221724B.10.00
Installation & Servicing Instructions
To be left with the user
Glow-worm 56/3pp
Back Boiler Unit
G.C. No. 44 047 03A
This Back Boiler Unit Is To Be Used Only With The Glow-worm Mk.3 Fire Front Range
6824
One Contact Local Service
This is a Cat I2H Appliance
Customer Services:
Tel: (01773) 828100
Fax: (01773) 828070
Nottingham Road, Belper, Derbyshire. DE56 1JT
Tel: (01773) 824141 Fax: (01773) 820569
Hepworth Heating Ltd.,
General/Sales enquiries:
1 General
The instructions consist of three parts, Installation and
Servicing Instructions for the Back Boiler Unit, Installation
and Servicing Instructions for the Fire Front and Instructions
for Use, 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.
This boiler is for use only with a specially designed Glowworm Gas Fire Front, see Table 1.
This boiler is NOT suitable for fitting to a precast flues.
The boiler is delivered in one pack which contains all the
parts necessary for the installation.
If installing the back boiler unit and fire front at the same time
please read both sets of instructions before starting.
1 General Notes and Information
IMPORTANT NOTICE
The back boiler is fitted with a safety device which will shut it
down if there is a lack of oxygen. If the back boiler shuts
down frequently for no apparent reason. The first things to
be checked are the chimney and air inlets into the room.
Any problems found must be put right, by a competent
person, before the back boiler is used again.
This back boiler is for use only on G20 gas.
Wherever possible, all materials, appliances and
components to be used shall comply with the requirements
of applicable British Standards.
Where no British Standard exists, materials and equipment
should be fit for their purpose and of suitable quality and
workmanship.
Sheet Metal Parts
WARNING. When installing or servicing this back boiler care
should be taken when handling the edges of sheet metal
parts to avoid any possibility of personal injury.
1.1 Statutory Requirements
The installation of this back boiler unit must be carried out by
a competent person in accordance with the current issue and
relevant requirements of:
Manufacturer’s instructions, supplied.
The Gas Safety (Installation and Use) Regulations, The
Building Regulations, The Building Standards (Scotland)
Regulations (applicable in Scotland), Local Gas
Undertaking, Byelaws of the Local Water Company, The
Health and Safety at Work Act, 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,
BS6891, BS5449, BS5546, BS6700, BS5871, BS5440 Part 1
and 2, BS6798, BS1251, BS7478, BS7593, BS7671.
Manufacturer’s notes must not be taken as overriding
statutory requirements.
1.2 Data
Gas connection Rc1/2 (1/2inBSPT)
Water connection Supplied in fittings pack
Electrical supply 230V~50Hz fused 3A
Weight, about 35kg
Water content 3.11Litres
Injector 3.6mm
Dimensions are given in millimetres (except as noted).
Data Label: Front, centre on base.
The Seasonal Efficiency Domestic Boilers UK (SEDBUK)
is 74.6%.
The value is used in the UK Government’s Standard
Assessment Procedure (SAP) for energy rating of dwellings.
The test data from which it has been calculated have been
certified by B.S.I.
1.3 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 back 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.
1.4 Electrical Supply
WARNING. This back boiler must be earthed.
All system components shall be of an approved type and
shall be connected in accordance with the current issue of
BS7671 and any applicable local regulations.
Connection of the back boiler and system controls to the
mains supply should be through a double pole isolating
switch, fused 3A having a minimum contact separation of
3mm in both poles.
Alternatively, a fused 3A 3 pin plug and unswitched socket
outlet to the current issue of BS1363 may be used.
o
Wiring to the back boiler must be PVC (85
to the current issue of BS6500 Table 16, not less than
0.75mm
2
(24/0.20mm).
C) insulated type
1.5 Site Requirements
Refer to diagram 1.1 for dimensions appropriate to the back
boiler.
For all types of installation a standard sized builder’s
opening is required, see diagram 1.2.
It is important that the opening is cleared of debris and
mortar.
It is recommended that the access hole for pipework into the
fireplace or builder’s opening is either at the left hand or right
hand side of the chimney breast. If access is required at
both sides then it may be necessary to prepare some of the
connections before fitting the back boiler into the builder’s
opening.
The prepared base for the back boiler must be level.
NOTE: For wider openings corner infills may be required
when fitting some fire fronts. The infills are for cosmetic
reasons only, see diagram 1.3.
Refer to Table 2 for dimensions of fire front fixing wall face
which must be true.
221724B
2
1 General
INSIDE DIAMETER
FIRE FIXING WALL FACE
C
L
E
T
G
FLUE
R
N
F
S
D
OF SOCKET FOR
125mm (5in)
NOMINAL DIAMETER
FLUE
P
B
H
C
L of Flue
WATER
CONNECTIONS
22mm COPPER PIPE
GAS CONNECTION
RC (1/2 in BSPT)
A
L
6837
C
M
SIDE ELEVATION
OVERALL DIMENSIONS
Dimension A B C D E F G H J K L M N P R S T
56/3pp 550 400 338 337 245 130 3 146 177 174 60 457 65 530 80 50 490
RANGE RATING TABLE
Minimum Medium Maximum Maximum
RANGE RATING
Brown Ember 3 Miami 3
J
FRONT ELEVATION
Black Ash 3 Melody 3
Saxony 3
HEAT
INPUT
(NETT)
HEAT
OUTPUT
HOT
BURNER
PRESSURE
kW
Btu/h
kW
Btu/h
mbar
in.w.g
10.8 14.5 17.6 18.2
36,950 49,550 59,900 62,150
9.4 12.9 15.8 16.4
32,000 44,000 54,000 56,000
5.1 9.2 13.7 14.8
2.0 3.7 5.5 5.9
K
J
Diagram 1.1
INJECTOR
MARKING
3.6 Pt. No. 230208
3
221724B
1 General
1.6 Water System - Open Vented
This back boiler can be used on an unrestricted open vented
system with the water supply taken from a feed and
expansion cistern, having a head between 1m (3ft3in)
minimum and 27m (90ft) maximum.
Diagrammatic layouts of systems are shown in diagram 1.4
and 1.5.
1.7 Sealed Water System
A kit and instructions, part number 459033, is available to
enable the back boiler to be used on a sealed water
system.
Please give the serial number of the back boiler when
ordering the kit.
1.8 Hot Water Cylinder
The back boiler is suitable for open vented systems using an
indirect cylinder (including single feed self priming type). The
indirect cylinder must be fitted to the manufacturer’s
recommendations and the system must conform to the
requirements of the current issue of BS5546 and BS6700.
It is recommended that the indirect cylinder be fitted with
some form of temperature control.
1.9 Frost Protection
If the position of the back boiler is such that it may be
vulnerable to freezing it should be protected as specified in
the current issue of BS5422.
It is also recommended that a frost protection thermostat is
fitted.
1.12 Back Boiler Location
This back boiler MUST NOT be installed in a private garage
or in a room containing a bath or shower or in a room used
or intended to be used as sleeping accommodation.
