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:

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 electrical equipment designed for
use within certain voltage limits.

3. Directive 89/336/EEC on the approximation of the Laws of
the Members States relating to electromagnetic
compatibility.Information for the Installer and Service Engineer.

Control of Substances Hazardous to Health

Under Section 6 of The Health and Safety at Work Act 1974, we
are required to provide information on substances hazardous to
health.

The adhesives and sealants used in this appliance are cured
and give no known hazard in this state.

Insulation Pads/Ceramic Fibre, 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 to the eyes or severe irritation to the skin
seek medical attention.

Boiler Thermostat

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 cases of skin contact, wash
with cold water.

If swallowed drink plenty of water and seek medical attention.

CONTENTS DESCRIPTION SECTION PAGE No.

INSTRUCTIONS

FOR USE

Introduction 3
Lighting the Boiler 4

INSTALLATION

INSTRUCTIONS

General Data 1 5
Water Systems 2 7
Flue and Ventilation 3 8
Installation 4 9
Casing Location 5 11
Electrical Wiring 6 12
Commissioning 7 13

SERVICING

INSTRUCTIONS

Servicing 8 15
Replacement Parts 9 17
Fault Finding 10 20
Spare Parts 11 24

221758A

2

Instructions for Use

Warning

Make sure that nothing obstructs the rear side grilles or
clearances. See diagram 1.2 and 1.3 for minimum clearances.

Boilers Installed in a Compartment

If the boiler is fitted in a compartment, cupboard etc., do not
obstruct the purpose built compartment vents or grille on the
boiler.

Do not use the compartment for storage purposes.

Maintenance

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 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.

It is the law that servicing is 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 inside of the front panel.

Please be advised that the ‘Benchmark’ logbook should be
completed by the installation engineer on completion of
commissioning and servicing.

All CORGI Registered Installers carry a CORGI ID card, and
have a registration number. Both should be recorded in your
boiler Logbook. You can check your installer is CORGI registered
by calling CORGI direct on :- 01256 372300.

FLUE BLOCKAGE
SAFETY DEVICE
RESET BUTTON

SETTING
POINTS

7991

THERMOSTAT
CONTROL
KNOB 'B'

PIEZO
IGNITION
BUTTON
'C'

GAS
CONTROL
KNOB 'A'

SETTING
POINT

E

Boiler Electrical Supply

WARNING. This boiler must be earthed.
The boiler must only be connected to a 230V~50Hz supply,

protected by a 3A fuse, maximum.
All wiring must be in accordance with the current issue of

BS7671.

2

Heat resistant cable having a conductor size of 0.75mm

0.22mm), to BS6500 Table 16 must be used.

, (24/

To Connect an Electrical Plug

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 brown must be connected to the terminal

marked “L” or Red.
The wire coloured blue must be connected to the terminal

marked “N” or Black.
The wire coloured green and yellow must be connected to the

terminal marked “E”, Green or the earth symbol

.

GAS CONTROL KNOB
= OFF

= PILOT/IGNITION
= MAIN BURNER

Diagram 1

3 221758A

Instructions for Use

Safety Device

This appliance is fitted with a flue blockage safety device which
will shut down the appliance in the event of abnormal flue
conditions. This device is NOT a substitute for an independently
mounted Carbon Monoxide detector.

The safety device is reset, after three minutes, by pushing in the
button shown in diagram 1.

Shut down can occur during certain climate conditions, but if it
recurs the chimney flue and air inlet into the room must be
checked and any problems found corrected by a competent
person, before the boiler is used again.

To Light the Boiler

WARNING. If the pilot light goes out for any reason, do not
attempt to relight until three minutes have gone by.

Remove the door by pulling forwards with the fascia at the top.
Lift up to free from bottom side lugs.

Refer to diagram 1 to identify the controls.
Check that the mains electrical supply to the boiler is switched

OFF.
Check that the Flue Blockage Safety Device has not operated,

that is, the button is in. Refer to Safety Device instructions.
Push in slightly and turn gas control knob “A” clockwise until

'is against its setting point.

'
Turn thermostat control knob “B” anticlockwise until “O” is

against its setting point.
Push in slightly and turn gas control knob “A” anticlockwise until

' is against its setting point, then push fully and hold in.

