Glow-worm Compact 100E User Manual

Instructions for Use

Installation and Servicing

To be left with the user

COMPACT 100e

G.C. No. 47 047 08A

Fanned Flue Combination Boiler

221894A.04.01

7086

This is a Cat I2H Appliance

The instructions consist of three parts, User, Installation and Servicing Instructions, which include 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.

Guarantee Registration

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

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

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

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

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

❑ ❑ ❑

✔ ✔ ✔

All replacement parts All labour charges All call-out charges

to offer our customers' a Comprehensive First Year Guarantee.

return as soon as possible.

Service number 01773 828100.

FOR 1ST YEAR GUARANTEE PROTECTION

CALL 0208 247 9857

One Contact Local Service

Customer Services: Tel: (01773) 828100 Fax: (01773) 828070

Hepworth Heating Ltd.,

Nottingham Road, Belper, Derbyshire. DE56 1JT

General/Sales enquiries:

Tel: (01773) 824141 Fax: (01773) 820569

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/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.

Substances Hazardous to Health

The adhesives and sealants used in this appliance are cured and give no known hazard in this state. INSULATION PADS/CERAMIC FIBRE, GLASSYARN, 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.

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.

CONTENTS DESCRIPTION SECTION PAGE No.

INSTRUCTIONS

FOR USE

INSTALLATION

INSTRUCTIONS

Introduction 3 Clock Settings 4 Lighting the Boiler 5

General Data 1 7 Boiler Position 2 9 Flue and Ventilation 3 10 Heating System 4 11 Domestic Hot Water System 5 12 Installation Preparation and Gas/Water Connections 6 13 Flue Preparation 7 13 Mounting the Boiler 8 16 Electrical Connections 9 20 Commissioning 10 22

SERVICING

INSTRUCTIONS

221894A

General Data 11 25 Servicing 12 25 Fault Finding 13 27 Replacement Parts 14 32 Spare Parts 15 43

Instructions for Use

Introduction

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

This boiler must have been installed by a competent person in accordance with the current rules in force in the countries of destination at the time of installation.

Once the controls are set, the boiler is automatic in operation. The Compact combination boiler is able to provide room heating

as part of a central heating system and domestic hot water direct from the cold water supply, without the need for secondary storage.

The boiler can be fitted with one of two makes of clock, which look like this:-

Clock / Timers

AUTO

DAY HR MIN

Digital timer

RUN

WThFSSu

Electro / mechanical clock / timer

IMPORTANT NOTICE:

This boiler is for use only on G20 gas.

Gas Leak or Fault

If a gas leak or fault exists or is suspected, turn the boiler off and consult your local gas company or your local installation/ servicing company.

Mains Water Temperature

NOTE: The mains incoming water temperature in the winter is lower than in summer.

To achieve the same outlet water temperature in the winter, it will be necessary to reduce the water flow rate using the hot water tap.

Boilers Installed in Compartments

If the boiler has been fitted into a compartment or cupboard, do not obstruct the compartment air supply vents.

Do not use the compartment for storage.

The colours of three core flexible cable are, blue - neutral, brown

- live, green and yellow - earth. As the markings on your plug may not correspond with these

colours continue as follows:The wire coloured blue must be connected to the terminal

marked “N” or “Black”. The wire coloured brown must be connected to the terminal

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

terminal marked “E” or “Green” or the earth symbol PVC flexible cable having a conductor size of 0.75mm

0.20mm) must be used within the boiler casing to connect to the boiler.

Electrical Supply Failure

6937

The boiler will not work without an electrical supply. Normal operation of the boiler should resume when the electrical

supply is restored. Note. The boiler safety cutoff may have operated, please refer

to the following section to reset. Reset any external controls, to resume normal operation of the

central heating. The digital timer, has a lithium battery back up and will not need

resetting. Unless it is without power for a considerable period.

Boiler Safety Cutoff Reset Button

The boiler is fitted with a safety cutoff device to prevent damage through overheating.

Should the main burner go out during a demand the red lockout light “F” will illuminate on the control fascia situated above the Reset Button “G”, see diagram 4.

The red light will not illuminate if there is no system demand.

Allow the boiler and system to cool down waiting at least a minimum of four minutes before pressing the Reset button “G”.

The boiler will take a few seconds to reset after the button is pressed.

If the problem persists, turn the boiler off and consult your installation/ servicing company.