TABLE 2
Dimensions
for minimum
FIRE TYPE
flat area
(no fixtures)
X Y X Y
Miami 3 BBU 642 698 750 836
Melody 3 BBU 642 698 750 836
Black Ash 3 BBU 700 660 840 890
Brown Ember 3 BBU 795 707 905 892
Saxony 3 BBU 700 625 840 860
ALL DIMENSIONS IN MM
Y
C
L
PREPARED
BASE
FRONT
OPENING
Dimensions
for fixture or
surround
protection
clearance
3013
X
1.10 Draining Tap
A draining tap must be provided at the lowest point of the
system which will allow the entire system, the back boiler
and hot water cylinder to be drained.
Draining taps shall be to the current issue of BS2879.
1.11 Safety Valve
A safety valve need not be fitted to an open vented system.
TABLE 1
FIRE TYPE
Miami 3 BBU 37-047-04A 37-047-07A
Melody 3 BBU 37-047-06A
Black Ash 3 BBU 37-047-08
Brown Ember 3 BBU 37-047-02A
Saxony 3 BBU 37-047-09
G.C No.
Teak Mahogany
C
PREPARED
BOILER
BASE
A B C
Miami 3 BBU 350 405 to 580 560 to 590
Melody 3 BBU 350 405 to 580 560 to 590
Black Ash 3 BBU 350 406 to 460 560 to 590
*Brown Ember 3 BBU 350 406 to 580 560 to 590
Saxony 3 BBU 350 406 to 460 560 to 590
FRONT OPENING
A
B 405 min.
Diagram 1.2
6302
221724B
4
1 General
6408
* CORNER IN-FILL
OPENING
(not required to be
full depth of opening)
405 mm. MIN.
Diagram 1.3
1.13 BSI Certification
FRONT
This appliance is certificated to the current issue of BS6332
Part 1 invoking the current issue of BS5258 Part 8 for safety
and performance. It is, therefore, important that no alteration
is made to it without permission, in writing, from Hepworth
Heating Ltd.
Any alteration that is not approved by Hepworth Heating Ltd.,
could invalidate the BSI Certification of the boiler, warranty
and could infringe the current issue of the Statutory
Requirements.
CE Mark
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 Member States relating to electromagnetic
compatibility.
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 for Regulation 5 certified by: Notified
body 0086.
Product/production certified by: Notified body 0086.
1.14 Inhibitor
Attention is drawn to the current issue of BS5499 and
BS7593 on the use of inhibitors in central heating systems.
If an inhibitor is to be used, contact a manufacturer for their
recommendations as to the best product to use.
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.
28mm
IMPORTANT
DIMENSION
NOT LESS
THAN 145mm
FLOW
DISTRIBUTOR
TUBE IN RETURN
CONNECTION
RETURN
INDIRECT
CYLINDER
22mm
CENTRAL
HEATING
RETURN
BOILER
22mm
CENTRAL
HEATING
FLOW
27 METRES
C
L
PUMPED HEATING &
GRAVITY DOMESTIC HOT
WATER (DIAGRAMMATIC)
Diagram 1.4
22mm MIN
OPEN VENT
MANUAL
AIR VENT
INDIRECT
CYLINDER
1 metre MIN
27 metres MAX
15mm
COLD
FEED
PUMP
150mm MAX
BOILER
The COLD FEED PIPE may be connected to the flow
pipe, adjacent to the open vent pipe as shown .
(THERE MUST ALWAYS BE A COLD WATER PATH
TO THE RETURN CONNECTION Of THE BOILER.)
C
L
HEATING
CIRCUIT
6242
MAXIMUM
7218
FULLY PUMPED SYSTEM
(DIAGRAMMATIC)
5
Diagram 1.5
221724B
2 Types of Installation
2.1 With Non-combustible Hearth
The back boiler must be installed level with the hearth or
above it, see diagram 2.1.
For minimum dimensions of a hearth see diagram 2.1.
2.2 Combustible Hearth
If the hearth is existing and made of a combustible material
the back boiler must be installed to the dimensions in
diagram 2.2.
Dimensions X, Y, and Z refer to
Fire Installation Instructions
PREPARED
BOILER
BASE
'X' mm MIN
HEARTH
2.3 With Surround
The combined thickness of the surround and lintel must be
checked, to make sure that the back boiler can be positioned
within the opening to allow easy connection of the flue into
the back boiler flue socket, see diagram 2.3.
The surround requires a minimum opening for access as
shown in diagram 1.2.
2.4 Wall Mounted - that is - Without Surround
or Hearth
If there is to be any combustible material beneath the fire
front, for example, carpet then the base of the builder’s
opening must not be less than 75mm above the floor
covering as shown in diagram 2.2.
The builder’s opening, with lintel must have minimum
dimensions as shown in diagram 1.2 and 2.3.
FIRE FIXING
5423
350mm
MIN.
WALL FACE
N.B. *Minimum dimension.
This dimension refers to
minimum clearance after
carpet or any floor
covering has been fitted.
PREPARED BASE
TOP OF CARPET,
FLOOR COVERING
OR
COMBUSTIBLE
HEARTH
1590
'Y' mm
165mm
MAX
350mm
MIN
'Z' mm
FIRE FIXING
WALL FACE
PREPARED BASE
TOPS OF HEARTH
MUST NOT BE
ABOVE PREPARED
BASE
13mm MIN
NON-COMBUSTIBLE
MATERIAL
Diagram 2.1
50mm
MIN
COMBUSTIBLE HEARTH / WALL
MOUNTED INSTALLATIONS
350mm MIN
FIRE FIXING
WALL FACE
FLUE
PIPE
*165mm
MAX
*NOTE
This dimension can
be increased up to
190mm if builder’s
opening depth is at
least 375mm deep
*75mm
Diagram 2.2
6838
Diagram 2.3
221724B
6
3 Flue and Ventilation
3.1 General
The general recommendations of the current issue of
BS5440 Part 1 should be followed.
In all cases the flue should be lined, preferably with a flexible
liner.
It is essential that the flue has an equivalent height of at least
2.5m (8.2ft) measured from the flue connection on the
appliance. The first 600mm, at least, above the draught
diverter must be vertical.
The flue socket is designed to take flue pipe to BS567. If
flue pipe conforming to a different standard is used a suitable
adapter must be fitted and secured to the flue socket.
A flexible flue liner may be used, with connection to the back
boiler flue socket made with a short vertical piece of flexible
liner, see diagram 3.2.
The existing flue may not be completely sound.To prevent
any possibility of leakage, additional sealing MUST be
carried out between the base of the chimney and the flue
liner.
The end of the liner at the chimney top must be adequately
sealed and clamped, using proprietary fittings suitable for the
flue liner used, see diagram 3.1.
The flue should, preferably, end above ridge height but at
least above the eaves of a pitched roof. Use a certificated
terminal.
If the flue is to pass through or near any combustible material
it should be installed in accordance with the current issue of
BS5440 Part 1. If in doubt seek advice from the local gas
undertaking or Hepworth Heating Ltd.
SEALING AND
CLAMPING
PLATE
AIR
SPACE
150mm (6in) plug of Mineral Wool or similar
SEALING
PLATE
600mm
6197
3.2 Existing Chimney
An existing brick chimney must be thoroughly swept and all
debris cleared away before lining.
Remove any register plates, dampers and the like.
Alternatively it may be locked in the open position.