'
Push and release piezo ignition button “C” until the pilot burner

lights.
Air may be present in the supply pipe so the lighting of the pilot

may need to be repeated until all the air has been expelled.
When the pilot is alight, view through window “E”, keep gas

control knob “A” fully pushed in for about 15 seconds, then
release.

If the burner fails to stay alight, wait three minutes, then repeat
the lighting procedure only now keep control knob “A” depressed
for a little longer before releasing. The Flue Blockage Safety
Device may also need resetting, refer to instructions above.

If the gas control knob “A” is turned to '
prevents it being turned on again for a short period. No attempt
should be made to relight the pilot for at least three minutes.

Make sure that the pilot is alight and stable, then switch on the
electrical supply.

Press in and turn gas control knob “A” anticlockwise until '
is against its setting point.

Set any remote controls to call for heat.
Turn the boiler thermostat knob “B” clockwise until “MAX” is

against its setting point and the main burner will light. Adjust
thermostat to required setting between “MIN” and “MAX”.
“MAX” is about 82

Refit the door by fitting the hooked runner at the bottom into the
slot in the side panels and pushing onto the studs.

o

C (180oF).

', a safety lock

To Turn the Boiler Off

For short periods. Turn the boiler thermostat control knob “B”
anticlockwise to “O”. The pilot will remain alight. To relight the
main burner turn the thermostat control knob “B” clockwise to
the desired setting between “MIN” and “MAX”.

For longer periods. Push in slightly and turn gas control knob
“A” fully clockwise until “
thermostat control knob “B” anticlockwise to “O”. Isolate the
boiler from the electrical supply. Follow the full lighting procedure
to relight.

Refer also to “Protection Against Freezing”.

” is against its setting point. Turn

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 the local gas undertaking or your installation/servicing
company.

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. If an immersion heater is fitted in the domestic hot
water cylinder make sure it is switched off.

Sheet Metal Parts

WARNING. This appliance contains metal parts (component)
and care should be taken when handling and cleaning, with
particular regard to edges.

Cleaning

Keep the casing clean by wiping it over occasionally with a
damp soapy cloth and dry with a polishing cloth.

Do not use abrasive cleaners.

Replacement Parts/Boiler Identification

If replacement parts are required apply to your local supplier or
gas undertaking. Please quote the name of the boiler and its
serial number which can be found on the data label positioned
on the boiler top, to the rear of the inclined flueway cleaning
door.

Clearance

Minimum clearances must be left around the boiler as shown in

'

diagram 1.2 and 1.3.

221758A

4

1 General

C

L

A

✽

N

C

L

✝ F(MIN.)

FLUE

C

M

L

B

D

J(MIN.)

C

E

GENERAL DIMENSIONS - given in millimetres (Approx. inches)

ABCDE FGHJK LMN

FLUE

L

L(MIN.)
G(MIN.)

H

K

(MIN)

✝ A SPECIAL TOP CASING

TO SUIT 600mm (23

5

/

in.)

8

WORKTOPS IS AVAILABLE

GAS CONNECTION

1

Rc

1

/

(

/

2

2

in. B.S.P.T.)

WATER CONNECTIONS
Rc1 (1in. B.S.P.T.)

WATER CONNECTIONS Rc1
reduced with DISTRIBUTOR

3

TUBE to Rc

3

/

(

/

4

in. B.S.P.T.)

4

(pumped return)

✽ INSIDE DIAMETER OF

SOCKET FOR 152mm (6in.)
NOMINAL DIAMETER FLUE
TO BS567

Diagram 1.1

1307

mm 474 214 598 294 400 533 3 300 445 121 89 900 172
in. 1811/1681/2231/2111/2153/421

1

/8113/4171/243/431/2351/263/

Sheet Metal Parts

Warning. When installing or servicing this boiler care should be
taken when handling sheet metal parts, to avoid the possibility
of personal injury.

Important Notice

This boiler is for use only on G20 gas.
Wherever possible, all materials, appliances and components

to be used shall comply with the requirements of British
Standards.