The Gas Safety (Installation & Use) Regulations

In your interests and that of safety it is the law that ALL gas appliances are installed by competant persons in accordance with the current issue of the above regulations.

(24/

Electrical Supply

WARNING. The boiler must be earthed. The boiler must be connected to a 230V~50Hz permanent

supply. Connection of the whole electrical system of the boiler and any

heating system controls to the electrical supply, must be through one common isolator.

Isolation should preferably be by a double pole switched fused spur box. The fused spur box should be readily accessible and preferably adjacent to the appliance. It should be identified as to its use.

Alternatively a fused 3A 3 pin plug and shuttered unswitched socket may be used.

221894A

Instructions for Use

Setting Instructions for Electro/mechanical Clock - if fitted

This clock has a twenty four hour dial, that is, 1pm is 13. To set the time, turn the whole face clockwise until the pointer

is against the time of day. To set any “Off” time, push the tappets outwards. To set any “On” time, push the tappets inwards. Time can be set either “On” or “Off” in fifteen minute segments. Note. The clock supplied could be fitted with an override device,

see diagram 1, which switches the clock programme “On” or “Off” permanently.

The switch will need to be repositioned to resume programmed working.

OVERRIDE

CLOCK FACE

SWITCH

POINTER

TAPPETS

CONSTANT OFF

PROGRAMMED CONSTANT ON

Diagram 1

Setting Instructions for the 7 Day Digital Clock/Timer

This is a 24 hour clock/timer, that is 1pm is 13:00, and has 8 “ON” and 8 “OFF” daily switching actions.

It is fitted with a lithium battery back up which protects the programme in the event of an electrical failure. The battery should have a life of several years.

6939

AUTO

RUN

WThFSSu

3. Set day of week by pressing button DAY.

4. Set time of day by pressing buttons HR and MIN.

5. Set RUN switch to the central position, colon will flash, this indicates the clock is set.

With the clock set, the factory preset programme shown below will operate.

Setting Timed Programmes

With the clock set to the correct time, see SETTING THE CLOCK paragraphs 1-4, and then continue as follows:

1. Set RUN switch to P , the display will indicate

MON/FRI

ON - 06:30 OFF - 08:30

6938

2. Set day of week to be programmed by pressing the

3. Set time of day by pressing the buttons HR and MIN.

4. Press button P to confirm programmes, the

5. Repeat procedures 2, 3 and 4 until desired

6. Set the RUN switch the central position, your

General Notes.

ON - 16:30 OFF - 22:30

the 1st (ON) preset programme and the symbol .

DAY button. Note: The days can be selected individually or as

groups: Mon-Fri., Mon-Sat., Mon-Sun., Sat/Sun. An arrow will be displayed under the day

or days selected.

display will indicate the 2nd (OFF) preset programme and subsequently, 3rd, 4th, 5th, 6th, 7th, 8th.

programmes are set. Note. It is not a requirement to use the 8 on/off

programmes.

appliance will now operate at the programmed times.

With the AUTO switch in the I position the central heating will operated constantly ON.

With the AUTO switch in the O position the central heating will not operate.

Soft Override button indicated by the symbol

, this function will override the current

central heating programme for the next available. ON time programmes are indicated by the symbol

SAT/SUN

ON - 07:00 OFF - 09:00 ON - 16:00 OFF - 23:00

DAY HR MIN

Diagram 2

Setting the Clock - Diagram 2

1. With both AUTO and RUN switches set to the central position, press R reset button, the display will flash.

2. Set RUN switch to .

221894A

To Light the Boiler

1. Check that all four isolating valves are open, the levers in line with the valvebody, see diagram 3.

2. Open the controls cover door and familiarise yourself with the controls, see diagram 4.

3. CAUTION. A sealed pressurised system must be filled and pressurised by a competent person. (Optional extra filling loop kit No. 457120).

Only operate the boiler when you are sure that the system has been filled and pressurised. Check this by looking at the pressure gauge “A”, it should read 0.7bar minimum.

Instructions for Use

4. Open a hot water tap, check that water flows, then close it.

5. If you are in any doubt about the boiler being filled with water contact your installation/servicing company or the local gas company.