A flexible flue liner is preferred but a rigid liner may be used,
with connection to the back boiler flue socket made with a
short vertical piece of flexible liner, see diagram 3.2.
Any air supply that enters the builder’s opening other than by
the front opening, that is underdraught openings and the like
must be completely sealed off.
The sealing plate also prevents debris falling and gives the
flue better insulation, reducing the possibility of
condensation, see diagram 3.1.
Check the flue system efficiency before installing the back
boiler.
3.3 New Chimney
A newly built chimney can be lined with a moisture resistant
lining, such as salt glazed pipe, of an appropriate diameter
as specified in the Building Regulations
In the case of a salt glazed lined flue, it is recommended that
a short vertical length of flue pipe, preferable flexible metallic
be used, fixed and sealed to the back boiler flue socket,
made good with approved packing and parged with fire
cement, see diagram 3.2.
BACK
BOILER
UNIT
Existing Flue Fitted with
Approved Lining
FLEXIBLE
LINER
Diagram 3.1
RIGID
FLUE
LINER
APPROVED
SEAL
7194
BACK BOILER
Diagram 3.2
7
221724B
3 Flue and Ventilation
If a flue and false chimney breast are to be constructed all
openings for pipework to upper floors etc., must be sealed.
The only opening for the back boiler must be at the front,
being of the dimensions as shown in diagram 1.2.
If a specially built compartment is constructed for the back
boiler, it must conform to the requirements of the current
issue of BS5440 Part 1 and BS5871.
The flue should, preferably, end above ridge height but at
least above the eaves of a pitched roof. Use a certificated
terminal.
3.4 Ventilation - Back Boiler and Fire Front
It is important that the room in which the back boiler unit is
installed has adequate air inlets to ensure correct operation
as specified in the current issue of BS5440 Part 2.
Ventilation requirement for this back boiler is:
2
(13.5in2)
87cm
This ventilation area takes into account the total requirement
of the back boiler unit and any of the specially designed gas
fire fronts.
The ventilation openings may communicate direct with
outside air or with an internal room or space (such as a hall)
which itself is provided with a permanent air vent of the same
effective area. The permanent air vent should be in a
position which minimizes nuisance to occupants due to
draughts.
This vent must NOT be placed in the builder’s opening.
If the appliance is to be installed in a room already containing
another fuel burning unit, the air supply required for this other
unit MUST be added to the figure above.
Any air vent taken through a cavity wall must be ducted.
3.5 Extract Fans
If an extract fan is fitted in the premises, there is a possibility
that if adequate air inlet openings are not provided spillage of
the products of combustion could occur.
When openings are fitted in accordance with the
recommendations of the current issue of BS5440 Part 2,
extract fans should not cause spillage.
Where such a fan installation is found, a clearance of
products test must be conducted as described in the fire front
Installation Instructions.
This test must be carried out with the back boiler fitted with
its fire front.
See also Section 6.3 of these instructions.
221724B
8
4 Installation
4.1 Preparation
Remove draught diverter assembly, flueway baffles and
fittings pack from carton.
Check contents of fittings pack against packed list.
Remove back boiler body assembly from carton.
4.2 Water Connections
IT IS EXTREMELY IMPORTANT THAT NO SERVICE
PIPES ARE ROUTED IN FRONT OF THE BOILER. If the
builder’s opening was previously used for solid fuel all
pipework within should be protected with PVC tape or equal.
Pipework passing through walls of the opening should be
sleeved and made good.
The two heat exchanger connections are supplied in the
fittings pack and MUST be used, see diagram 4.1.
NOTE: Take care when soldering the copper connections not
to damage the sealing washers.
4.3 Pumped Heating with Gravity Domestic
Hot Water
NOTE: The draught diverter assembly and capillaries are
shown to aid plumbing, but would not be fitted at this stage.
All pipework must comply with the current issue of BS5546.
The domestic hot water flow and return pipes must be
28mm.
Refer to diagrams 1.3 and 1.4 for a diagrammatic layout.
If it is necessary to route pipework from both sides of the
builder’s opening, it is recommended that the heat exchanger
is positioned on the combustion chamber so that the gravity
circuits exit on the same side as the boiler connections.
If the heat exchanger connections are opposite hand to that
required, the heat exchanger can be turned, as follows,
remove the four screws securing the heat exchanger to
combustion chamber, see diagram 4.2. Turn heat
exchanger, refit the four screws.
It is recommended that pumped heating connections are prepiped as in diagram 4.4.
Note: The diagram 4.4 shows two methods “A” and “B” of
plumbing the flow pipe.
The central heating return must have the injector fitted on
both methods “A” and “B”, see diagram 4.4 for fitting the
injector.
4.4 Pumped Heating and Hot Water
NOTE: The draught diverter assembly and capillaries are
shown to aid plumbing, but would not be fitted at this stage.
Refer to diagram 1.5 for a diagrammatic layout.
If it is necessary to route pipework from both sides of the
builder’s opening it is recommended that the heat exchanger
is positioned on the combustion chamber such that the flow
pipe exits on the same side as the boiler connections.
It is recommended that the pumped return is pre-piped as in
diagram 4.3.
If the heat exchanger connections are opposite hand to that
required, turn in the same manner as described in Section
4.3 paragraph 6.
22mm COPPER PIPE
SUPPLIED WITH
APPLIANCE (Do not cut)
INJECTOR
SEALING
WASHERS
HEAT
EXCHANGER
SECURING
SCREWS (4)
22mm COPPER PIPE
SUPPLIED WITH
APPLIANCE (Do not cut)
Pumped Heating and Hot Water
UNEQUAL
TEE PIECE
22mm
COPPER
PIPE
SUPPLIED
WITH
APPLIANCE
(Do not cut)
Diagram 4.1
COMBUSTION
CHAMBER
Diagram 4.2
22mm
RETURN
22mm
FLOW
22mm COPPER
PIPE SUPPLIED
WITH APPLIANCE
(Do not cut)
Diagram 4.3
6254
6839
6840
9
221724B
4 Installation
FITTING THE
INJECTOR
6842
145 mm
MINIMUM
22mm
COPPER PIPE
SUPPLIED
WITH
APPLIANCE
(Do not cut)
METHOD A
28mm DOMESTIC HOT
WATER FLOW
(Must rise to allow air to
escape from the system)
22mm COPPER
PIPE SUPPLIED
WITH APPLIANCE
(Do not cut)
22mm COPPER PIPE
SUPPLIED WITH
APPLIANCE (Do not cut)
22mm
22mm CENTRAL
HEATING RETURN
28mm
22mm CENTRAL
HEATING FLOW
(Must run down
to allow air in
system to
escape)
145 mm
MINIMUM
22mm
CENTRAL
HEATING
RETURN
INJECTOR
(Supplied)
UNEQUAL TEE
(supplied)
22mm COPPER
PIPE SUPPLIED
WITH APPLIANCE
(Do not cut)
22mm COPPER
PIPE SUPPLIED
WITH APPLIANCE
(Do not cut)
28mm
DOMESTIC
HOT WATER
FLOW
22mm
CENTRAL
HEATING
RETURN
6841
28mm
DOMESTIC
HOT
WATER
RETURN
6843
145 mm
MINIMUM
221724B
28mm
COPPER
PIPE
28mm DOMESTIC
HOT WATER
RETURN
22mm COPPER PIPE
SUPPLIED WITH
APPLIANCE
(Do not cut)
10
METHOD B
22mm CENTRAL
HEATING FLOW
Note: If the tee piece is
fitted away from the
boiler, the central
heating flow pipe must
be increased to 28mm
as shown.