Where no British Standards exist, materials and equipment
should be fit for their purpose and of suitable quality and
workmanship.

1.1 Data

Approx.weight of boiler: 140kg (310 lb)
Water content: 11.7litre (2.57 gal)
Gas connection: Rc1/2(1/2 BSP)
Water connection: Rc1 (1inch BSP)
Electrical supply: 230V - 50Hz fused at 3A
Burner: Aeromatic

The Seasonal Efficiency Domestic Boilers UK (SEDBUK) is
73%.

The value is used in the UK Government’s Standard Assessment
Procedure (SAP) for energy rating of dwellings. The test data
from which it has been calculated have been certified by B.S.I.

1.2 Range Rating

This boiler is range rated and may be adjusted to suit individual
systems. The table gives settings and outputs.

The boiler input is supplied preset to maximum and should be
adjusted to suit system requirements.

RANGE RATING

NOMINAL
HEAT INPUT
(GROSS)

NOMINAL
HEAT
OUTPUT

BURNER
SETTING
PRESSURE
(HOT)

INJECTOR

1.3 Statutory Requirements

The installation of this 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, Local Water Company Byelaws, The Building
Standards (Scotland) Regulations, applicable in Scotland, The
Health and Safety at Work Act, The Control of Substances
Hazardous to Health, The Electricity at Work Regulations and
any applicable local regulations.

Detailed recommendations are contained in the current issue of
the following British Standards and Codes of Practice:

BS6798, BS5440 Part 1 and 2, BS5449, BS6700, BS6891,
BS5546, BS7478, BS7593, BS7671.

Manufacturer’s instructions must not be taken as overriding
statutory requirements.

HIDEAWAY 120

kW

37.10 40.5 43.96

126,600 138,200 150,000

Btu/h

kW

29.31 32.24 35.17

Btu/h

100,000 110,000 120,000

mbar

in.w.g

4

min medium max

9.4 11.1 12.9

3.8 4.4 5.2

205746

5 221758A

1 General

1.4 B.S.I. Certification

This boiler is certificated by B.S.I. for safety and performance.
It is, therefore, important that no alteration is made to the boiler
unless approved, in writing, by Hepworth Heating Ltd.

Any alteration not approved by Hepworth Heating Ltd., could
invalidate the B.S.I. certification, boiler warranty and could also
infringe the statutory requirements.

1.5 Gas Supply

The gas installation shall be in accordance with the current
issue of BS6891.

The supply from the governed meter must be of adequate size
to provide a steady inlet working pressure of 20mbar (8in wg) at
the boiler.

On completion test the gas installation using the pressure drop
method and suitable leak detection fluid, purge in accordance
with the current issue of BS6891.

1.6 Electrical

Warning. This boiler must be earthed.
The electrical installation must be carried out by a competent

person. All external components must be of the approved type
and must be connected in accordance with the current issue of
BS7671 and any local regulations which may apply.

Connection of the boiler and any system controls to the mains
supply should be through a 3A fused double pole isolating
switch, having a minimum double pole contact separation of
3mm, serving only the boiler and system controls.

2

Heat resistant flexible cable of at least 0.75mm
issue of BS6500 Table 16 must be used for all connections
within the boiler casing.

, to the current

1.7 Boiler Location

The boiler must not be installed in a room used or intended to
be used as sleeping accommodation or a room containing a
bath or shower.

This boiler is not suitable for installation out of doors.
The boiler must stand on a level floor, conforming with local

authority requirements and building regulations. The base
temperature is within the requirements of the current issue of
BS5258. The boiler may be stood on a wooden floor but a metal
plate is required to protect plastic tiles and similar floor coverings.

Suitable clearance needs to be available at the sides of the
boiler to ease connection of pipework. The actual clearances
will vary according to site conditions.

When the boiler is to be installed level with work surfaces,
minimum clearances to fixtures, walls and the like should be
provided, see diagram 1.2.

To ease minimum clearances it may be necessary to modify
units or fixtures.

A front access clearance should be provided as shown in
diagram 1.3.

The minimum gap behind the top casing is dimension “G” in
diagram1.1. The boiler can be sited further away from the wall
if required to align with kitchen units.

Combustible wall material must be 25mm (1in) away from flue
components.