6. Check that the electrical supply to the boiler is ON at the external isolator.

7. Check lockout light, refer to boiler safety cutoff reset button.

8. Set the switch “B” to 1 situated on the control fascia.

9. Set the summer / winter button “J”, light “L” or “K” will illuminate.

10. Set “C”, clock/timer (if fitted) and any remote controls as required.

11. Check the lights “D” and “E” are illuminated on the control fascia.

Close the controls cover door. In certain circumstances, a surge in water pressure may cause

the appliance to operate momentarily, this will be indicated by the pump starting and the fan speed increasing. This is quite normal.

Domestic Hot Water Temperature

The sanitary water temperature control knob “M”, see diagram 4, will control the desired temperature of the water until the flow exceeds the capability of the boiler to give the required temperature rise.

Then the temperature is determined by controlling the hot water flow from the tap ie: reduce flow - increase temperature

increase flow - reduce temperature

NOTE : The mains incoming water temperature in the winter is lower than in the summer.

SAFETY VALVE DISCHARGE PIPE POSITION

Summer / Winter Selector Button

Adjust the central heating water temperature control knob “N” to desired setting.

For central heating set button “J” to Winter light “K” will illuminate. The main burner will light. The burner ON light “D” will illuminate.

When the heating is controlled by a room thermostat and/or a time switch, button “J” must be set to Winter light “K” will illuminate.

If a hot water tap is opened while the boiler is on for heating, priority will be given to hot water.

To turn the heating off for short periods, set button “J” to summer “Off” light “L” will illuminate.

To turn on again set button “J” to winter “On”, light “K” will illuminate.

To Turn the Boiler Off

To turn the boiler off, set switch "B" to O. To turn on again follow the operating instructions.

Maintenance and Servicing

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 servicing will depend upon the particular installation conditions and usage, but in general once a year should be enough.

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

Servicing/maintenance should be carried out by a competent person in accordance with the rules in force in the countries of destination.

To obtain service, please call your installer or Heatcall (Glowworm’s own service organisation) using the telephone number

7013

behind the controls cover door. 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.

HEATING FLOW

LEVER (OPEN) HEATING FLOW/ RETURN

HOT WATER OUT

GAS SERVICE COCK

LEVER (OPEN) COLD WATER SUPPLY IN/OUT

COLD WATER SUPPLY IN

HEATING RETURN

SLOT (OPEN) GAS SERVICE COCK

Diagram 3

Clearances

The boiler requires a clearance in front, below and at the sides of the casing for safety, servicing and maintenance access, see diagram 2.1.

Protection Against Freezing

The boiler has a 2 stage built in frost protection. Provided power and gas are available and there is adequate pressure in the system, if the water temperature within the appliance falls below

C approx. the pump only will come on. If the water temp

10 continues to fall to 6oC approx. the main burner will fire at min rate until the water in the appliance is greater than 15 This is a separate function to any remote frost protection fitted.

C approx.

221894A

Instructions for Use

PRESSURE GAUGE ‘A’

CONTROLS FASCIA

RESET BUTTON

‘G’

‘D’

‘H’

‘E’

‘F’

SUMMER/ WINTER BUTTON

‘L’

‘K’

CENTRAL HEATING WATER TEMPERATURE

CONTROL KNOB

‘J’

‘N’

SANITARY WATER TEMPERATURE

CONTROL KNOB

‘P’

CLOCK TIMER IF FITTED

‘Q’

MAINS ELECTRIC

SWITCH

6941

‘M’

‘C’

‘B’

KEY TO NEON LIGHTS

‘F’ BOILER LOCKOUT

‘D’ BURNER IGNITED

‘H’ ‘L’

‘K’ WINTER SETTING

Other system pipework external to the boiler may require frost protection.

If the boiler is to be out of use for any long periods during severe weather, it is recommended that the whole system, including the boiler, should be drained to avoid the risk of freezing. Make sure that, if fitted, the immersion heater in the cylinder is switched off.

If in doubt, contact you installation/servicing company for advice.

LOW WATER PRESSURE SUMMER SETTING

‘E’ ‘P’

‘Q’ CENTRAL HEATING DEMAND

POWER ‘ON’ SANITARY DEMAND

Draining and Filling

CAUTION. This boiler works in a pressurised system which must only be drained, refilled and pressurised by a competent person.

Note: If the pressure gauge indicates a loss of system pressure, that is, less than 0.7bar, YOU MUST CONTACT YOUR INSTALLER.