Diagram 4.4
4 Installation
4.5 Heat Shield Assembly
If the boiler electrical supply cable has to be routed down the
left hand side of the combustion chamber you must fit the
heat shield assembly and clips supplied in the fittings pack.
Refer to Section 5.1 and diagrams 5.2 and 5.3.
4.6 Circulating Pump
Isolating valves, integral if possible, must be fitted each side
of the circulating pump.
4.7 Gas Supply
Remove the combustion chamber extension by slackening
the two securing screws and removing the two base securing
screws, see diagram 4.5.
The gas installation must be fitted in accordance with the
recommendations of the current issue of BS6891.
1
Do not use pipe of a smaller diameter than Rc
inlet or 15mm, see diagram 1.1 for position of gas
connection.
The gas meter must be capable of passing natural gas at the
following rates: 58.3ft3/h to 88.5ft3/h (1.65m3/h to 2.51m3/h).
This rate is in addition to all other natural gas appliances
supplied from the same meter.
It is recommended that the gas supply enters the builder’s
opening on the right hand side.
If the gas supply enters from the left hand side it will be
necessary to route the pipe behind the combustion chamber
before final fixing.
/2 (1/2BSP)
4.8 Positioning the Back Boiler
To position the back boiler lift by the heat exchanger casting
and place centrally in the builder’s opening. The installation
centre line is indicated by a cut-out on the front edge of the
base, see diagram 4.6.
The back boiler must be positioned so that a line across the
opening of the fire fixing wall face coincides with the marks
indicated by an 'A' on the appliance, see diagram 4.6.
Check that the back boiler is level. If packing is required to
adjust the level of the back boiler, use metal shims and pack
under the full width of the base.
Mark through a minimum of two of the five fixing holes
available, see diagram 4.7. Remove the back boiler unit.
Drill holes using a 5mm masonry drill bit to accept the plugs
and fixings provided
SECURING
SCREW (2)
Slacken,
Do not remove
COMBUSTION
CHAMBER
EXTENSION
BASE
SECURING
SCREW (2)
Fit the lint arrester over the air intake hole, secure with
retaining clip. Push fit the sensing tube onto the flue
blockage safety device and draught diverter. Secure the
sensing tube assembly with the securing screw, see
diagram 4.10.
Where a flexible flue liner is being used, fully fit the
3
/8" self tapping screw provided into the rear of the
No8x
flue socket as in diagram 4.11.
Reposition the back boiler unit into the builder’s opening.
Connect the system pipework to the back boiler unit, preplumbed pipework.
Connect gas supply to gas service cock. Leave gas
service cock in the “OFF” position, see diagram 4.12.
NOTE: When connecting the gas supply use a spanner
to support the gas service cock, see diagram 4.12.
If a flexible flue liner is being used, position the liner in to
the flue socket. Using two No8x
coloured black, from the fittings pack, screw through the
two remaining holes in the flue socket to centralise and
secure the flue liner, see diagram 4.11. Seal with a
suitable fire clay cement.
1
/2" self tapping screws,
Diagram 4.5
6870
4.8 Positioning the Back Boiler - continued
Fit the flueway baffles, ensuring that they are fitted correctly
into the flueways, see diagram 4.8.
NOTE: The front flueway does not have a baffle.
NOTE: If the heat exchanger has been turned the baffles
must still be fitted into the back and middle flueways only.
Fit the spigot duct to the draught diverter assembly with the
two securing screws supplied in the fittings pack, see
diagram 4.9.
Fit the draught diverter assembly onto the heat exchanger
with the two securing screws supplied in the fittings pack,
see diagram 4.9.
11
221724B
4 Installation
FIXING
WALL
FACE
HEAT
EXCHANGER
CASTING
CUT-OUT
Line the appliance
up with the wall
fixing face
Diagram 4.6
6872
BAFFLES
BACK
FLUEWAY
HEAT EXCHANGER
Pipework removed for clarity
DRAUGHT
DIVERTER
SECURING
SCREW (2)
ASSEMBLY
MIDDLE
FLUEWAY
Diagram 4.8
SPIGOT
DUCT
6177
6847
FIRE
FIXING
WALL
FACE
FIXING
HOLE
(5 OFF)
TOP VIEW INSIDE
BUILDERS OPENING
6875
SECURING
SCREW (2)
Pipework removed for clarity
Diagram 4.9
221724B
FIXING HOLE (5 OFF)
Minimum of 2
must be used
Diagram 4.7
12
4 Installation
DRAUGHT
DIVERTER
6848
SENSING
TUBE
(push fit)
SENSING
TUBE
ASSEMBLY
SENSING
TUBE
BRACKET
SECURING
SCREW
Fully fit No. 8 3/
8 in.
screw into rear of
socket. Centralise
flexible flue liner
using the two
No. 8 1/
2 in.
screws provided.
SUPPORT
WITH
A SPANNER
AT THIS
POINT
No. 8 3/
SCREW
8 in.
SOCKET
REAR
FRONT
No. 8 1/
SCREWS
(BLACK)
Diagram 4.11
6849
2 in.
6873
“O” RING
SEALS ON THE
FLUE
BLOCKAGE
SAFETY
DEVICE
LINT
ARRESTER
BACK BOILER
ONLY 'ON'
TURNED FULLY
CLOCKWISE
BACK BOILER
AND FIRE FRONT
'ON'
TURNED TO
MID POSITION
GAS
SERVICE
COCK
90°
RETAINING CLIP
SENSING
TUBE
(push fit)
Diagram 4.10
13
'OFF'
TURNED FULLY
ANTI-CLOCKWISE
180°
Diagram 4.12
221724B
5 Electrical Wiring
5.1 General
WARNING. This boiler must be earthed.
ISOLATE THE ELECTRICAL SUPPLY BEFORE DOING
ANY WIRING
All of the electrical installation must be correctly earthed and
be in accordance with the current issue of BS7671 and be
carried out by a competent person.
The boiler electrical supply is 230V~ 50Hz, fused at 3A. A
double pole isolating switch, having a minimum contact
separation of 3mm in both poles should be used.
The boiler will only require a permanent live if a fire front with
lights or ignition is to be fitted.
External controls are connected to the live 'Ls' terminal on
the 3 way terminal block, as an example see diagram 5.1.
o
Supply cable should be (85
current issue of BS6500 Table 16, not less than 0.75mm
(24/0.20mm).
NOTE: The supply to the boiler and any remote control must
be through the same isolating switch or plug and socket.
It is preferable to have the boiler electrical supply cable
entering the builder’s opening at the left.
If the cable has to be routed down the left hand side of the
combustion chamber the heat shield assembly supplied in
the fittings pack must be used and the cable routed through
the clips, see diagram 5.2.
C) PVC insulated type to the
2
If right hand access is required fit the three clips from the
fittings pack to the combustion chamber extension and route
the cable down the right hand side of the combustion
chamber. Keep the cable well clear of hot surfaces, see
diagram 5.3.
