Glow-worm 80BF User Manual

Instructions for Use

Installation and Servicing

To be left with the user

Hideaway

80B

G.C. No. 41 313 24

221763A.10.00

0863

Balanced Flue Boiler

BS 6332
BS 5258

This is a Cat I2H Appliance

Reference in these instructions to British Standards and Statutory

Regulations/Requirements apply only to the United Kingdom.

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

For Ireland the rules in force must be used.

Card. The instructions are an integral part of the appliance and must, to comply with the current issue of the Gas Safety

(Installation and Use) Regulations, be handed to the user on completion of the installation.

Guarantee Registration

Thank you for installing a new Glow-worm appliance in your home.

Glow-worm appliances' are manufactured to the very highest standard so we are pleased

to offer our customers' a Comprehensive First Year Guarantee.

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

return as soon as possible.

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

Service number 01773 828100.

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

✔

All replacement parts

❏

✔

All labour charges

❏

All call-out charges

✔

❏

One Contact Local Service

REGISTER YOUR GLOW-WORM APPLIANCE

FOR 1ST YEAR GUARANTEE PROTECTION

CALL 0208 247 9857

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

Nottingham Road, Belper, Derbyshire. DE56 1JT

Tel: [phone] Fax: [phone]

Hepworth Heating Ltd.,

General/Sales enquiries:

Important Information

Testing and Certification

This boiler is tested and certificated for safety and performance. It is therefore important that no alteration is made to the boiler, without
permission, in writing, from Hepworth Heating Ltd.

Any alteration not approved by Hepworth Heating Ltd., could invalidate the certification, boiler warranty and may also infringe the
current issue of the Statutory Requirements, see Section 1.4.

CE Mark

This boiler meets the requirements of Statutory Instrument No. 3083 The boiler (Efficiency) Regulations, and therefore is deemed
to meet the requirements of Directive 92/42/EEC on the efficiency requirements for new hot water boilers fired with liquid or gaseous
fuels.

Type test for purposes of Regulation 5 certified by: Notified body 0086.
Product/productioncertifiedby: Notified body 0086.
The CE mark on this appliance shows compliance with:

1. Directive 90/396/EEC on the approximation of the laws of the Member States relating to appliances burning gaseous fuels.

2. Directive 73/23/EEC on the harmonization of the Laws of the Member States relating to the electrical equipment designed
for use within certain voltage limits.

3. Directive 89/336/EEC on the approximation of the Laws of the Member States relating to electromagnetic compatibility.

INFORMATION FOR THE INSTALLER AND SERVICE ENGINEER.

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

CERAMIC FIBRE/INSULATION PADS, GLASSYARN.

These can cause irritation to skin, eyes and the respiratory tract. If you have a history of skin complaint you may be susceptible to
irritation. High dust levels are usual only if the material is broken. Normal handling should not cause discomfort, but follow normal
good hygiene and wash your hands before eating, drinking or going to the lavatory. If you do suffer irritation of the eyes or severe
irritation to the skin seek medical attention.

THERMOSTATS

These contain very small amounts of xylene in the sealed phial and capillary. If broken, under normal circumstances the fluid does
not cause a problem, but in case of skin contact, wash with cold water. If swallowed drink plenty of water and seek medical attention.

CONTENTS DESCRIPTION SECTION PAGE No.

INSTRUCTIONS

FOR USE

INSTALLATION

INSTRUCTIONS

Introduction 3
Lighting the Boiler 4

General Data 1 5
Water Systems 2 7
Flue and Ventilation 3 8
Installation 4 9
Casing Location / Fitting 5 12
Electrical Wiring 6 14
Commissioning 7 15

SERVICING

INSTRUCTIONS

221763A

Servicing 8 17
Replacement Parts 9 18
Fault Finding 10 21
Spare Parts 11 24

2

Instructions for Use

General Information

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

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

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

Important Notice

This boiler is for use only on G20 gas.

Gas Safety (Installation and Use) Regulations

In your own interests and that of safety, is the law that ALL gas
appliances are installed by a competent person in accordance
with the current issue of the above regulations.