Pressure Relief Safety Valve

CAUTION. A pressure relief safety valve and discharge pipe is fitted to the boiler. This valve must not be touched. Should there be any discharge from the pipe, turn the boiler off, isolate from the electrical supply and contact your installation/servicing company.

7565

CONTROLS COVER

Diagram 4

Cleaning

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

The boiler casing can be cleaned using a mild liquid detergent with a damp cloth, then a dry cloth to polish.

Do not use any form of abrasive or solvent cleaner as you may damage the paint work

Boiler Casing

CAUTION. Do not remove or adjust the casing in any way, as incorrect fitting may result in incorrect operation or failure to operate at all. If in doubt seek advice from the local gas company or your installation/servicing company.

Replacement Parts

If replacement parts are required apply to your local supplier or British Gas.

Please quote the name of the appliance.

221894A

1 General Data

9mm

Optional flue kits are available Horizontal top outlet and Vertical.

Diagram 1.1

A B C D E F G H J K L M N P

6942

450 700 300 100 75 138 142 18 135 65 110 138 85 115 103

EXTD. EASYFIT

TABLE 1

Lift Weight 31.7kg (69.89b) Total Weight 41.1kg (90.61lb)

Gas connection Ø 15mm compression Heating and return Ø 22mm compression Domestic hot water Ø 15mm compression Safety valve Preset 3bar (43.5lbf/in Safety valve discharge Ø 15mm copper Water content 1.42 litres (0.31 gallon)

■ Expansion vessel capacity 6 litres (1.32 gallons)

Heating cold fill 0.7bar pressure minimum (10.1lbf/in2)

❋ D.H.W 0.8 to 10bar

working pressure

■ Maximum Heating 60 litres

system water (13.2 gallons) content using with a cold fitted expansion fill pressure vessel. of 0.7bar

Electrical supply 230V~50Hz Electrical rating 150W fused 3A Internal Fuse rating 1) Type T2A

❋ Boiler starts at an inlet pressure of 0.5bar but

requires 0.8bar for maximum output.

■ For larger systems use an additional expansion

vessel, see Section 4.

Approximate gas 3.03m3/h rate at max input (107ft3/h)

1.1 Installation

Materials and equipment should be fit for their purpose and of suitable quality and workmanship.

1.2 Important Notice

This boiler is for use only on natural gas, G20.

1.3 Sheet Metal Parts

)

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

1.4 Requirements

The installation of this boiler must be carried out by a competent person in accordance with the current rules in force in the countries of destination at the time of installation.

Manufacturer’s instructions, supplied. Manufacturer’s instructions must not be taken as overriding

statutory requirements.

1.5 Data Label

The data label is on the inner case front, see diagram 1.2.

1.6 Data

See table 1 and diagrams 1.1, 1.2 & 1.3. The Seasonal Efficiency Domestic Boilers UK (SEDBUK) is

78.3%. 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.

221894A

1 General Data

1.7 Gas Supply

The gas installation shall be in accordance with the rules in force in the countries of destination.

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. With all other appliances operating.

1.8 Electrical Supply

WARNING. This boiler must be earthed. All system components shall be of an approved type. The electrical installation shall be in accordance with the current

rules in force in the countries of destination at the time of installation.

Connection of the whole electrical system of the boiler and any heating system controls to the electrical supply, must be through one common isolator.

Isolation should be by a double pole switched fused spur box, having a minimum contact separation of 3mm in each pole. The fused spur box should be readily accessible and preferably adjacent to the appliance. It should be identified as to its use.

Alternatively, a fused 3A 3pin plug and unswitched socket may be used, provided they are not used in a room containing a bath or shower.

The mains supply cable and other cables connected to the boiler must be the PVC flexible type of at least 0.75mm

0.20mm) .

(24/

1.9 Heating System Controls

The heating system should have installed: a timer 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: All systems must have at least one radiator not fitted with a thermostatic valve.

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

HEPWORTH HEATING LTD., BELPER,DERBYS. DE56 1JT

COMPACT 100E

230V 50Hz 150W Fused at 3A For us e on : -G20 - 20 mbar Thi s bo iler is in tend ed exclu siv ely

TYPE : C NO Class 5

to be installed on a gas supply with a governed meter

SPECIFIC WATER RA TE 14.03 l/min. DOMESTIC CIRCUIT PMW = 10 bar HEATING CIRCUIT PMS = 2.5 bar

G20 HOT BURNER PRESSURE HEAT HEAT

SERIAL

INPUT NETT OUTPUT

No.