NOTE: The boiler electrical supply cable must not be
routed along the back of the appliance.
The cable must be kept well clear of hot surfaces.
When fitting the back boiler unit do not trap the cable.
5.2 Control Thermostat Phial
Unwind the capillary avoid kinking, make sure that the
capillary is positioned so that it passes through the cut out in
the side of the control box, see diagram 5.7. Route the
capillary well clear of any part of the back boiler which
becomes hot. Use the capillary clips, supplied. Secure the
capillary and push the phial into the pocket, secure the phial
with the retaining pin supplied, see diagram 5.4. Again make
sure that the capillary is not touching the casting.
NOTE: When fitting the phial into the phial pocket use the
heat sink compound supplied in the fittings pack.
HEAT
SHIELD
ASSEMBLY
6878
Double
Pole
Switchspur
L
N
E
CABLE CLIPS
Froststat
ELECTRICAL
SUPPLY
CABLE
Pipestat
RoomstatProgrammer
Pump
Ls
3 Way
N
terminal
block at
E
Appliance
Diagram 5.1
6452
CABLE
CLIPS (3)
ELECTRICAL
SUPPLY
CABLE
Diagram 5.2
6871
ELECTRICAL
SUPPLY
CABLE
221724B
Diagram 5.3
14
5 Electrical Wiring
5.3 Boiler Control Box
Taking care that the POWER IS OFF.
Remove the control box, hold with both hands squeeze tilt
forward and unhook, see diagram 5.5.
Remove the gas valve lead.
Thread the mains cable through the side of the box, see
diagram 5.6.
The mains cable outer insulation must not be cut back
external to the clamp.
When making connections, make sure that the earth
conductor is made of a greater length than the current
carrying conductors, so that if the cable is strained the earth
conductor would be the last to become disconnected.
Connect the incoming mains earth conductor to the 3 way
terminal block, see diagram 5.6.
Connect the incoming mains neutral conductor to N and
boiler control live to Ls.
Restrain the mains cable with the clamp supplied.
NOTE: If a Burnt Ember Fire Front is to be fitted a four core
mains supply cable will be required and connected as
diagram 5.8.
5.4 Testing - Electrical
Checks to ensure electrical safety must be carried out by a
competent person.
After installation of the system, preliminary electrical system
checks as below should be carried out,
1. Test insulation resistance to earth of mains cable.
2. Test the earth continuity and short circuit of all cables.
3. Test the polarity of the mains.
4. With the mains supply off.
Refit the control box,.
Refit the gas valve electrical plug.
5.5 Overheat cut-off device (sealed systems
only).
A Kit No. 459033 is available with fitting instructions.
CONTROL THERMOSTAT
PHIAL
RETAINING
PIN
C
OVERHEAT
CUT-OFF
DEVICE
A
C
D
B
LEFT HAND CLIPPING POSITIONS A and B
RIGHT HAND CLIPPING POSITIONS C and D
Diagram 5.4
6879
15
CLAMP
MAINS
CABLE
RETAINING
LIP
CONTROL
BOX
SLOT
7091
RETAINING
LIP
Diagram 5.5
221724B
5 Electrical Wiring
CONTROL BOX
N
Ls
KEY
br - brown
b - blue
g/y - green/yellow
r - red
N - neutral
Lp - permanent live
Ls - switched live
CABLE CLAMP
3 WAY
TERMINAL
BLOCK
SWITCHED
CONTROLLED
MAINS SUPPLY
230V~50Hz
Diagram 5.6
g/y
7155
N
CONTROL BOX
7092
SLOT
CAPILLARY
Diagram 5.7
7883
3WAY
r
b
Ls
TERMINAL
BLOCK
230V~50Hz
SWITCHED
CONTROLLED
SUPPLY
GAS CONTROL VALVE
b
br
g/y
r
br
r
CONTROL
CHASSIS
EARTH
THERMOSTAT
OVERHEAT CUT-OFF
(SEALED SYSTEMS ONLY)
Diagram 5.8
221724B
16
6 Commissioning
6.1 Commissioning the Back Boiler
Before commissioning the back boiler, the whole of the
system should be thoroughly flushed out with cold water with
the circulation pump removed. Replace the pump, fill the
system and examine for water soundness. Vent air from the
system and pump.
The back boiler unit is fitted with a flue blockage safety
device, which will shut it down if there is a lack of oxygen.
The principle by which this operates is that when there is a
depletion of oxygen resulting from a build up of combustion
products, flame on the pilot light will become unstable and lift
up off the thermocouple. This will deactivate the mag unit in
the gas control valve, cutting off the gas supply.
If the back boiler unit shuts down frequently for no apparent
reason the first things to be checked are the chimney and air
inlets into the room. Any problems found must be put right,
by a competent person, and a full operational test carried
out before the back boiler unit is used again.
The flue blockage safety device incorporates the electrode,
thermocouple and pilot assemblies.
The flue blockage safety device MUST NOT be adjusted or
disconnected. It must be serviced strictly in accordance with
the instructions in this book. Any unauthorised interference
could result in the device failing to operate, creating a
potentially dangerous situation. If replacing, use only the
correct and approved part.
CAUTION: The following work should be carried out by a
competent person.
Identify the back boiler controls by reference to diagram
6.1.
Note: Overheat cut-off, see diagram 6.1 is applicable only
where the back boiler unit is incorporated in a sealed water
system.
Open all windows and put out any naked lights, cigarettes
etc.
Test the gas supply for soundness. Purge air in accordance
with the current issue of BS6891.
Check that the electrical supply to the back boiler is switched
off.
Set the thermostat control knob “A” to “Off” that is, fully anticlockwise.
Make sure the thermostat phial is fitted correctly, see
diagram 5.4.
Remove the back boiler burner pressure test screw “H” and
connect a suitable pressure gauge.
Turn gas service cock “K” to Back Boiler only “On” position,
see diagram 4.12.
Push in slightly and turn gas control knob “B” anti-clockwise
until
hold, at the same time press and release piezo button “D”
until the pilot burner lights.
Note, at this stage air may be present in the pilot supply so
this operation may need to be repeated.
When the pilot burner lights, keep gas control knob “B” fully
pushed in for about 15 seconds. If the pilot burner fails to
stay alight, repeat the lighting procedure but now keep the
control “B” knob pushed in for a little longer.
Check that the pilot flame is stable and has a length as
shown in diagram 6.2.
Push in slightly and turn gas control knob “B” anti-clockwise
until
If the gas control knob “B” is turned until
setting point, a safety lock prevents it being turned on again
until the thermocouple has cooled. NO ATTEMPT SHOULD
BE MADE TO TURN THE CONTROL KNOB “B” UNTIL AT
LEAST 3 MINUTES HAVE GONE BY.
Switch on electrical supply and set any remote controls that
is, clock, thermostats and the like, for heating. Refer to
control manufacturers’ instructions for specific details.
Turn thermostat knob “A” clockwise until “MAX” is against the
setting point. The main burner should now light.
Test for gas soundness using a suitable leak detection fluid.
The back boiler is supplied preset to a maximum heat output
setting of 15.8 kW (54000 Btu/h) but may be adjusted to suit
design requirements.
