Glow-worm 80CFF User Manual
Instructions for Use
Installation and Servicing
To be left with the user
Hideaway
80C FF
G.C. No. 41-047-41
2000225006B.03.02
9919
Chimney
Fanned Flue Boiler
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: (01773) 828100
Fax: (01773) 828070
Nottingham Road, Belper, Derbyshire. DE56 1JT
Tel: (01773) 824141 Fax: (01773) 820569
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 1.3.
CE MARK
This boiler meets the requirements of Statutory Instrument No. 3083 The boiler (Efficiency) Regulations, and therefore is deemed
to meet the requirements of Directive 92/42/EEC on the efficiency requirements for new hot water boilers fired with liquid or gaseous
fuels.
Type test for purposes of Regulation 5 certified by: Notified body 0086.
Product/production certified by: 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.
SPARE PARTS
REMEMBER, when replacing a part on this appliance, use only spare parts that you can be assured conform to the safety and
performance specification that we require. Do not use reconditioned or copy parts that have not been clearly authorised by Hepworth
Heating Ltd.
MANUAL HANDLING GUIDANCE
During the appliance installation and the replacement of the heat exchanger it will be necessary to employ caution and assistance
whilst lifting as the appliance or component exceeds the recommended weight for a one man lift.
In certain situations it may be required to use a mechanical handling aid.
Take care to avoid trip hazards, slippery or wet surfaces.
CONTENTS DESCRIPTION SECTION PAGE No.
INSTRUCTIONS
FOR USE
INSTALLATION
INSTRUCTIONS
Introduction 3
Lighting the Boiler 4
General Data 1 5
Water Systems 2 8
Flue & Ventilation 3 9
Installation 4 10
Electrical Wiring 5 17
Commissioning 6 18
Instructions to User 7 20
SERVICING
INSTRUCTIONS
2000225006B
Servicing 8 20
Fault Finding 9 23
Replacement Parts 10 26
Spare Parts 11 28
2
Instructions for Use
Introduction
Please read these instructions and follow them carefully for the
safe and economical use of your boiler.
The Glow-worm Hideaway C FF series are fanned flue boilers
with a chimney flue adapter. They provide heating and if
required, an indirect domestic hot water supply.
The boiler is automatic in operation, having only one user
control, the boiler temperature control.
Gas Safety (Installation and Use) Regulations
In your own interests and that of safety, it is the law that ALL gas
appliances are installed by a competent person in accordance
with the current issue of the above regulations.
WARNINGS
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.
Clearances
Make sure that nothing obstructs the ventilation grills or
clearances.
Minimum clearances must be left around the boiler as
shown in diagrams 1.6, 1.7 & 1.8.
Sheet Metal Parts
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.
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 grill on the
boiler.
Do not use the compartment for storage purposes.
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.
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 inside of the front panel.
Please be advised that the ‘Benchmark’ logbook should be
completed by the installation engineer on completion of
commissioning and servicing.
All CORGI Registered Installers carry a CORGI ID card, and
have a registration number. Both should be recorded in your
boiler Logbook. You can check your installer is CORGI registered
by calling CORGI direct on :- 01256 372300.
Boiler Electrical Supply
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
.
2
,
3
2000225006B
Instructions for Use
To Turn the Appliance On
Turn the electrical supply on to the boiler and check that all
remote controls are calling for heat.
Turn the boiler temperature control clockwise to any position
between “0” and "Max", see diagram 1.
"MAX" is approximately 82°C (180°F).
The boiler lighting operation is now automatic as follows:
The fan operates and after a short period of time, the spark
ignition operates, the solenoid opens, then the burner will light
shown by the burner ON neon (green) on the control panel
lighting up.
The burner will remain alight until switched off by the control
thermostat or any remote control.
Note: If the boiler is turned OFF at the boiler temperature
control, wait at least 30 seconds before switching on again.
When the boiler switches off, the burner will go out.
The automatic lighting sequence will operate again when heat
is required.
It should be noted that this is a fanned flue appliance and fan
operation may be heard.
If the reset neon lights, turn the boiler temperature control to "0"
(off), wait 30 seconds, then repeat the lighting instructions.
BOILER
TEMPERATURE
CONTROL
9857
To Turn the Appliance Off
For short periods, turn the boiler temperature control fully anticlockwise to “0” (off).