Q =

DHW MAX.

mbar

14.3

30.61

28.2 8.79

INJECTOR: 4.6mm 205768

GC No. 47-047-08A

0086

86/AU/587

CH MAX.

14.3

28.2

457075

GB IE

MIN

0.6

10.3730.61

9409

OVERHEAT CUT-OFF

LOW WATER PRESSURE SWITCH

PRESSURE DIFFERENTIAL MICRO SWITCH

MOTORISED 3 WAY VALVE HOUSING

TEMP. SENSOR

C.H.

RETURN

FANNED FLUE

HEAT EXCHANGER

MAIN BURNER

GAS VALVE

TEMP. SENSOR

VALVE

PLATE TO PLATE HEAT EXCHANGER

BYPASS VALVE

D.H.W. HOT OUTLET

The appliance flue type is a C flue where the fan is downstream of the heat exchanger. The C12 is

and C32. This refers to a concentric

a horizontal flue termination, and the C32 is a vertical flue termination.

EXPANSION

VESSEL

AUTOMATIC AIR VENT

D.H.W. MICRO SWITCH

SAFETY VALVE

SAFETY

VALVE

DISCHARGE

GAS

PUMP

HOUSING

D.H.W. COLD INLET

C.H. FLOW

Diagram 1.2

7641

Diagram 1.3

221894A

2 Boiler Position

2.1 Location

This boiler must be installed in accordance with the rules in force in the countries of destination.

This boiler is not suitable for fitting outside. Any electrical switch must be positioned so that it cannot be

touched by a person using the bath or shower. The boiler must be mounted on a flat wall which is sufficiently

robust to take its weight, refer to Table 1, “Data”. If the location of the boiler or any part of the system is subject

to severe cold weather conditions, it is recommended that a frost thermostat is fitted. Any part of the system that may be vulnerable to freezing must be protected.

2.2 Boilers in a compartment

Where the installation of the boiler will be in an unusual position, the current issue of BS6798 gives detailed guidance on these requirements.

An existing cupboard or compartment modified for the purpose may be used, providing minimum clearances are maintained. Details of essential requirements for cupboard or compartment design are given in the current issue of BS6798.

The door way opening should be of sufficient size to allow for easy removal of the boiler.

Where the boiler is fitted in a cupboard or compartment, permanent ventillation is not required.

Any existing compartment air vents must not be removed or blocked off.

2.3 Clearances

The boiler should be positioned so that at least the minimum operational and servicing clearances are provided, see diagram

2.1. Additional clearances may be required around the boiler for installation.

25 ABOVE THE TOP OF THE BOILER CASE OR THE FLUE ELBOW IF FITTED

150

To achieve minimum "Installation" clearance of 5mm. The side panels will have to be fitted prior to boiler mounting.

DIMENSIONS IN MILLIMETRES

450

Diagram 2.1

7087

2.4 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.

221894A

3 Flue and Ventilation

3.1 General

The flue must be installed in accordance with the rules in force in the countries of destination.

3.2 Terminal Position

The minimum acceptable siting dimensions for the terminal from obstructions, other terminals and ventilation openings are shown in diagram 3.1.

The terminal must be exposed to the external air, the position allowing free passage of air across it at all times.

Car port or similar extensions of a roof only, or roof and one wall, require special consideration with respect to any openings, doors, vents or windows under the roof. Care is required to protect the roof if made of plastic sheeting. If the car port comprises of a roof and two or more walls seek advice from the local gas undertaking before installing the boiler.

If the terminal is fitted within 600mm below plastic guttering, an aluminium shield 1500mm long should be fitted immediately beneath the guttering or eaves. If the terminal is fitted within 450mm below painted eaves or a painted gutter, an aluminium shield 750mm long should be fitted immediately beneath the guttering or eaves.

3.3 Flue Options

There are various flue systems to choose from, as follows: Standard Top Outlet Flue Pack - Pt.No. 230483 Easyfit Top Outlet Flue Pack - Pt.No. 232057 Standard Rear Outlet Flue Pack - Pt.No. 230482 Extended Top Outlet Flue Pack - Pt. No. 230487 1 Metre Extension Kit - Pt. No. 230484 Optional Wall Liner Kit No. 900862 A Flue Bend Kit or Vertical Flue Kit can be supplied, see

Hepworth Heating "Flue Options Guide" for configurations available.