Warning

Make sure that nothing obstructs the rear side grille or clearances.
See page 4 for minimum clearances.

Boilers Installed in a Compartment

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

Do not use the compartment for storage purposes.

Maintenance

To ensure the continued efficient and safe operation of the
boiler it is recommended that it is checked and serviced as
necessary at regular intervals. The frequency of servicing will
depend upon the particular installation conditions and usage,
but in general once a year should be enough.

It is the law that servicing must be carried out by a competent
person.

If this appliance is installed in a rented property there is a duty
of care imposed on the owner of the property by the current
issue of the Gas Safety (Installation and Use) Regulations,
Section 35.

To obtain service please call your installer or Heatcall (Glow­worm’s own service organisation) using the telephone number
given on the front panel.

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

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

Boiler Electrical Supply

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

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

BS7671.
Heat resistant flexible cable having a conductor size of 0.75mm

to the current issue of BS6500 Table 16 must be used.

To Connect an Electrical Plug

The standard colours of three core flexible cable are,
Brown - live, Blue - neutral, Green and Yellow - earth.

As the markings on your plug may not correspond with these
colours, continue as follows:

The Blue cable must be connected to the terminal marked “N”
or “Black”.

The Brown cable must be connected to the terminal marked “L”
or “Red”.

The Green and yellow cable must be connected to the terminal
marked “E” or “Green” or the earth symbol

To Light the Boiler

WARNING. If the pilot light goes out for any reason, do not
attempt to relight until 3 minutes have elapsed.

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

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

OFF.
Push in slightly and turn gas control knob “A” clockwise until

is against its setting point.
Turn thermostat control knob “B” anticlockwise until “O” is

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

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

Push in and release piezo ignition button “C” until the pilot
burner lights.

THERMOSTAT

9009

PIEZO IGNITION
BUTTON 'C'

GAS
CONTROL
KNOB 'A'

E

SETTING
POINTS

2

,

GAS CONTROL KNOB
= OFF

= PILOT/IGNITION
= MAIN BURNER

CONTROL
KNOB 'B'

.

SETTING
POINT

Diagram 1

3

221763A

Instructions for Use

Air may be present in the supply pipe so the lighting of the pilot
may need to be repeated until all the air has been expelled.

When the pilot is alight, view through window “E”, keep gas
control knob “A” fully pushed in for about 15 seconds, then
release.

If the burner fails to stay alight, wait 3 minutes, then repeat the
lighting procedure only now keep control knob “A” pushed in for
a little longer before releasing.

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

If the gas control knob “A” is turned to
it being turned on again for a short period. No attempt should
be made to relight the pilot until 3 minutes have elapsed.

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

Set any system controls to “ON” or “HIGH”.
Turn the boiler thermostat knob “B” clockwise until “MAX” is

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

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

o

C (180oF).

, a safety lock prevents

is

To Turn the Boiler Off

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

For longer periods, depress slightly and turn gas control knob
“A” fully clockwise until is against its setting point. Turn
thermostat control knob “B” anticlockwise to “O”. Isolate the
boiler from the electrical supply. Follow full lighting procedure
to relight. Refer also to “Protection Against Freezing”.

Replacement Parts/Boiler Identification

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

Clearances

Minimum clearances must be left around the boiler as shown in
diagrams 1.3, 1.4 and 1.5.

Gas Leak or Fault

If a gas leak fault exists or is suspected the boiler must be turned
off, including the electrical supply and must not be used until the
fault has been put right. Advice/help should be obtained from
the local gas undertaking or your installation/servicing company.

Protection Against Freezing

If the boiler is to be out of use for any period of time during severe
weather conditions we recommend the whole system including
the boiler, be drained off to avoid the risk of freezing up. If an
immersion heater is fitted to the hot water cylinder make sure it
is switched off.

Sheet Metal Parts

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

Cleaning

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

Do not use abrasive cleaners.

221763A

4

General Data

✽ Refer to BOILER CASING
HEIGHT diagram

✝ A SPECIAL TOP CASING

5

TO SUIT 600mm (23

in.)