To relight, turn the boiler temperature control to any position
between “0” and “Max”.
For longer periods, turn the boiler temperature control fully anticlockwise to “0” (off) and switch off the electrical supply to the
boiler.
To relight follow the lighting sequence given above.
"OFF"
POSITION
RESET
NEON
"BURNER ON"
NEON
Diagram 1
2000225006B
4
1 General Data
A
10125
B
C
*
L
M
J
D
C
E
GENERAL DIMENSIONS - given in millimetres
F
L
K
H
G
NOTE:
The boiler casing can be set at
two heights, MAX. and MIN.
WATER CONNECTIONS
Rc1 reduced with
DISTRIBUTOR TUBE to
3
Rc
(pumped return)
GAS CONNECTION
Rc
WATER CONNECTIONS
Rc1 (1in. B.S.P.T.)
INSIDE DIAMETER OF
*
ADAPTOR FOR 125mm (5in)
NOMINAL DIAMETER FLUE
TO BS567
3
/
(
/
in. B.S.P.T.)
4
4
1
1
/
(
/
in. B.S.P.T.)
2
2
Diagram 1.1
A B C D E F G H J K L M
mm 387 145 558 294 364 555 442 3 Max 900/ 300 80 32
Min 860
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.
Refer to Manual Handling Operations, 1992 Regulations.
Sheet Metal Parts
WARNING. When installing or servicing this boiler, care should
be taken to avoid any possibility of personal injury when handling
the edges of sheet metal parts.
1.1 Technical Data
Refer to diagrams 1.1, 1.2, 1.3 and 1.4.
All dimensions are given in millimetres (except as noted)
Approximate weight of complete boiler : 131.5kg (290lb)
Water content : 5.76 litre (1.27gallons)
Gas connection : Rc
Water connection : Rc1 (1in BSPT)
Electrical supply : 230V~50Hz, fused 3A
Burner : Aeromatic
1
/2 (1/2in BSPT)
.
The Seasonal Efficiency Domestic Boilers UK (SEDBUK)
is "D" 78.4%.
The value is used in the UK Government’s Standard Assessment
Procedure (SAP) for energy rating of dwellings. The test data
from which it has been calculated have been certified by B.S.I.
1.2 Range Rating
See diagrams 1.2, for boiler ratings.
10153
Diagram 1.2
5
2000225006B
1 General Data
1.3 Statutory Requirements
The installation of this appliance must be carried out by a
competent person and must be in accordance with the relevant
requirements of the current issue of:
Manufacturer’s instructions supplied.
The Gas Safety (Installation and Use) Regulations, Building
Regulations, Local Water Company Bye-laws, The Building
Standards (Scotland) Regulations, (applicable in Scotland),
Health and Safety at Work Act, 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.
1.4 B.S.I Certification
This boiler is certificated by B.S.I., for safety and performance.
It is, therefore, important that no alteration is made to the boiler
unless agreed, in writing, by Hepworth Heating Ltd.
Any alteration not approved by Hepworth Heating Ltd., could
invalidate the B.S.I. certification, boiler warranty and could
infringe the current issue of the Statutory Requirements.
To
floor
level
MAX.900
MIN. 860
MAX.
MIN.
FLOOR LEVEL
BOILER CASING HEIGHT(S)
WORKTOP
9922
BOILER
CASING
ALTERNATIVE
HEIGHT
POSITIONS
Diagram 1.3
9923
407 MIN.
1.5 Gas Supply
The gas installation should be fitted in accordance with the
current issue of BS6891.
The supply from the governed meter must be of adequate size
to provide a steady inlet working pressure of 20mbar (8in wg) at
the boiler.
On completion test the gas installation using the pressure drop
method and suitable leak detection fluid, purge in accordance
with the current issue of BS6891.
1.6 Electrical
WARNING. This boiler must be earthed.
The electrical installation must be carried out by a competent
person. All external components 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 plug, both to the current issue of BS1363.
Alternatively, a 3A fused double pole isolating switch may be
used, having a minimum double pole contact separation of
3mm, serving only the boiler and system controls.
Heat resistant cable of at least 0.75mm
current issue of BS6500 Table 16, must be used for all
connections within the boiler casing, to the control box, pump
etc.
