221725B.10.00
Installation & Servicing Instructions
To be left with the user
Glow-worm 56/3e
Back Boiler Unit
G.C. No. 44 047 04A
This Back Boiler Unit Is To Be Used Only With The Glow-worm Mk.3 Fire Front Range
6836
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
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 Glow-worm
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,
Bye-laws 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 78.6%.
The value is used in the UK Government’s Standard Assessment
Procedure (SAP) for energy rating of dwellings. The test data
from which it has been calculated have been certified by B.S.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
the current issue of BS6500 Table 16, not less than 0.75mm
(24/0.20mm).
C) insulated type to
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.
2
221725B
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
56/3e 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
5.0 9.0 13.7 14.8
2.0 3.6 5.5 5.9
K
J
Diagram 1.1
INJECTOR
MARKING
3.6 Pt. No. 230208
3
221725B
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.
1.10 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.
1.12 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
1.11 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
221725B
4
1 General
* 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.
6408
1 metre MIN
27 metres MAX
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
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
FULLY PUMPED SYSTEM
(DIAGRAMMATIC)
Diagram 1.5
6242
MAXIMUM
7218
5
221725B
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.
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
Dimensions X, Y, and Z refer to
Fire Installation Instructions
PREPARED
BOILER
BASE
'X' mm MIN
HEARTH
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
221725B
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
221725B
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.
221725B
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.
22mm COPPER PIPE
SUPPLIED WITH
APPLIANCE (Do not cut)
SEALING
WASHERS
HEAT
EXCHANGER
SECURING
SCREWS (4)
INJECTOR
UNEQUAL
TEE PIECE
22mm
COPPER
PIPE
SUPPLIED
WITH
APPLIANCE
(Do not cut)
COMBUSTION
CHAMBER
6254
Diagram 4.1
6839
Diagram 4.2
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)
Pumped Heating and Hot Water
9
22mm
RETURN
22mm
FLOW
22mm COPPER
PIPE SUPPLIED
WITH APPLIANCE
(Do not cut)
Diagram 4.3
221725B
6840
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)
6843
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
145 mm
MINIMUM
221725B
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
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: 58.3ft
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.
3
/h to 88.5ft3/h (1.65m3/h to 2.51m3/h).
/2 (1/2BSP) inlet
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
6844
BASE
SECURING
SCREW (2)
Where a flexible flue liner is being used, fully fit the No8x3/8" self
tapping screw provided into the rear of the 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 No8x1/2" self tapping screws, 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.
Diagram 4.5
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.
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.
11
221725B
4 Installation
FIXING
HOLE
6845
(5 OFF)
6846
FIXING
WALL
FACE
A
HEAT
EXCHANGER
CASTING
CUT-OUT
Line the appliance
up with the wall
fixing face
FIRE
FIXING
WALL
FACE
BAFFLES
BACK
FLUEWAY
FIXING HOLE
(5 OFF)
Minimum of 2
must be used
TOP VIEW INSIDE
BUILDERS OPENING
Diagram 4.7
6177
MIDDLE
FLUEWAY
Diagram 4.6
HEAT EXCHANGER
Pipework removed for clarity
DRAUGHT
DIVERTER
SECURING
SCREW (2)
ASSEMBLY
Pipework removed for clarity
Diagram 4.8
SPIGOT
DUCT
SECURING
SCREW (2)
Diagram 4.9
6847
221725B
12
4 Installation
DRAUGHT
DIVERTER
6848
SENSING
TUBE
(push fit)
SENSING
TUBE
ASSEMBLY
SENSING
TUBE
BRACKET
SECURING
SCREW
Fully fit No. 8 3/
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
8 in.
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
'OFF'
TURNED FULLY
ANTI-CLOCKWISE
13
180°
Diagram 4.12
221725B
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 'L' terminal in the 5
way plug, as an example see diagram 5.1.
o
Supply cable should be (85
current issue of BS6500 Table 16, not less than 0.75mm
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
(24/
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 10.3. 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
6883
Double
Pole
Switchspur
L
N
E
Froststat
Pipestat
RoomstatProgrammer
Pump
Ls
5 Way
N
Plug at
Appliance
E
Diagram 5.1
6452
CABLE
CLIPS (3)
ELECTRICAL
SUPPLY
CABLE
Diagram 5.2
6869
ELECTRICAL
SUPPLY
CABLE
CABLE CLIPS
221725B
ELECTRICAL
SUPPLY
CABLE
Diagram 5.3
14
5 Electrical Wiring
5.3 Boiler Control Box
Taking care that the POWER IS OFF, wire the incoming mains
cable to the mains plug supplied in the fittings pack. Do not
connect the mains supply plug to the control box socket, see
diagram 5.5.