Flue Bend Pack - Pt. No. 230485

Flue Bend Pack - Pt. No. 230486

90 In Line Flue Adapter Kit - Pt. No. 230488 Vertical Flue Kit No. 458115

3.4 Internal Access Flue

All flue assemblies are designed for internal installation, given that there is sufficient clearances opposite to the flue for the installation of the flue.

If there is insufficient clearance the flue can be installed from outside.

For a wall thickness up to 300mm, provided that there is sufficient space and the optional wall liner kit is used, the flue can be installed from the inside.

For a wall thickness of over 300mm the external flue hole will need to be made good from the outside, this also applies if you use the flue kit without the optional wall liner kit, irrespective of wall thickness.

3.5 Terminal Guard

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.

The guard should be similar to that shown in diagram 3.1 .

3.6 Room Ventilation

Ventilation must be provided in accordance with the rules in force in the countries of destination. The boiler is room sealed, so where the boiler is fitted in a room or space, a permanent air vent is not required.

3.7 Cupboard/Compartment Ventilation

If the boiler is to be fitted in a cupboard or compartment. Refer to Section 2.2.

B,C

UNDER CAR PORT etc.

B,C

H,I

MINIMUM SITING DIMENSIONS FOR FANNED FLUE TERMINALS POSITION

A DIRECTLY BELOW, ABOVE OR

HORIZONTALLY TO AN OPENING, AIR BRICK, OPENING WINDOWS, AIR VENT OR ANY

OTHER VENTILATION OPENING. 300 B BELOW GUTTER, DRAIN/SOIL PIPE 25 C BELOW EAVES 25 D BELOW A BALCONY 25

OR CAR PORT 200 E FROM VERTICAL DRAIN PIPES AND

SOIL PIPES 25 F FROM INTERNAL OR EXTERNAL

CORNERS 25 G ABOVE ADJACENT GROUND OR

BALCONY LEVEL 300 H FROM SURFACE FACING THE

TERMINAL 600 I FACING TERMINALS 1200 J FROM OPENING (DOOR/WINDOW)

IN CAR PORT INTO DWELLING 1200 K VERTICAL FROM A TERMINAL 1500 L HORIZONTALLY FROM A TERMINAL 300

TERMINAL GUARD TYPE K3 SUPPLIED BY :

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

Diagram 3.1

MINIMUM SPACING

2816

221894A

4 Heating System

6.0 Dt at 100000 btu output Dp (M H2O)

5.0

4.0

3.0

2.0

1.0

Remaining conveying capacity (m H

0.0

0 5 10 15 20 25 30

Circuit flow rate (l/min)

∆t (°C)

Diagram 4.1

7486

4.1 General Notes

The boiler is intended for use in a sealed system only.

4.2 Safety Valve

The safety valve is an integral part of the boiler. It cannot be adjusted but has a manual test device.

4.3 Pressure Gauge

A pressure gauge is incorporated into the boiler to indicate the system pressure.

The gauge has a cold fill set pointer.

4.4 Pump

The circulation pump is integral with the boiler. The remaining circulating pressure head available from the

boiler is shown in diagram 4.1, Glow-worm pump.

4.5 Expansion Vessel

The boiler has an integral expansion vessel with a capacity of 6 Litres. If the system water content exceeds the maximum quoted in Table 1, Data, an additional vessel should be connected into the system as close as possible to the central heating return connection of the boiler, see diagram 4.2.

The charge pressure shall not be less that the static head at the point of connection, that is, the height of the top point of the system above the expansion vessel.

4.7 Bypass

The bypass is an integral part of the boiler.

4.8 Filling Sealed Systems

An optional extra filling loop is available Part No. 457120 Provision for filling the system at a low level must be made. Three methods of filling are shown in diagram 4.3.

There must be no permanent connection to the mains water supply, even through a non-return valve.

NOTE: It is important that fittings used for connection to potable water comply with the water undertakers requirements.

4.9 Corrosion Inhibitor

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

When fitting the boiler into an existing system, special care should be taken to drain the entire system, including radiators, then thoroughly cleaning out before fitting the boiler whether or not adding an inhibitor.

4.10 Draining

A draining tap must be provided at the lowest points of the system, which will allow the entire system to be drained. An additional draining tap MUST be fitted close to the boiler.