A special top casing, part number 425562 can be bought, to
enable boiler casings to be arranged flush with 600mm (23
deep worktops.

Where the installation of the boiler will be in an unusual location,
special procedures may be necessary, the current issue of
BS6798 gives detailed guidance on this aspect.

5

/8in)

A compartment used to enclose the boiler must be designed
and constructed specifically for this purpose. An existing
cupboard or compartment modified for the purpose may be
used. Details of essential features of cupboard and compartment
design are given in the current issue of BS6798.

Make sure that nothing will obstruct the side clearances or side
grilles. If installing the boiler in a compartment make sure that
openings and vents are not obstructed.

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.

WORKTOP

254

W

(10 in.)

BOILER

Y

BOILER

Diagram 1.2

Diagram 1.3

Z

0911

X

W

X

BOILER

W (MIN) X (MIN) Y (MIN) Z (MIN)
mm in mm in mm in mm in

NOT PERMITTED 624 245/8 75 3

TOP & SIDE CLEARANCES

WALL OR
FIXTURE

530 (21in.)

FRONT CLEARANCE

1308

221758A

6

2 Water Systems

2.1 Water Pressure Head

This boiler must not be connected to a sealed water system.
This boiler shall only be connected to an open vented cistern

water supply, with a minimum head of 1metre (39in) and a
maximum of 27metre (90ft).

2.2 Inhibitor

Attention is drawn to the current issue of BS5449 and BS7593
on the use of inhibitors in central heating systems.

If an inhibitor is to be used in the system contact should be made
with a manufacturer so that they can recommend their most
suitable product.

If using in an existing system take special care to drain the entire
system, including the radiators, then thoroughly cleaning out
before fitting the boiler, whether or not adding an inhibitor.

2.3 Gravity Domestic Hot Water and Pumped
Central Heating

It is recommended that a cylinder thermostat is used to prevent
the stored water temperature becoming too high when the
heating pump is off.

The domestic hot water primary flow and return must be 28mm
od. The installation must comply with the current issue of
BS5546 and BS6700, see diagram 2.1.

If the above conditions cannot be met, it is suggested that a fully
pumped system is used.

2.4 Pumped Central Heating and Domestic Hot
Water

Where a single flow and return is taken from the boiler, a
minimum static head of 1metre (39in) must be provided between
the water level in the cold water cistern and the centre of the
waterway, see diagram 2.2.

2.5 Circulation Pump

Normally the pump should be set to give a temperature difference

oC

(20oF), across the boiler. At the appropriate flow rate the

of 11
resistance through the boiler can be found by reference to the
pressure loss graph, diagram 2.3.

Use a pump with integral valves or fit valves as close to the
pump as possible.

REFER TO BS 5546

22mm VENT

15mm COLD FEED

INDIRECT
CYLINDER

(Shown with
27metres
Max.

DRAIN OFF
COCK

recommended

thermostat and valve).

28mm

PUMP

BOILER
C

Distributor tube in
pumped return
connection

L

PUMPED HEATING AND GRAVITY
DOMESTIC (DIAGRAMMATIC)

22mm VENT

15mm
COLD FEED

1 metre
MIN.
27metres
MAX.

DRAIN OFF
COCK

TO INDIRECT
CYLINDER

PUMP

BOILER
C

L

Distributor tube in

pumped return

connection

FULLY PUMPED SYSTEM
(DIAGRAMMATIC)

0869

To Heating
Circuit

Diagram 2.1

0870

To Heating
Circuit

Diagram 2.2

2.6 Domestic Hot Water Cylinder

For all systems supplying domestic hot water the cylinder must
be indirect.

2.7 Safety Valve

A safety valve need not be fitted to an open vented system.

2.8 Draining Tap

A drain tap must be fitted at the lowest points of the system
which will allow the draining of the entire system, including the
boiler and domestic hot water cylinder.