NOTE: The ignition sequence is fully automatic and will
commence when mains voltage is applied.
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. Plug the mains supply plug into the
control box socket, see diagram 5.5.
5.5 Overheat cut-off device (sealed systems
only).
A Kit No. 459033 is available with fitting instructions.
RETAINING
PIN
OVERHEAT
CUT-OFF
DEVICE
CONTROL THERMOSTAT
PHIAL
6203
C
A
C
D
B
LEFT HAND CLIPPING POSITIONS A and B
RIGHT HAND CLIPPING POSITIONS C and D
Diagram 5.4
CONTROL
BOX
KEY
br - brown
7884
b - blue
g/y - green/yellow
SL - switched live
g/y
br
Ls
SL
N
b
230V~50Hz
MAINS
SUPPLY
MAINS
SUPPLY
PLUG
15
Diagram 5.5
221725B
5 Electrical Wiring
230V~50Hz
SWITCHED
CONTROLLED
SUPPLY
SL
FLUE BLOCKAGE
p
r
KEY
br - brown
b - blue
y - yellow
r - red
g/y - green/yellow
wh - white
SL - Switch Live
SAFETY
DEVICE
bk - black
or - orange
p - purple
bk
CONTROL BOX AND
GAS VALVE WIRING
GAS
VALVE
g/y
7885
br
LN
CN1
3 PIN
MAINS
SOCKET
g/y
OVER HEAT
CUT-OFF
SAFETY DEVICE
(sealed systems only)
b
TC-GND
TC-SGN
or r p
CN2
Orange
link
yy
RESET /
LOCKOUT
CN5
pp
br b bk
CN3
EVI
FUSE
F1A
CN6
or
EVN EV2
LN
br
b
EARTH
POST
HV
CN4
g/y
whwh
CONTROL
THERMOSTAT
Diagram 5.6
221725B
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 control thermostat knob “A” to “0”, “Off” position that is,
fully anti-clockwise, see diagram 6.1.
Make sure the thermostat phial is fitted correctly, see diagram
5.4.
Remove the back boiler burner pressure test screw “B” and
connect a suitable pressure gauge.
Turn gas service cock “D” to the “On” position making sure that
the fire front service cock “D” is in the “Off” position, see diagram
4.12.
Technical Sequence of Operation
When an external control calls for heat there is approximately
a 30 second purge. The control board (PCB) energises the
thermoelectric valve and spark unit. With the thermoelectric
valve open gas is allowed to pass to the combustion products
discharge safety device which will be ignited by the sparks.
This ignition attempt will continue until the milli-voltage generated
by the thermocouple is sufficient to hold open the pilot valve. At
this point the thermoelectric valve and spark unit are deenergised and the green light on the lockout reset button “E” will
illuminate, see diagram 6.1. The main gas control valve is
energised through the closed contacts of the control thermostats.
When the water temperature has reached the set point the
control thermostat contacts open, the main gas control valve is
closed. The pilot will, however, remain alight since the
thermocouple is generating the required milli-voltage.
When the water temperature falls below the set point the control
thermostat control will close, thus energising the main gas
control valve and allow the main burner to light from the pilot
light.
The boiler will continue to cycle in this manner until the external
control stops its demand for heat. At this point external power
is removed the main gas control valve and the thermocouple
milli-voltage is reduced to zero.
That is to say whilst ever there is a demand for heat from an
external control the pilot will remain alight despite the boiler
thermostat cycling on or off.
Check the pilot flame is stable and has a length as shown in
diagram 6.2.
Note: Should the red light on the lockout reset button “E” come
on, it indicates that the pilot light is not operating correctly, or the
combustion products discharge safety device has been
activated.
Depress the lockout reset button “E”, when the fault has been
corrected indicated by the green light illuminating, see diagram
6.1.
Turn control thermostat knob “A” clockwise until “MAX” is
against the pointer positioned on the control box front cover “F”.
The main burner will light.
Test for gas soundness using a suitable leak detection fluid.
CONTROL BOX
POINTER
“F”
MAX
0
MIN
CONTROL
THERMOSTAT
KNOB “A”
GREEN
RED
OVERHEAT CUTOFF DEVICE
(sealed systems only)
PRESSURE TEST POINT “B”
LOCKOUT
RESET
BUTTON “E”
17
ADJUSTER “G”
ELECTRICAL
PLUG
6821
GAS CONTROL VALVE
GAS SERVICE
COCK “D”
Diagram 6.1
221725B
6 Commissioning
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.