The flow and return isolation valves are provided with drain points for boiler heat exchanger drainage.

4.6 Flow Rate

A valve must be incorporated in the main flow or return of the system, valve “A” shown in the flow diagram 4.2. This valve must be lockable and positioned so that inadvertent closure or unauthorised interference is not possible. The design differential can be between 11°C (20°F) and 17°C (30°F), dependent upon the system resistance and the available pump head.

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METHOD 1

METHOD 2

METHOD 3

SUPPLY STOP VALVE

SUPPLY PIPE

HOSE UNIONS

SERVICING VALVE

TEMPORARY HOSE

HEATING SYSTEM

TEMPORARY HOSE

HOSE UNIONS

SERVICING VALVE

SUPPLY PIPE

SUPPLY STOP VALVE

DOUBLE CHECK VALVE ASSEMBLY

HEATING SYSTEM

SERVICING VALVE

SUPPLY STOP VALVE

SUPPLY PIPE

HOSE UNIONS

DOUBLE CHECK VALVE ASSEMBLY

OVERFLOW

CISTERN

COMBINED CHECK VALVE AND VACUUM BREAKER

PRESSURE REDUCING VALVE

4 Heating System

ADDITIONAL EXPANSION VESSEL (if required)

HEATING CIRCUIT

RETURN

BOILER

’A’

FLOW CONTROL VALVE

DOMESTIC

WATER

HOT

COLD SUPPLY

OPTIONAL FILLING KIT AVAILABLE No. 457120

FILLING POINT

DRAIN POINT

ALTERNATIVE METHODS OF FILLING

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5.1 General

The domestic hot water service must be in accordance with the rules in force in the countries of destination.

5.2 Water Pressure

For the minimum and maximum working pressures of the domestic hot water circuit of the boiler refer to diagram 1.2.

If the cold water supply pressure exceeds the maximum, a governor must be fitted in the supply to the boiler to reduce the pressure to within the limits given.

Diagram 4.2

5 Domestic Hot Water System

5.3 “Hard” Water Areas

In areas where the water is “hard”, more than 200mg/litre, it is recommended that a proprietary scale reducer is fitted in the cold water supply to the boiler. Consult the local water company for additional advice.

A double check valve assembly must be fitted upstream of the scale reducer. For the relative position of the scale reducer and pressure reducing valve, if required, refer to the manufacturer’s instructions.

Diagram 4.3

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6 Installation Preparation and Gas / Water Connections

The installation requires the following components :-

1. Plumbing jig Carton

2. Boiler Carton

3. Flue Pack

6.1. Plumbing Jig

Remove from the wall template, then follow the instructions given on the template.

Note: Leaving the service cock bracket (lower jig) fixing screws loose will make the fitting of the boiler service elbows on to the service cocks easier. Once the service connections are made, tighten service cock bracket (lower jig) fixing screws. It is important that the wall hanging bracket and the service cock bracket (lower jig) are fitted to a flat and true wall area for correct alignment with the boiler. If this cannot be achieved it is acceptable to pack out the service cock bracket (lower jig) to obtain the correct alignment with the wall hanging bracket.

6.2 Gas Connection

Provision is made for the gas supply to be connected from below the boiler, see diagrams 1.1 and 6.1 for position.

Refer also to “Gas Supply”, Section 1.7. Make the gas supply connection to the gas service cock. While

making the connection, do not subject the gas service cock to heat as you may damage the seals.

6.3 Water Connections

Provision is made for the domestic cold water inlet to be connected from below or through an internal wall at the rear of the boiler, see diagram 1.1 and 6.1 for position.

Refer also to Section 5 “Domestic Hot Water System”. Provision is made for the water connections to be connected

from below or from above, passing down either side of the boiler. Take care that any pipework connected from above will clear the expansion vessel. Refer to the wall template. If connecting from above a vertical piping kit 457160 is available and is recommended.

NOTE: Top rear flue outlet is not possible with a vertical piping kit.

If necessary, temporarily fit the boiler. Flush out the domestic water and heating system before

connecting the boiler. Make the connections to the domestic hot water outlet and the

heating system by means of the isolating valves, see diagram

6.1. While making the connections. Do not subject any of the

isolating valves to heat as you may damage the seals. Make sure that the drain and operating screw heads on the

isolating valves are accessible.