This value 15.8 kW must not be exceeded when using the
boiler in combination with a Brown Ember 3, Black Ash 3 or
Saxony 3 fire front.
is against the setting point, now push fully in and
is against the setting point.
is against the
CONTROL BOX
POINTER
“F”
CONTROL
THERMOSTAT
KNOB “A”
GAS
CONTROL
VALVE “J”
PIEZO UNIT
BUTTON “D”
OVERHEAT
CUT-OFF DEVICE
(sealed systems only)
GOVERNOR
ADJUSTMENT
COVER SCREW “G”
BOILER DATA
BADGE “E”
17
BURNER PRESSURE
TEST POINT “H”
SETTING
POINT “C”
GAS
SERVICE
COCK “K”
GAS
CONTROL
KNOB “B”
Diagram 6.1
221724B
6822
6 Commissioning
If the boiler is used with a Miami 3 or Melody 3 fire front it is
permitted to increase the output to 16.4 kW (56000) Btu/h).
If adjustment is required, TEN MINUTES after lighting,
remove cover “G” and turn adjustment screw, anti-clockwise
to suit system design heat input.
Should any doubt exist, the gas rate should be checked at
the gas meter.
The rate of the back boiler should be within the range,
For Saxony, Black Ash, Brown Ember:
3
/h (40.5ft3/h) to 1.86m3/h (65.7ft3/h)
1.15m
For Melody, Miami:
1.15m3/h (40.5ft3/h) to 1.94m3/h (68.5ft3/h)
Note, if the gas rate is checked, make sure that all other gas
appliances and pilot lights are turned off.
Turn control thermostat knob “A” anti-clockwise to “O” “Off”
position. Remove pressure gauge and replace test point
screw ensure a gas tight seal is made. Replace governor
cover screw “G”.
Relight the back boiler by turning thermostat knob “A”
clockwise to “MAX”.
Use the self adhesive arrow from the fittings pack and stick it
against the relevant heat input figure on the Data Label.
6.2 Testing the Back Boiler Controls
To check the operation of the flame failure device proceed as
follows:
With the main burner alight, slightly push in gas control knob
“B” and then turn it fully clockwise until
setting point. This will put out the main and pilot burners.
Note, relighting will not now be possible as the safety device
in the gas valve has been activated.
Check that the flame failure device closes within 60 seconds,
indicated by a click from the valve.
DO NOT ATTEMPT TO RELIGHT UNTIL AT LEAST 3
MINUTES HAVE GONE BY.
Relight the pilot and main burner as described in the relevant
part of Section 6.1.
Check that the boiler thermostat and any external controls
operate the back boiler correctly.
is against the
There should be no undue noise in the pipework or heat
emitters. There must be NO pumping over of water or entry
of air at the open vent pipe above the feed and expansion
cistern.
Make sure the back boiler thermostat knob “A” is turned
clockwise to “MAX” against the setting point, allow the water
to reach maximum working temperature. Examine the
system for water soundness.
Turn the thermostat knob “A” anti-clockwise to “Off” and
rapidly drain the system whilst still hot, to complete the
flushing process.
Refill the system, vent and check again for water soundness.
Fire Front Installation and Servicing Instructions are packed
with the fire.
13mm
FLAME
DIMENSION
Diagram 6.2
6357
6.3 Clearance of Products
A clearance of products (spillage) test must be carried out
after installation of the back boiler and its fire.
Before fitting the fire check that the heat exchanger baffle is
fitted and seated correctly, see Section 4.8.
Details of the necessary tests to be carried out will be found
under “TEST FOR CLEARANCE OF PRODUCTS” in the fire
Installation Instruction Booklet.
Note: This test must only be carried out after the fire front
has been fitted to the back boiler unit.
6.4 Commissioning the System
Set all controls to operate the heating system. Adjust
circulating pump and balance the system to give a
temperature drop across the boiler of 11
appropriate flow rate, the resistance of the back boiler can be
found by reference to diagram 6.3.
221724B
o
C (20oF). At the
18
700
600
500
With injector
fitted
400
300
200
100
0
PRESSURE LOSS (mm head of water)
-100
injector fitted
0 5 10 15 20 25 30
FLOW RATE (litres / minute)
Diagram 6.3
7296
Without
7 Fire Installation
7.1 Completion - After Installation of the Fire
Front
Instruct and demonstrate to the user, the efficient and safe
operation of the boiler, heating and hot water system and fire
front.
Hand the Instructions for Use to the user, making sure that
they are understood.
Advise the user that to ensure the continued efficient and
safe operation of the appliance it is recommended that it is
checked and serviced as necessary at regular intervals. The
frequency of the 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 any servicing must be carried out by a
competent person.
Set any remote controls for the system to settings requested
by the user.
Advise that the boiler is fitted with a flue blockage safety
device and refer to the Instructions for Use.
Advise the user of the importance to keep any purpose built
ventilation system where the appliance is installed, clear of
any obstruction that would impede its efficiency.
Reminder, leave these instructions with the user.
Advise the user that the ‘Benchmark’ logbook should be
completed by the installation engineer on completion of
commissioning or servicing.
19
221724B
8 Servicing
Servicing Notes
a) To ensure the continued efficient and safe operation
of the appliance it is recommended that it is checked
and serviced as necessary at regular intervals. The
frequency of the servicing will depend upon the
particular installation conditions and usage, but in
general once a year should be enough.
b) It is the Law that servicing must be carried out by a
competent person.
c) Remove the fire front
d) Refer to the Gas Fire Front Installation and Servicing
Instructions for full details of fire front removal.
e) After completing any servicing always test for gas
soundness with a suitable leak detection fluid and
carry out functional check on controls.
f) Unless stated otherwise reassembly of all components
is in the reverse order to that for removal.
g) The Flue Blockage Safety Device MUST NOT be
adjusted or disconnected. If replacing use only the correct
and approved part.
8.1 Isolation of Services
With the fire front removed.
Isolate the electrical supply to the back boiler.
Refer to diagram 6.1 to identify the controls.
Turn the gas control knob “B” to
the appliance gas service cock to “Fire and Boiler Off”, see
diagram 4.12.
“Off” position and turn
SENSING TUBE
FITTING
INTERNAL
FILTER
TUBING
NUT
SENSING TUBE
FLUE BLOCKAGE
SAFETY DEVICE
RETAINING
NUT
BRACKET
SECURING
SCREW
DRAUGHT
DIVERTER
6851
8.2 Sensing Tube Assembly.
Remove the combustion chamber extension, see diagram
4.5. Unclip the mains supply cable if required.
Remove the spigot duct, see diagram 8.10.
Remove the sensing tube bracket securing screw, carefully
pull the sensing tube assembly away from the sensing tube
fitting on the draught diverter assembly and from the flue
blockage safety device.
Clean or replace the lint arrester, see diagram 8.1.
Remove the sensing tube fitting and the tubing nut to access
the internal filter.
Clean or replace the internal filter, check the “O” rings for
damage, replace if necessary, see diagram 8.1.
IMPORTANT NOTE: When replacing the sensing tube check
the “O” rings, internal filter and lint arrester are fitted.
8.3 Gas Controls Assembly and Burner.
Remove the control box, hold with both hands squeeze tilt
forward and unhook, see diagram 5.5.