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:
Light the boiler and run for TEN MINUTES.
Turn adjustment screw “G”, to suit system design heat input,
see diagram 6.1.
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 “0”, “Off”
position. Remove pressure gauge and replace test point screw
ensure a gas tight seal is made.
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.
Refer to sequence of operation below.
LIGHTING: SEQUENCE OF OPERATION
1. Switch on the electrical supply to the boiler
and heating sytsems.
6.3 Clearance of Products
A clearance of products (spillage) test must be carried out after
installation of the back boiler and it's fire.
Before fitting the fire, check that the heat exchanger baffles are
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
Front 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
resistance of the back boiler can be found by reference to
diagram 6.3.
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 control 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 control 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.
6679
o
C (20oF). At the appropriate flow rate, the
13mm
FLAME
DIMENSION
6357
2. Set external controls if fitted, to demand heat.
3. Turn the boiler control thermostat knob
fully clockwise to the maximum setting.
The lighting sequence is automatic as follows:-
4. Approximate 30 second purge.
5. Ignition initiated sparking at electrode
EV1 energised, (Pilot solenoid)
pilot lights.
6. EV2 energised, (Main burner solenoid)
main burner lights.
6.2 Testing the Back Boiler Controls
To test the lockout device, turn the boiler on. After about 3
minutes, turn the gas off at the gas service cock, the lockout
device should now operate. This is indicated by the red light
coming on at the reset button.
To restart the boiler, turn on the gas supply at the gas service
cock and press the lockout reset button “E”.
DO NOT ATTEMPT TO RELIGHT UNTIL AT LEAST 3 MINUTES
HAVE GONE BY.
Check that the boiler thermostat control and any external
controls operate the back boiler correctly.
If removed refit the combustion chamber extension.
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 6.2
7296
Without
Diagram 6.3
221725B
18
7 Fire Installation
Fire Front Installation and Servicing Instructions are packed
with the fire.
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
221725B
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
Isolate the electrical supply to the back boiler.
With the fire front removed.
Refer to diagram 6.1 to identify the controls.
Turn control thermostat knob “A” anti-clockwise to “0” “Off”
position.
Turn appliance gas service cock to “Off”, see diagram 4.12.
8.2 Sensing Tube Assembly.
Remove the combustion chamber extension, see diagram 4.5.
Unclip the mains supply cable if required.
Remove 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 combustion products
discharge 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.
INTERNAL
FILTER
SENSING
TUBE FITTING
RETAINING
NUT
BRACKET
TUBING
NUT
SENSING TUBE
SECURING
SCREW
DRAUGHT
DIVERTER
FLUE
BLOCKAGE
SAFETY DEVICE
SENSING
“O” RINGS
TUBE
RETAINING
CLIP
LINT
ARRESTER
Diagram 8.1
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,
see diagram 8.2.
6851
8.3 Gas Controls Assembly and Burner.
Remove the control box, hold with both hands squeeze tilt
forward and unhook, see diagram 8.3.
Turn the box over.
Disconnect the ignition lead from the control board and remove
by threading it through the grommet in the rear of the control
box, see diagram 10.6.
Disconnect the mains electrical plug from 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.
221725B
20
8 Servicing
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.
COMBUSTION CHAMBER
COMBUSTION
CHAMBER
SECURING SCREWS (4)
BURNER SECURING
SCREWS (3)
7860
UNION
GAS SERVICE
COCK
COMBUSTION
CHAMBER
FRONT COVER
MAINS
ELECTRICAL
PLUG
CONTROL
BOX
CONTROL BOX
7098
GAS CONTROL VALVE
GAS
CONTROL
VALVE
Diagram 8.2
7071
RETAINING
LIP
SLOT
RETAINING LIP
Diagram 8.3
21
GAS CONTROL
COCK
RETAINING PIN
Diagram 8.4
221725B
8 Servicing
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 8.7.
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.
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.
SECURING
SCREWS
GAS
MANIFOLD
PILOT TUBE NUT
LINT ARRESTER
THERMOCOUPLE
NUT
6886
GAS
CONTROL
VALVE
Diagram 8.5
6191
SECURING SCREW (4)
Diagram 8.6
221725B
22
8 Servicing
8.8 Ignition Lead
Inspect the ignition lead for wear or damage, clean or replace as
necessary.
8.9 Back Boiler Flueways
Remove the spigot duct, see diagram 8.10.
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.