SAFETY DISCHARGE PIPE ROUTING POSITION

HEATING FLOW

LEVER (OPEN) HEATING FLOW/ RETURN

HOT WATER OUT

GAS SERVICE COCK

LEVER (OPEN) COLD WATER SUPPLY IN/OUT

COLD WATER SUPPLY IN

HEATING RETURN

SLOT (OPEN) GAS SERVICE COCK

Diagram 6.1

6.4 Safety Valve Discharge

WARNING. It must not discharge above an entrance or window or any type of public access area.

A short discharge pipe is supplied loose with the boiler, which when fitted to the safety valve, will end below the boiler the position is next to the heating return, for position see diagram

6.1. This must be extended, using not less than 15mm od metal

pipe, to discharge, in a visible position, outside the building, facing downwards, preferably over a drain. The pipe must have a continuous fall and be routed to a position so that any discharge of water, possibly boiling, or steam cannot create any danger to persons, damage to property or external electrical components and wiring.

Note. To ease future servicing it is advisable to use a compression type fitting to extend the discharge pipe.

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7 Flue Preparation

TOP OUTLET FLUE PACK

STD/EXTD 'X' plus 254mm (RH) = flue length 'X' plus 10mm (LH) = flue length

EASYFIT 'X' plus 282mm (RH) = flue length 'X' plus 38mm (LH) = flue length

5mm*

FLUE LENGTH

MAX 840mm (extd.)

MAX 570mm (std/easyfit)

15mm

(must include 50mm min.

239mm*

side clearance)

SCREW

TOP OUTLET/ SIDE FLUE

'X'

& T APE

*STD/EXTD flue only

TOP OUTLET/ REAR FLUE

STD/EXTD 'Y' plus 69mm = flue length EASYFIT 'Y' plus 97mm = flue length

EASYFIT/STD./EXTD. TOP OUTLET FLUE PACK & 1 METRE EXTENSION

3 x 1 metre extension kits may be joined together.

NOTE: REMOVE HEAT EXCHANGER BAFFLE OVER 2.5M

15mm

VIEW 'B'

SCREW & T APE

'Y'

SCREW & T APE

'X'

SIDE FLUE STD/EXTD 'X' plus 254mm (RH) = flue length 'X' plus 10mm (LH) = flue length EASYFIT: 'X' plus 282mm (RH) 'X' plus 38mm (LH) = flue length

REAR FLUE STD/EXTD 'Y' plus 69mm = flue length EASYFIT 'Y' plus 97mm = flue length

FLUE LENGTH

MAX 840mm (extd.)

MAX 570mm (std/easyfit)

54mm*

'Y'

VIEW 'B'

9377

15mm

SCREW & T APE

REAR OUTLET FLUE PACK

FLUE LENGTH

REAR OUTLET FLUE PACK & 1 METRE EXTENSION KIT

2 x 1 metre extension kits may be joined together.

510mm MAX.

15mm

80mm

FOAM SEAL

'Y'

SCREW & T APE

'Y' plus 95mm = FLUE LENGTH

FLUE

PACKS

TOP STD.

REAR SIDE R.H. SIDE L.H.

TOP EXTD.

REAR SIDE R.H. SIDE L.H.

REAR STD.

REAR 75 170 510 415 -

MINIMUM

WALL

THICKNESS

MINIMUM

LENGTH

75 75 75

FLUE

144 334

MAXIMUM

FLUE

LENGTH

570 570 570

840 840 840

BOILER MOUNTING FACE

TO EXTERNAL WALL FACE

80mm

FOAM SEAL

'Y' plus 95mm = FLUE LENGTH

MAXIMUM DISTANCE FROM

"Y"

500

770

"X"

BOILER CASING TO

EXTERNAL WALL FACE

316 560

586 830

SCREW

15mm

& T APE

'Y'

SCREW & T APE

NOTE :

IF IT IS NECESSARY TO CUT THE DUCTS TO ACHIEVE THE "FLUE LENGTH" MAKE SURE THAT THE OVERLAPS ARE AS FOLLOWS :THE OVERLAP FOR AIR DUCT = 25mm THE OVERLAP FOR FLUE DUCT = 50mm

THE MAXIMUM LENGTHS CAN BE INCREASED BY AN ADDITIONAL 2 METRES WITH THE USE OF THE 1 METRE EXTENSION KITS. NOTE :THIS APPLIES TO STANDARD KITS ONLY.

Diagram 7.1

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