/

8

WORKTOPS IS AVAILABLE

A

C

L

B

✽

C

GAS CONNECTION

1

1

/

Rc

/

(

2

2

in. B.S.P.T.)

WATER CONNECTIONS

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

✝ F(MIN.)

G(MIN.)

H

D

J

WATER CONNECTIONS Rc1 reduced
with DISTRIBUTOR TUBE to

3

Rc

L

C

K

3

/

(

/

in. B.S.P.T.) (pumped return)

4

4

N

L

C

M

L

P

E

G(MIN.)

GENERAL DIMENSIONS - given in millimetres (Approx. inches)

Diagram 1.1

ABCDE✝FG H J K L MN P

mm 387 171 558 294 363 533 3 300 445 121 156 664 292 398

1071

in. 151/463/422 111/2141/421

Important Notice

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

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

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

1.1 Data

Weight of boiler 105.8kg (232lb)
Water content 8.64litre (1.9 gall)
Gas connection Rc
Water connection Rc1 1 in BSP
Electrical supply 230V ~ 50Hz fused 3A
Burner Aeromatic

All dimensions are given in millimetres (except as noted).
The Seasonal Efficiency Domestic Boilers UK (SEDBUK)

is 72.6%.
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

/2 1/2inBSP

1.2 Range Rating

This boiler is range rated and may be adjusted to suit individual
system requirements.

The tables give the appropriate settings and ratings.
The boiler heat input is factory preset to its maximum rating.

This should be adjusted to suit individual system requirements.
The arrow indicator, from the loose items pack, should be stuck

on the data label to indicate the setting.

1.3 Sheet Metal Parts

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

1

/8113/4171/243/461/8261/8111/2155/

8

1.4 Statutory Requirements

The installation of this boiler must be carried out by a competent
person in accordance with the relevant requirements of the
current issue of:

Manufacturer’s instructions, supplied.
The Gas Safety (Installation and Use) Regulations, The Building

Regulations, Local Water Company Bye-laws, The Building
Standards (Scotland) Regulations (applicable in Scotland) Health
and Safety at Work Regulations, Control of Substances
Hazardous to Health, 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, BS5440 Part 1 and 2, BS6798, BS5449, BS5546,
BS6700, BS7478, BS7593, BS7671.

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

RANGE RATING

NOMINAL
HEAT INPUT
(GROSS)

NOMINAL
HEAT
OUTPUT

BURNER
SETTING
PRESSURE
(HOT)

INJECTOR

5

kW

Btu/h

kW

Btu/h

mbar

in.w.g

min medium max

25.76 27.58 29.41

87,900 94,100 100,350

20.52 21.98 23.45

70,000 75,000 80,000

11.5 13.2 15.2

4.6 5.3 6.1

205749

221763A

General Data

1.5 B.S.I. Certification

This boiler is certificated by B.S.I. for safety and performance.
It is, therefore, important that no alteration is made to the boiler,
without permission, in writing, from Hepworth Heating Ltd.

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

1.6 Gas Supply

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

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

1.7 Electrical

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

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

Connection of the boiler and any system controls to the mains
supply through an unswitched shuttered socket outlet and 3A
fused 3 pin BS1363 plug. Alternatively, a 3A fused double pole
isolating switch may be used, having a minimum double pole
contact separation of 3mm, serving the boiler and system
controls only.

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

1.8 Boiler Location

This boiler is not suitable for outside installation.
The boiler may be installed in any room, although particular

attention is drawn to the requirements of the current issue of
BS7671 with respect to the installation of the boiler in a room
containing a bath or shower. Any electrical switch or boiler
control utilising mains electricity should be so situated that it
cannot be touched by a person using the bath or shower. The
electrical provisions of the Building Standards (Scotland)
Regulations are applicable to such installations in Scotland.

The boiler must stand on a level floor, conforming with the local
authority requirements and building regulations. The base
temperature is within the requirements of BS5258. The boiler
may be stood on a wooden floor but a metal base plate is
required to protect plastic tiles and similar floor coverings.

Suitable clearance needs to be available at the sides of the
boiler to facilitate direct connection of pipework and making
good around the flue assembly. The actual clearance required
will vary with site conditions.