Turn the box over.
Disconnect the ignition lead from the piezo unit and remove
by threading it through the grommet in the rear of the control
box, see diagram 8.2.
Disconnect the union at the gas service cock, support with a
spanner see diagram 4.12.
Remove the thermostat phial and overheat cut-off device
phial if fitted (sealed systems only), from the phial pockets,
unclip the capillary tubes, see diagram 5.4.
Remove the four combustion chamber securing screws.
Pull the gas control valve forward releasing it from the
retaining pin, see diagram 8.4.
Slide the control/burner assembly forwards and up to
remove.
RETAINING
CLIP
EARTH
POST
PIEZO
UNIT
“O” RINGS
IGNITION
LEAD
CONTROL BOX
LINT
ARRESTER
GROMMET
SENSING
TUBE
Diagram 8.1
7212
Diagram 8.2
221724B
20
8 Servicing
COMBUSTION
CHAMBER
COMBUSTION
CHAMBER
FRONT COVER
CONTROL
BOX
COMBUSTION CHAMBER
SECURING SCREWS (2)
BURNER SECURING
SCREWS (3)
MAINS
ELECTRICAL
CABLE
GAS
MANIFOLD
SECURING
SCREW (2)
GAS
CONTROL
ELECTRICAL
PLUG
7093
UNION
NUT
GAS SERVICE
COCK
GAS
CONTROL
VALVE
Diagram 8.3
8.4 Burner
Disconnect the pilot tube nut and the thermocouple nut from
the gas control valve, see diagram 8.5.
Remove the screws which locate the gas manifold to burner,
see diagram 8.5.
The gas control valve can now be lifted clear of the burner.
Clean the burner as necessary, do not use a brush with
metallic bristles.
8.5 Lint Arrester
Remove the four securing screws to disengage the two lint
arresters, see diagram 8.6.
Clean the lint arresters as required.
8.6 Main Burner - Injector
Inspect the main burner injector for damage or blockage,
clean or replace as necessary. If replacing ensure the new
copper washer is fitted, see diagram 8.8.
Do not use a wire or sharp instrument to clean the injector
hole.
8.7 Flue Blockage Safety Device Assembly
Gain access as relevant part of Section 8.3. Remove any
dust and lint, inspect the pilot for damage. Remove the
sensing tube adapter, to clean, blow through, do not use a
wire or sharp instrument. Inspect the electrode and
thermocouple for wear or damage, clean, or replace as
necessary the flue blockage safety device, see diagram 8.8.
To remove the safety device, disconnect the pilot tube nut
and two securing screws, see diagram 8.9.
Ensure the electrode is in line with the earth post and the
spark gap is as shown in diagram 8.8.
GAS CONTROL VALVE
SECURING BRACKET
GAS CONTROL
RETAINING PIN
Diagram 8.4
Note: When reassembling the burner assembly the following
points should be observed:
a) Make sure that the lint arresters are engaged in the
correct position on the burner support bracket.
b) DO NOT replace the combustion chamber control/burner
assembly into the back boiler until the boiler flueways
servicing has been carried out.
8.8 Ignition Lead
Inspect the ignition lead for wear or damage, clean or
replace as necessary.
7095
21
221724B
8 Servicing
GAS
CONTROL
VALVE
GAS
MANIFOLD
PILOT TUBE
NUT
THERMOCOUPLE
NUT
LINT ARRESTER
SECURING
SCREWS
Diagram 8.5
8.10 Back Boiler Flueways
Remove the spigot duct, see diagram 8.10.
6905
Remove the draught diverter plate by slackening the two side
securing screws and removing the rear securing screw, see
diagram 8.10.
Lift out the flueway baffles, see diagram 8.11.
Place a sheet of paper in the base of the combustion
chamber.
Clean the boiler flueways with a suitable stiff brush.
To make sure that the flueways are clean, view with the aid
of a mirror or reflector.
Remove the paper and debris.
When refitting make sure that the baffles are correctly seated
in the back and middle flueways, see diagram 8.11.
NOTE: If the heat exchanger has been turned the baffles
must still be fitted into the back and middle flueways.
Refit the draught diverter plate.
Refit the control/burner assembly.
6191
SPARK GAP
EARTH
POST
3 +1 or -0.5
6301
SECURING SCREW (4)
COPPER
WASHER
GAS
MANIFOLD
Diagram 8.6
6834
ELECTRODE
TOP VIEW
THERMOCOUPLE
FRONT
VIEW
EARTH
POST
Diagram 8.8
6207
MAIN BURNER
INJECTOR
221724B
Diagram 8.7
22
PILOT TUBE
NUT
SECURING
SCREW (2)
FLUE
BLOCKAGE
SAFETY
DEVICE
Diagram 8.9
8 Servicing
DRAUGHT
DIVERTER
ASSEMBLY
SPIGOT DUCT
SECURING
SCREW (3)
SECURING
SCREW (2)
DRAUGHT
DIVERTER
PLATE
Diagram 8.10
9 Fault Finding
9.1 Electrical
Carry out the preliminary electrical system checks as
contained in a multimeter instruction book.
Refer to electrical fault finding chart, diagram 9.1 and
functional flow wiring diagram 9.1
On completion of the fault finding task which has required the
breaking and remaking of electrical connections, the checks
for earth continuity, short circuit, polarity and resistance to
earth must be repeated.
6835
BACK
FLUEWAY
FLUEWAY
BAFFLES
MIDDLE
FLUEWAY
HEAT
EXCHANGER
Diagram 8.11
9.4 Flue Blockage Safety Device and Ignition
Fault Finding
To check the safety device and ignition, refer to fault finding
chart, diagram 9.1.
7195
9.2 Thermocouple
To test the thermocouple, a meter with a range of
0 - 30mV is required together with a thermocouple interrupter
test unit.
9.3 Electrical Fault Finding Back Boiler
Refer to diagram 9.1.
7298
23
Diagram 9.1FUNCTIONAL FLOW AND ELECTRICAL FAULT-FINDING BACK BOILER
221724B
10 Replacement of Parts
Notes.
a) Replacement of parts must be carried out by a
competent person.
b) Unless stated otherwise all parts are replaced in the
reverse order to that of removal.
c) After replacing any gas carrying parts always test for
gas soundness using a suitable leak detection fluid.
Also carry out functional check of controls.
d) Refer to the Gas Fire Installation Instructions for
details of the removal of the fire front.
e) Isolate the electrical supply to the back boiler.
f) Refer to diagram 6.1 to identify the back boiler
controls.
Turn the gas control knob “B” to
the appliance gas service cock to “Fire and Boiler Off”, see
diagram 4.12.
“Off” position and turn
10.1 Sensing Tube Assembly.
Refer to Section 8.2.
10.2 Flue Blockage Safety Device
Follow the instructions in Section 8.2 and 8.3 to remove the
sensing tube assembly and controls assembly and burner.
Disconnect the ignition lead from the electrode.
Disconnect the thermocouple nut.
Disconnect the pilot pipe nut.
Remove the safety device securing screws.
Remove the safety device.
10.3 Thermocouple
Proceed as in Section 10.2.
10.7 Injector - Main Burner
Follow the instructions in Section 8.4 to remove the burner.