Draining taps should be to the current issue of BS2879

FLOW RATE (GALLON/MINUTE)
012345678 109

1.2

1.0

0.8

40

30

0.6
20

0.4

0.2

WATER PRESSURE LOSS

(metre HEAD OF WATER)

0

10

0

20 30

40 50

10

WATER PRESSURE LOSS

(INCHES HEAD OF WATER)

0

FLOW RATE (LITRES/MINUTE)

PRESSURE LOSS OF BOILER

Diagram 2.3

7 221758A

1370

3 Flue and Ventilation

Important Note

The boiler is fitted with a Flue Blockage Safety Device, which
will shut down the boiler if there is an unacceptable spillage of
products at the draught diverter.

This safety device MUST NOT under any circumstances be
interferred with or put out of action. The safety device must only
be replaced with the Glow-worm parts.

3.1 Flue

The integral draught diverter on the Hideaway range of boilers
makes the combustion performance independent of conditions
in the secondary flue, but in common with other fuels an efficient
flue is necessary to make sure of a trouble free installation.

The flue must be at least equivalent to 1m vertical.
The boiler flue socket is designed to take flue pipes to the

current issue of BS567. If a flue pipe to BS715 is to be used, an
adapter must be fitted to the boiler flue socket, as diagram 1.1.

The flue must be in accordance with the current issue of
BS5440 Part 1.

3.2 Flue Guidelines

The flue should be kept as short as possible. Horizontal or very
shallow runs of the flue should be avoided as they encourage
local cooling.

Always choose a flue route which will cause the least cooling of
the flue.

There should be a vertical rise of at least 600mm (2ft) before
using a bend. 90

End with a certificated flue terminal, preferably above ridge
height, but at least above the eaves of a pitched roof.

An existing chimney must be thoroughly swept and all debris
cleared away before lining.

o

elbows should not be used.

3.3 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. If in doubt seek advice from the local
gas undertaking or Hepworth Heating Ltd.

3.5 Ventilation for Boilers Installed in a
Cupboard or Compartment

When the boiler is fitted in a cupboard or compartment, high and
low level purpose designed, permanent openings must be
provided to supply air for combustion and compartment
ventilation.

The air vents must have minimum areas in accordance with
“Compartment Air Vent B”. The figures quoted refer to the
minimum acceptable effective area.

Both the high and low level openings must communicate with
the same room, or must both be on the same wall to outside air.

If air vent grilles are fitted to a cavity wall, the opening through
the wall must be ducted.

Where ventilation air to a compartment is taken from a room or
space, then the room or space must be fitted with a ventilation
opening as specified in “Air Vent Table A”.

For information regarding compartment requirements refer to
the appropriate section of the current issue of BS6798.

AIR VENT TABLE 'A' FOR

ROOM/SPACE INSTALLATIONS

2

EFFECTIVE
AREA OF VENT

COMPARTMENT AIR VENT TABLE 'B'

COMPARTMENT
VENTILATION
REQUIREMENTS

VENTILATION
FROM ROOM
OR SPACE

FROM
OUTSIDE

cm

in

171

2

26

HIGH LEVEL LOW LEVEL

VENT AREA VENT AREA

405cm262in2810cm2123in

202cm231in2405cm262in

2

2

3.4 Ventilation for Boiler Installed in a Room
or Space

If the boiler is to be installed in a room or space a purpose
designed permanent ventilation opening, to supply air for
combustion, must be provided on an outside wall to external air,
refer to the current issue of BS5440 Part 2 for details.

The opening may be directly into the room or the space
containing the boiler, or an outside wall of an adjacent room or
space which has an internal permanent air vent, of the same
size, into the room or space containing the boiler.

Do not ventilate through a bedroom, bedsitting room, private
garage or a room containing a bath or shower.

When the boiler is installed in a room or internal space already
containing other fuel burning appliances then the air supply of
such appliances must be taken into account.

The ventilation opening areas are given in “Air Vent Table A”.
The figures quoted refer to the minimum acceptable effective
area.

221758A

3.6 Extract Fans

If an extract fan is fitted in the premises, there is a possibility that
if adequate inlet openings are not provided, spillage of the
products from the boiler could occur.

When openings are fitted in accordance with the current issue
of BS5440 Part 2 and this section, extract fans should not cause
down draught, but where such fan installations are found, a
spillage test must be carried out in accordance with the current
issue of BS5440 Part 1 and any corrective work done.

8