The casing can be fitted to the boiler at various heights. The top
casing can be discarded, if preferred, when fitting the boiler
under a worktop or fixture, see diagram 1.2.

When the boiler is to be installed level with work surfaces etc.,
minimum clearances should be provided as shown in diagram

1.3. Work tops which overhang the cupboard sides almost in
contact with the casing top, require a larger minimum air gap.
Flush sided fixtures require the same overall minimum space
but can have a reduced air gap on one side.

Boilers to be installed under work tops or fixtures, with or without
the casing top fitted, should be positioned to provide minimum
clearances as shown in diagram 1.4.

2

(24/0.20mm)

0982

To
floor
level

MAX.900 (35
MID. 890 (35in.)
MIN. 860 (34in.)

MAX.
MID.

MIN.

FLOOR
LEVEL

BOILER
WITH TOP
CASING

1

/

in.)

2

MAX.867 (34
MID. 857 (33
MIN. 827 (32

MAX.
MID.

MIN.

BOILER CASING ALTERNATIVE
HEIGHT POSITIONS

BOILER CASING HEIGHT(S)

WORKTOP

BOILER

10

3

(

/

8

in.)

10

3

(

/

8

in.)

407 MIN.
(16 in.)

CUPBOARDS

MINIMUM CLEARANCES
LEVEL WITH WORKTOP

WORKTOP OR FIXTURE

CUPBOARD

10

3

(

/

in.)

8

BOILER

10 (

/

in.)

3 (

8

10

3

(

/

in.)

8

3

WITH

TOP

CASING

CUPBOARD

MINIMUM CLEARANCES
UNDER WORKTOP, FIXTURES

BOILER
WITHOUT
TOP CASING

407 MIN.
(16 in.)

BOILER

5
(

1

/

in.)

8

BOILER

WITHOUT

TOP

CASING

1

/

in.)

8

3

/

in.)

4

1

/

in.)

2

Diagram 1.2

3

/

in.)

16

Diagram 1.3

CUPBOARD

10

3

(

/

in.)

8

Diagram 1.4

1066

0865

221763A

6

1 General Data

To facilitate minimum clearances it may be necessary to modify
the kitchen units or fixtures, depending upon which type of
connections are used.

A front access clearance should be provided as shown in
diagram 1.5.

The minimum gap behind the top casing is as shown in diagram

1.1. The boiler can be sited further away from the wall if required
to align with kitchen units etc. Refer to Section 3.5.

Combustible wall material must be 25mm (1in) away from flue
components. Refer to Section 3.5.

A special top casing, part No. 425524, can be purchased to
enable the boiler casings to be arranged flush with 600mm (23

in) deep work tops and kitchen units.

8

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

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

If the boiler is to be installed in a compartment, make sure that
nothing will obstruct the openings/vents in the compartment.

1.8 Heating System Controls

The heating system should have installed: a programmer and
room thermostat controlling the boiler.

Thermostatic radiator valves may be installed in addition to the
room thermostat.

Note: For further information, see The Building Regulations
1991 - Conservation of fuel and power, 1995 edition - Appendix
G, table 4b.

5

/

BOILER

700 (27

WALL OR
FIXTURE

FRONT CLEARANCE

1

/

in.)

2

0906

Diagram 1.5

2 Water Systems

2.1 Water Pressure Head

This boiler shall only be connected to a cistern supply, with a
minimum head of 1 metre (3ft) and a maximum of 27 metres
(90ft) and having an open vent in the system.

The boiler must not be connected to a sealed water system.

2.2 Inhibitor

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

When an inhibitor is to be used in the system, contact should be
made with an inhibitor manufacturer so they can recommended
their most suitable product.

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

2.3 Gravity Domestic and Pumped Heating

It is recommended that a cylinder thermostat is used to prevent
the stored water temperature becoming unnecessarily high.

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

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

2.4 Fully Pumped System

Where a single pumped, flow and return is taken from the boiler,
refer to diagram 2.2.

2.5 Circulation Pump

The pump should be set to give a temperature difference of
11oC (20oF) across the system. At the appropriate flow rate the
resistance through the boiler can be found from the pressure
loss graph, diagram 2.3.