2
(24/0.20mm), to the
10
407 MIN.
BOILER
CUPBOARDS
MINIMUM CLEARANCES
LEVEL WITH WORKTOP
WORKTOP
OR FIXTURE
25
10
10
5
BOILER
Diagram 1.4
10
9924
10
1.7 Condensate Drain
A plastic drain pipe may need to be fitted to allow discharge of
condensate to a drain.
Condensate should, if possible, be discharged into the internal
household draining system. If this is not practical, discharge can
be made externally into the household drainage system or a
purpose designed soak away, see section 4.10 for more details.
2000225006B
CUPBOARD
MINIMUM CLEARANCES
UNDER WORKTOP, FIXTURES
6
CUPBOARD
Diagram 1.5
1 General Data
1.8 Boiler Location
This boiler is not suitable for outside installation.
The boiler casing can be fitted at two heights. Refer to
diagram 1.3.
The boiler is assembled at the factory with the control box and
heat shield fitted in the lower position.
The boiler must stand on a level floor, conforming with local
authority requirements and building regulations.
The base temperature is within the requirements of the current
issue of BS5258. The boiler may stand on a wooden floor but
a metal base plate is required to protect plastic tiles and similar
floor coverings.
Suitable installation 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.
When the boiler is to be installed level with work surfaces and
the like, minimum clearances should be provided as shown in
diagram 1.4. 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, should be
positioned to provide minimum clearances as shown in diagram
1.5. To facilitate minimum clearances it may be necessary to
modify kitchen units and fixtures.
Combustible material must not be 25mm (1in) away from flue
components see diagram 1.5.
A front access clearance for servicing, should be provided as
shown in diagram 1.6.
The boiler must not be installed in a room used or intended to
be used as sleeping accommodation or a room containing a
bath or shower.
Where the installation of the boiler will be in an unusual location,
special procedures are necessary the current issue of BS6798
gives detailed guidance on this aspect.
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 or compartment
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.
700
WALL OR
FIXTURE
FRONT CLEARANCE
9713
BOILER
Diagram 1.6
1.9 Heating System Controls
The heating system should have installed: a programmer and
room thermostat controlling the boiler.
Thermostatic radiator valves may be installed, however they
must not be fitted in a room where the room thermostat is
located.
Note: For further information, see the current issue of the
Building Regulations, approved document L1, and the
references:
1) GIL 59, 2000: Central heating system specification (CheSS)
and
2) GPG 302, 2001: Controls for domestic central heating
system and hot water. BRECSU.
7
2000225006B
2 Water Systems
2.1 Water Pressure Head
The boiler shall only be connected to a cistern water supply with
a minimum head of 1metre (3ft3in) and a maximum head of
27metres (90ft) which has an open vent in the system.
The working pressure must be within the range 0.1bar to 2.7bar
(1.3 to 39lbftin
The boiler MUST NOT be connected to a sealed water system.
2
).
2.2 Inhibitor
Attention is drawn to the current issue of BS5449 and BS7593
on the use of inhibitors in central heating systems.
If an inhibitor is to be used in the system, contact should be
made with the inhibitor manufacturers so that they can
recommend their most suitable product.
When using in an existing system take special care to drain the
entire system, including the radiators, then thoroughly clean 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
when the central heating pump is off.
The domestic primary flow and return must be 28mm o.d. 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 Pumped Heating and Hot Water
Where a single flow and return is taken from the boiler, a
minimum static head of 1metre (3ft3in) must be provided
between the water line of the feed tank and the centre of the
waterway, see diagram 2.2.
2.5 Circulation Pump
Normally the pump should be set to give a temperature difference
o
of 11
C (20oF) across the boiler. At the appropriate pumped flow
rate the pressure loss through the boiler can be found from the
graph, diagram 2.3.
Use a pump with integral valves or fit isolating valves as close
to the pump as possible.
2.6. Cylinder
For all systems supplying domestic hot water the cylinder must
be indirect.
2.7 Safety Valve
A safety valve need not be fitted to an open vented system.
2.8 Draining Tap
A draining tap must be provided at the lowest points of the
system which will allow the draining of the entire system,
including the boiler and hot water cylinder.
Draining taps should be to the current issue of BS2879.
2.9 Thermostatic Radiator Valves
If thermostatic radiator valves are fitted care must be taken to
ensure that there is an adequate flow rate through the boiler
when they close, refer to the current issue of BS7478 for
guidance. If fitted to all radiators ensure a bypass is fitted and
adjust to achieve a temperature difference no greater than 20oC
between flow and return with the thermostatic valves closed.