Replace the main injector. Ensure you fit the new copper
washer, see diagram 8.7.
10.8 Gas Control Valve
Remove the combustion chamber extension, see diagram
4.5.
Refer to diagram 10.2.
Disconnect the union nut at the at the gas service cock,
support with a spanner, refer to diagram 4.12.
Disconnect the gas control electrical plug.
Disconnect the thermocouple nut at the gas control valve
and ease out, see diagram 10.1 for position.
Disconnect the pilot tubing nut at the gas control valve.
Undo the securing screws to separate the gas control valve
from the supply pipe flange and gas manifold.
Pull the gas control valve forward releasing it from the
retaining pin, see diagram 8.4.
Remove the liner and union nut.
Transfer the liner and union nut using a small amount of
approved jointing compound on the external threads only to
the replacement gas control valve.
Fit the new 'O' ring seal supplied with new gas control valve.
10.9 Burner
Follow the relevant instructions in Section 8.3 and 8.4 to
remove the burner.
Transfer the flue blockage safety device to the new burner,
see diagram 10.1.
10.4 Electrode
Proceed as in Section 10.2.
10.5 Ignition Lead
Remove the combustion chamber extension, see diagram
4.5.
Remove the control box refer to the relevant parts of Section
8.3.
Remove the lead from the electrode.
Remove the lead from the piezo.
When replacing make sure the lead passes through the
grommet in the rear of the control box and the protective
silicone sleeve is replaced.
10.6 Piezo
Remove the combustion chamber extension, see diagram
4.5.
Remove the control box refer to the relevant parts of Section
8.3.
Remove the lead from the piezo.
Remove the piezo.
THERMOCOUPLE
NUT
FLUE
BLOCKAGE
SAFETY
DEVICE
7070
IGNITION
LEAD
SILICONE
SLEEVE
SECURING
SCREW (2)
221724B
24
PILOT PIPE NUT
Diagram 10.1
10 Replacement of Parts
10.10 Control Thermostat
Remove the combustion chamber extension, see diagram
4.5.
Remove the control box refer to the relevant parts of Section
8.3.
Remove the control thermostat phial and unclip the capillary
tube, see diagram 5.4.
Remove the control knob, see diagram 10.3.
Remove the two electrical connections from the control
thermostat, see diagram 10.3.
Remove the two securing screws and remove the control
thermostat and capillary from the cut out slot, see diagram
10.3.
When refitting the capillary should pass through the cut out
slot on the control box.
The capillary tube must not touch any part of the back boiler
that becomes hot, re-clip the capillary tube and push the
phial into the pocket.
NOTE: When fitting the phial use heat sink compound.
When refitting refer to diagram 5.4.
10.11 Over Heat Cut-off Device (Sealed
systems only)
Remove the combustion chamber extension, see diagram
4.5.
Remove the control box refer to the relevant parts of Section
8.3.
Remove the over heat phial and unclip the capillary tube, see
diagram 5.4.
Remove the locknut, see diagram 10.4.
Remove the over heat electrical connections, see diagram
10.4.
Remove the over heat cutoff device and capillary from the
cut out slot, see diagram 10.4.
NOTE: When refitting, the capillary should pass through the
cut out slot on the control box, see diagram 10.4.
When refitting refer to the wiring diagram 5.8.
The capillary tube must not touch any part of the back boiler
that becomes hot, re-clip the capillary tube and push the
phial into the pocket.
SECURING
SCREWS
(4)
PILOT TUBING
NUT
CAPILLARY
7159
CONTROL
THERMOSTAT
GAS
CONTROL
VALVE
THERMOCOUPLE
NUT
SECURING
SCREW (2)
UNION
NUT
GAS
SERVICE
COCK
GAS CONTROL
VALVE ELECTRICAL
PLUG
Diagram 10.2
ELECTRICAL
CONNECTIONS (2)
CONTROL
KNOB
Diagram 10.3
7094
25
221724B
10 Replacement of Parts
10.12 Insulation
Follow the relevant instructions in Section 8.3 to remove the
controls assembly and burner.
Remove the five burner securing screws to remove the
combustion chamber front cover from the controls assembly
and burner, see diagram 8.2.
Refer to diagram 10.5
Remove the front cover insulation,
Slide out the side insulation pieces.
With the side insulation pieces removed, lift out the rear
insulation.
Note: Remove any debris that falls when the insulation has
been replaced.
CAPILLARY
LOCKNUT
ELECTRICAL
CONNECTIONS (2)
COMBUSTION
CHAMBER
FRONT COVER
OVER HEAT
CUTOFF
DEVICE
Diagram 10.4
SIDE
INSULATION
PIECE
7158
REAR INSULATION
PIECE
SIDE INSULATION
6853
PIECE
SECURING
SCREW (5)
221724B
FRONT
INSULATION PIECE
Diagram 10.5
26
11 Spare Parts
When spare parts are required apply to your local supplier.
Please quote the name of the appliance, Glow-worm 56/3pp BBU, with a relevant BBU Fire Front, also the serial number of the
boiler, to be found on the data label on the appliance.
If ordering from the local gas undertaking the appropriate appliance GC number should also be quoted together with the GC
number of the part.
Key No. Part No. Description GC Part No.
1 WX5505 Ignition lead ****
2 426766 Gas control valve 191264
3 800204 Injector 313485
4 451477 Flue blockage safety device - SIT Ref:-9403 191 310
5 800933 Control thermostat E03 972
6 800928 Control knob E03 970
7 800999 Overheat cut off device E03 997
8 801002 Flue blockage safety device 'O' Rings E04 001
9 208693 Sensing Tube Internal Filter E03 987
10 459026 Lint Arrester ****
11 213043 Lint Arrester Retaining Clip ****
12 202713 Piezo ****
7161
3
2
8
9
4
5
7
6
10
11
12
1
Diagram 11.1
27
221724B
Control of Substances Hazardous to Health
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.
The adhesives and sealants used in this appliance are cured and give no known hazard in this state.
RADIANTS, FUELBEDS, ARTIFICIAL FUEL
After handling wash hands thoroughly.
INSULATION PADS/CERAMIC FIBRE, GLASSYARN, MINERAL WOOL
These can cause irritation to skin, eyes and the respiratory tract.
If you have a history of skin complaint you may be susceptible to irritation. High dust levels are usual
only if the material is broken.
Normal handling should not cause discomfort, but follow normal good hygiene and wash your hands
before eating, drinking or going to the lavatory.
If you do suffer irritation to the eyes or severe irritation to the skin seek medical attention.
THERMOSTATS
These contain very small amounts of trichlorofluoromethane in the sealed phial and capillary. If broken,
under normal circumstances the fluid does not cause a problem, but it can, in exceptional cases cause
freeze burns.
If there is skin burn or irritation to the eyes or 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 cases of skin contact, wash with cold water.
If swallowed drink plenty of water and seek medical attention.
CUT-OFF DEVICES
These contain a very small amount of ethylene glycol and methanol in the capillary. If broken, under
normal circumstances the fluid does not cause a problem, but in cases of skin or eye contact, wash with
cold water.
If swallowed drink plenty of water and seek medical attention.
Because of our constant endeavour for improvement details may vary slightly from those in the instructions.
221724B
28
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