If possible use a pump with integral valves, if not fit valves as
close as possible each side of the pump.

Note: If the pump is to be fitted inside the boiler casing a heat
shield kit is required. Kit No. 425838.

REFER TO BS 5546

22mm VENT

15mm COLD FEED

INDIRECT
CYLINDER

27metre
Max.

28mm

PUMP

BOILER
C

L

To Heating
Circuit

DRAIN OFF
COCK

Distributor tube in
pumped return
connection

Diagram 2.1

0869

7

221763A

2 Water Systems

2.6 Cylinder

For all systems supplying domestic hot water the cylinder must
be indirect and to the appropriate British Standard.

2.7 Safety Valve

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

22mm VENT

15mm
COLD FEED

1 metre
MIN.
27metres
MAX.

DRAIN OFF
COCK

FULLY PUMPED SYSTEM
(DIAGRAMMATIC)

TO INDIRECT
CYLINDER

PUMP

BOILER
C

L

Distributor tube in
pumped return
connection

To Heating
Circuit

Diagram 2.2

2.8 Drainage

A drain tap must be provided at the lowest points of the system
which will allow the entire system, including the boiler and
domestic hot water cylinder to be drained. Drain taps shall
comply with the current issue of BS2879.

FLOW RATE (GALLON/MINUTE)

0870

WATER PRESSURE LOSS

(metre HEAD OF WATER)

PRESSURE LOSS OF BOILER

0123456789

2.00

1.75

1.50

1.25

1.00

0.75

0.50

0.25

0

6

0

FLOW RATE (LITRES/MINUTE)

12 18

24 30 36 42

Diagram 2.3

1074

70

60

50

40

30

20

WATER PRESSURE LOSS

10

0

(INCHES HEAD OF WATER)

3 Flue and Ventilation

3.1 Flue

Detailed recommendations for flues are given in the current
issue of BS5440 Part 1.

The boiler must be installed so that the flue terminal is exposed
to the external air. It is important that the position allows the free
passage of air across it at all times.

3.2 Terminal Positioning

The minimum acceptable spacings for the terminal to
obstructions, other terminals and ventilation openings are given
in diagram 3.1.

Car port or similar extensions of a roof only, or roof and one wall,
require special action with regard to openings, doors and
windows under the roof. Care is required in protecting plastic
roofs. If the car port consists of a roof and two or more walls
seek advice form the local gas region.

Where the terminal is within 850mm (34in) below plastic guttering,
or within 450mm (18in) of painted eaves or gutter an aluminium
shield 1.5 metres (5ft) long should be fitted to the underside and
immediately beneath the guttering.

The air inlet/products outlet duct and the terminal of the boiler
must not be closer than 25mm (1in) to combustible material.

3.3 Timber Frame Buildings

If the boiler is to be installed in a timber frame building it should
be fitted in accordance with the Institute of Gas Engineers
document IGE/UP/7/1998. If in doubt seek advice from the local
gas undertaking or Hepworth Heating Ltd.

3.4 Protecting the Terminal

A terminal guard is required if persons could come into contact
with the terminal or the terminal could be subject to damage.

If a terminal guard is required, it must be positioned to provide
a minimum of 50mm clearance from any part of the terminal and
be central over the terminal.

A suitable guard is available from

Tower Flue Components Ltd.,
Morley Road,
Tonbridge,
Kent.
TN9 1RA

reference type “F”

3.5 Flue Duct Length

The flue lengths quoted below allow the minimum rear clearance
of 3mm (1/8inch) behind the boiler, although the boiler can be
installed further away from the inside wall. In such cases any
extra clearance behind the boiler must be added to the wall
thickness to obtain the flue duct length.

Check the wall thickness/flue duct length where the boiler is
fitted. Flues available are:

Standard pack - 280 to 410mm (11 to 16inches)
Short pack - 150 to 280mm (6 to 11inches)
Extension Kit (+standard pack) 410 to 610mm

(16 to 24inches)

The short flue pack, 424638 and the extension kit, 424680 are
available to order. Standard pack is 424604.

221763A

8