PILOT TUBE
NUT
SECURING
SCREW (2)
FLUE
BLOCKAGE
SAFETY
DEVICE
Diagram 8.9
DRAUGHT
DIVERTER
ASSEMBLY
6207
6835
COPPER
WASHER
MAIN BURNER
INJECTOR
EARTH
POST
SPARK GAP
3 +1 or -0.5
THERMOCOUPLE
Diagram 8.7
6834
6301
SECURING
SCREW (2)
DRAUGHT
DIVERTER
PLATE
BACK
FLUEWAY
SPIGOT DUCT
SECURING
SCREW (3)
Diagram 8.10
FLUEWAY
BAFFLES
7195
ELECTRODE
TOP VIEW
FRONT
VIEW
EARTH
POST
Diagram 8.8
23
HEAT
EXCHANGER
MIDDLE
FLUEWAY
Diagram 8.11
221725B
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 9.2.
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.
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.
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.
221725B
24
9 Fault Finding
Ensure all connections are correctly made, that gas supply is available free of obstruction
and purged of air. Ensure that external controls, if fitted, are calling for heat.
Connect a multimeter
set to mVDC to pins
TC-GND and TC-SGN
on CN1 on the
control board (PCB).
Does sparking take
place, does milli-voltage
increase towards 5mV?
YES
NO
START
≈ 30 seconds after a call
for heat, does the
control board (PCB)
start to spark.
Pilot not lit.
Check condition of
electrode and HT lead.
Replace as necessary.
NO
Faulty control board (PCB).
Replace.
YES
Does green light on
lockout reset button
illuminate and sparking
NO
Is milli-voltage > 5mV?
YES
NO
Faulty thermocouple.
Replace.
stop when milli-voltage
is >5mV?
Faulty control board (PCB).
Replace.
YES
Turn control thermostat
knob to maximum.
Does main burner light?
NO
Is there 230V at
both connections on
the thermostat control
NO
Faulty thermostat
control. Replace.
with reference
YES
to neutral?
7301
Does red light on
lockout reset button
illuminate?
YES
The flue blockage
safety device
has operated, the main
burner has gone out.
Check adequate
ventilation is available,
check flue has not
become blocked.
Press lockout reset
button. Ignition should
take place, appliance
should work satisfactorily.
NO
YES
Is there 230V at
PIN EV2 on CN3 on
control board (PCB)
with reference to neutral?
YES
Check continuity of lead
from control board (PCB)
to gas control valve,
is there continuity?
YES
Faulty gas control valve.
Replace.
Appliance working
satisfactorily.
NO
Faulty control board (PCB).
Replace.
NO
Faulty lead.
Replace.
25
Diagram 9.1ELECTRICAL FAULT-FINDING BACK BOILER
221725B
CONTROL BOARD (PCB)
FUSE
TYPE
T1A
CN5
9 Fault Finding
Ls
br
LINK (OVERHEAT THERMOSTAT
IF FITTED)
or
br BROWN
b BLUE
w WHITE
7186
KEY
bk BLACK
or ORANGE
CN3 EV1
TH
TH
CN3 EV2
HV
CN4
br
w
w
bk
SPARK
ELECTRODE
PILOT
CONTROL
SOLENOID
THERMOSTAT
MAIN
SOLENOID
5 WAY SOCKET CONNECTIONS
PCB CONNECTIONS
b
b
b
N
N
Diagram 9.2FUNCTIONAL FLOW
221725B
26
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 thermostat control knob clockwise to “0”, “Off” position.
Turn the appliance gas service cock to the “Off” position, see
diagram 4.12.
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.
Refer to diagram 10.1.
Remove 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.
10.4 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 control board (PCB).
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 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.
10.7 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.
Disconnect interrupter electrical connections.
Disconnect the pilot tubing nut at the gas 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.
IGNITION LEAD
PILOT PIPE NUT
THERMOCOUPLE NUT
SECURING
SCREW (2)
SILICONE SLEEVE
FLUE BLOCKAGE
SAFETY DEVICE
6887
Diagram 10.1
27
221725B
10 Replacement of Parts
Remove the interrupter.
Remove the liner and union nut.
Transfer the interrupter to the replacement gas control valve.
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.
Note. When replacing the thermocouple only tighten the nut a
quarter turn beyond finger tight.
Should the solenoids require replacing, refer to Section 10.12.
10.8 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.
10.9 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 10.4.
Remove the two electrical connections from the control
thermostat, see diagram 10.4.
Remove the two securing screws and remove the control
thermostat and capillary, see diagram 10.4.
When refitting, the capillary should pass through the cut-out slot
in the control box, see diagram 10.3.
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 and
ensure the phial is fully inserted into the phial pocket.
When refitting refer to diagram 5.4.