REFER TO BS 5546
22mm VENT
15mm COLD FEED
INDIRECT
CYLINDER
(Shown with
27metres
Max.
LER
1 metre
MIN.
27metres
MAX.
BOILER
C
L
DRAIN OFF
COCK
DRAIN OFF
COCK
recommended
thermostat and valve).
28mm
PUMP
Distributor tube in
pumped return
connection
22mm VENT
15mm
COLD FEED
PUMP
FULLY PUMPED SYSTEM
(DIAGRAMMATIC)
FLOW RATE (GALLON/MINUTE)
0123456789
2.00
1.75
1.50
1.25
1.00
0.75
0.50
WATER PRESSURE LOSS
(metre HEAD OF WATER)
0.25
0
6
0
FLOW RATE (LITRES/MINUTE)
12 18
Heating
Circuit
Diagram 2.1
TO INDIRECT
CYLINDER
Heating
Circuit
Distributor tube in
pumped return
connection
Diagram 2.2
24 30 36 42
Diagram 2.3
0869
0870
1074
70
60
50
40
30
20
WATER PRESSURE LOSS
10
0
(INCHES HEAD OF WATER)
2000225006B
8
3 Flue and Ventilation
Important Notes
The flue must be installed in accordance with the rules in force
in the countries of destination.
The flue must be in accordance with the current issue of
BS5440 Part 1.
The Chimney Flue Adapter Kit (Pt. No. 2000461993) socket is
designed to take flue pipes to the current issue of BS567. If a
flue pipe to BS715 is to be used, an adapter must be fitted to the
boiler flue socket.
The flue must be at least equivalent to 1m vertical.
The maximum flue length must not exceed 15m vertical.
Due to the Sedbuk D efficiency of the Hideaway FF if the flue
length exceeds the following ;
80C FF - 9m
then provision must be made to ensure that the condensate
products are drained away and that the flue liner is of the
appropriate specification. We would recommend that one of the
following flue liners should be used or an equivalent specification:
Ritevent - Chimflex LW or SB
Selkirk - Selflex TS or TSE
An existing liner must be changed if there is any doubt that it will
not operate safely throughout the life of any new appliance.
A drain point is incorporated on the chimney flue adapter to
which a drain pipe can be connected, refer to section 4.10.
SEALING AND
CLAMPING
PLATE
AIR
SPACE
150mm (6in) plug of Mineral Wool or similar
SEALING
PLATE
600mm
9914
3.1 Flue Guidelines
The flue should be kept as short as possible. Horizontal or very
shallow runs of the flue should be avoided as they encourage
local cooling.
Always choose a flue route which will cause the least cooling of
the flue.
There should be a vertical rise of at least 600mm (2ft) before
using a bend. 90o elbows should not be used.
The existing flue may not be completely sound. Therefore, to
prevent the possibility of leakage, additional sealing MUST be
carried out between the base of the chimney and the flue liner.
The end of the flue 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 the
least above the eaves of a pitched roof. Use a certificated
terminal.
If the flue is passed through or near any combustible material it
should be installed in accordance with the current issue of
BS5440 Part 1.3. If in doubt seek advice from the local gas
undertaking or Hepworth Heating Ltd.
3.2 Existing Chimney
An existing brick chimney must be thoroughly swept and all
debris cleared away before lining.
Remove any damper or register plate. Alternatively it may be
locked in the fully open position.
A flexible flue liner is preferred but a rigid liner may be used, with
connection to the boiler flue socket made with a short vertical
piece of flexible liner, see diagram 3.2.
The sealing plate also prevents debris falling and gives the flue
better insulation, reducing the possibility of condensation, see
diagram 3.1.
Check the system efficiency before installing the boiler.
Diagram 3.1
RIGID
FLUE
LINER
FLEXIBLE
LINER
APPROVED
SEAL
BOILER
Diagram 3.2
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, preferably flexible metallic be
used. Fix and seal it to the boiler flue socket and make good with
an approved seal.
If a flue and false chimney breast are to be constructed all
openings for pipework to upper floors etc. must be sealed.
If a specially built compartment is constructed for the boiler, it
must conform to the requirements of the current issue of
BS5440 Part 1 and BS5871.
9915
9
2000225006B
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