THERMOCOUPLE NUT
ELECTRICAL
CONNECTIONS
SECURING
SCREWS (4)
CONTROL BOX
SLOT
INTERRUPTER
LINER
PILOT
TUBING
NUT
GAS CONTROL
ELECTRICAL PLUG
GAS
SERVICE
COCK
UNION
NUT
Diagram 10.2
6882
7178
10.9 Lockout Reset Button
Remove the combustion chamber extension, see diagram 4.5.
Remove the control box refer to the relevant parts of Section
8.3.
Remove the lockout reset button multi pin connector from the
control board, release the tabs to remove the lockout reset
button, see diagram 10.5.
NOTE: Turn the multi pin connector and carefully ease through
the hole in the front of the control box as shown in diagram 10.5.
When refitting refer to the wiring diagram 5.6.
10.10 Control Board (PCB)
Remove the combustion chamber extension, see diagram 4.5.
Remove the control box refer to the relevant parts of Section
8.3.
Refer to diagram 10.6.
Disconnect the ignition lead.
Disconnect the electrical connections from the control thermostat.
Disconnect the four multi pin connector .
Disconnect the earth lead.
CAPILLARY
ELECTRICAL
CONNECTION (2)
CONTROL
THERMOSTAT
SECURING
SCREWS
Diagram 10.3
7157
CONTROL
KNOB
Diagram 10.4
221725B
28
10 Replacement of Parts
Release the wires from the mains terminal strip.
Carefully pull the board from its supports.
When refitting refer to the wiring diagram 5.6.
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 10.7.
Remove the over heat electrical connections, see diagram
10.7.
Remove the over heat cutoff device and capillary, see diagram
10.7.
When refitting, the capillary should pass through the cut-out slot
in the control box, see diagram 10.3.
When refitting refer to the wiring diagram 5.6.
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.
10.12 Solenoids
Refer to diagram 10.8.
Remove the gas control plug at the gas control valve.
Remove the solenoid securing screw.
Remove the solenoids.
MULTI PIN
CONNECTOR
LOCKOUT
RESET
BUTTON
RELEASE
TABS
MULTI PIN
CONNECTOR
6199
HOLE IN FRONT
OF CONTROL BOX
FRONT VIEW
SHOWING HOLE IN
FRONT OF
CONTROL BOX
Diagram 10.5
SUPPORT (4)
CONTROL
BOARD
(PCB)
Lead plug
replaces
orange link
MULTI PIN
CONNECTOR (4)
GROMMET
IGNITION
LEAD
MAINS
TERMINAL
STRIP
EARTH
LEAD
7182
OVERHEAT CUT-OFF DEVICE
(SEALED SYSTEMS ONLY)
29
Diagram 10.6
221725B
10 Replacement of Parts
10.13 Interrupter
Remove the combustion chamber extension, see diagram 4.5.
Refer to diagram 10.9
Carefully disconnect the thermocouple nut.
Remove the electrical connections.
Remove the interrupter.
10.14 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 10.10.
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
MULTI PIN
CONNECTOR
7156
SOLENOIDS
GAS
CONTROL
VALVE
ELECTRICAL
CONNECTIONS
SECURING
SCREW
THERMOCOUPLE NUT
INTERRUPTER
6888
PLUG
Diagram 10.8
6882
COMBUSTION
CHAMBER
FRONT COVER
SECURING
SCREW (5)
OVER HEAT
CUTOFF
DEVICE
LOCKNUT
ELECTRICAL
CONNECTORS
Diagram 10.7
SIDE
INSULATION
PIECE
REAR INSULATION
PIECE
Diagram 10.9
6853
SIDE INSULATION
PIECE
221725B
FRONT
INSULATION PIECE
Diagram 10.10
30
11 Spare Parts
When spare parts are required apply to your local supplier.
Please quote the name of the appliance, Glow-worm 56/3e 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 WY0200 Ignition lead ****
2 800929 Gas control valve E03 982
3 800204 Injector 313485
4 202015 Fuse (Type T1A) 334 750
5 202273 Control board (PCB) E03 966
6 451477 Flue blockage safety device - SIT Ref:-9403 191 310
7 202577P Lock out reset button E04 330
8 800933 Control thermostat E03 972
9 800928 Control knob E03 970
10 800999 Overheat cut off device E03 997
11 801002 Flue blockage safety device 'O' Rings E04 001
12 208693 Sensing Tube Internal Filter E03 987
13 459026 Lint Arrester ****
14 213046 Lint Arrester Retaining Clip ****
7
4
7222
8
9
10
6
5
13
1
3
14
12
11
31
2
Diagram 11.1
221725B
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 provideinformation 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.
221725B
32
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