Glow-worm Compact 75E User Manual

221895A.04.01

Instructions for Use

Installation and Servicing

To b e l e f t w i t h t h e u s e r

7086

COMPACT 75e

G.C. No. 47 047 06A

Fanned Flue Combination Boiler

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 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

REGISTER YOUR GLOW-WORM APPLIANCE

FOR 1ST YEAR GUARANTEE PROTECTION

CALL 0208 247 9857

			Customer Services:		Hepworth Heating Ltd.,
					Nottingham Road, Belper, Derbyshire. DE56 1JT
			Tel: (01773)	828100
					General/Sales enquiries:
	One Contact Local Service Fax: (01773)			828070
					Tel: [phone] Fax: [phone]

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		Introduction				3
		Clock Settings				4
FOR USE		Lighting the Boiler				5
		General Data		1		7
INSTALLATION		Boiler Position		2		9
		Flue and Ventilation		3		10
INSTRUCTIONS
		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
		General Data		11		25
SERVICING		Servicing		12		25
INSTRUCTIONS		Fault Finding		13		27
		Replacement Parts		14		32
		Spare Parts		15		43

221895A

2

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						6937
								0
I AUTO	RUN P					12	11		I
				14	13			10
				15				9
M T W	Th F	S Su		16				8
				17				7
				18				6
				19				5
				20				4
P DAY	HR	MIN		21				3
				22	23	24	1	2
	R
Digital timer				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.

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.

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 0.75mm2 (24/ 0.20mm) must be used within the boiler casing to connect to the boiler.

Electrical Supply Failure

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.

3

221895A

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		6938
CLOCK FACE						SWITCH
						0
	14	13	12	11	10	I
						9
	15
	16					8
	17					7
	18					6	POINTER
	19					5
	20					4
	21					3
	22	23		1	2
			24
						TAPPETS
0 CONSTANT OFF
I	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.

I AUTO	RUN P	6939
M T W	Th F S Su

P DAY HR MIN

R

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 .

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 SAT/SUN

ON	-	06:30	ON	-	07:00
OFF -		08:30	OFF -		09:00
ON	-	16:30	ON	-	16:00
OFF -		22:30	OFF -		23:00

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

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

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

4.Press button P to confirm programmes, the display will indicate the 2nd (OFF) preset programme and subsequently, 3rd, 4th, 5th, 6th, 7th, 8th.

5.Repeat procedures 2, 3 and 4 until desired programmes are set.

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

6.Set the RUN switch the central position, your appliance will now operate at the programmed times.

General Notes.

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 .

To Light the Boiler

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

2.Open the controls cover door and familiarize 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.

221895A

4

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					7013
	DISCHARGE PIPE POSITION
	HOT	GAS	COLD		HEATING
HEATING					RETURN
	WATER SERVICE WATER
FLOW	OUT	COCK	SUPPLY IN
LEVER (OPEN)		LEVER (OPEN)		SLOT (OPEN)
HEATING		COLD WATER		GAS SERVICE
FLOW/ RETURN		SUPPLY IN/OUT		COCK
					Diagram 3

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 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.

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

5

221895A

Instructions for Use

		CONTROLS						6941
						SANITARY WATER
	PRESSURE	FASCIA
					SUMMER/ WINTER	TEMPERATURE
	GAUGE ‘A’				BUTTON ‘J’	CONTROL KNOB ‘M’
				‘F’	‘L’	‘P’	CLOCK TIMER
							IF FITTED ‘C’
	RESET			‘H’
	BUTTON ‘G’
			‘D’
						‘Q’
					‘K’
				‘E’	CENTRAL HEATING		MAINS
					WATER		ELECTRIC
					TEMPERATURE		SWITCH ‘B’
					CONTROL KNOB ‘N’
KEY TO NEON LIGHTS							7565
‘F’	BOILER LOCKOUT							CONTROLS
								COVER
			‘D’	BURNER IGNITED
‘H’	LOW WATER PRESSURE		‘E’	POWER ‘ON’
‘L’	SUMMER SETTING		‘P’	SANITARY DEMAND
‘K’	WINTER SETTING		‘Q’	CENTRAL HEATING DEMAND
								Diagram 4

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.

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

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.

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.

221895A

6

1 General Data

E	C	P
	M
D	N
		C	C	F
D
		L	L
E				G
		B
				9mm

H

Optional flue kits are available Horizontal top outlet and Vertical.

6942

														K												K
																L									J
																					A																					Diagram 1.1
A	B	C		D		E	F	G					H											J									K					L	M	N			P
450	700	300	100			75	138	142			18												135							65								110	138	85		115	103
																																								STD/EXD.	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/in2)
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	2.33m3/h
rate at max input	(82.23ft3/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 rules in current 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 diagram 1.1, 1.2 & 1.3.

The Seasonal Efficiency Domestic Boilers UK (SEDBUK) is 77.4%.

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.

7

221895A

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 0.75mm2 (24/ 0.20mm) .

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.

HEPWORTHHEATINGLTD.,

7525

BELPER,DERBYSDE561JT.

COMPACT 75E

457151

230V~ 50Hz 150W Fused at 3A

TYPE :C12 - C32

For use on :I 2H -G20 - 20 mbar

NOx Class 3

GC No. 47-047-06A

This boiler is intended exclusively

to be installed on a gas supply

0086

GB

IE

with a governed meter

86/AU/587

SPECIFIC WATER RATE

10.52 l/min.

DOMESTIC CIRCUIT PMW = 10 bar

HEATING CIRCUIT PMS

=

2.5 bar

G20

DHW MAX.

CH MAX.

MIN

HOT BURNER PRESSURE mbar

14.7

14.7

1.71

HEAT INPUT NETT Q

=

kW

24.45

24.45

10.85

HEAT OUTPUT P

=

kW

21.98

21.98

8.79

SERIALNo.

INJECTOR:4.1mm 205770

The appliance flue type is a C12 and C32. This refers to a concentric flue where the fan is downstream of the heat exchanger. The C12 is a horizontal flue termination, and the C32 is a vertical flue termination.

Diagram 1.2

FANNED FLUE

EXPANSION

VESSEL

7641

		HEAT EXCHANGER
	OVERHEAT
	CUT-OFF	MAIN BURNER
	LOW WATER
	PRESSURE	GAS VALVE
	SWITCH
	PRESSURE	TEMP.		AUTOMATIC
			PUMP	AIR VENT
	DIFFERENTIAL
		SENSOR	HOUSING
	MICRO SWITCH
		VALVE		D.H.W.
				MICRO SWITCH

	MOTORISED
	3 WAY VALVE	PLATE TO PLATE
	HOUSING				SAFETY
	TEMP.	HEAT EXCHANGER
					VALVE
	SENSOR	BYPASS
	C.H.	VALVE			SAFETY
	RETURN
		D.H.W.	GAS	D.H.W. C.H.	VALVE
		HOT		COLD FLOW	DISCHARGE
		OUTLET		INLET	Diagram 1.3

221895A

8

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.

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.

	25 ABOVE THE TOP OF THE BOILER CASE	7087
	OR THE FLUE ELBOW IF FITTED

5	5
	450

150

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

to boiler mounting.

DIMENSIONS IN MILLIMETRES

Diagram 2.1

9

221895A

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.

45o Flue Bend Pack - Pt. No. 230485

90o Flue Bend Pack - Pt. No. 230486

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.

2816

A				C
	B,C		B,C	K
A	G		L	L
			K
				K
F		F	F
	A
G
	E	G		G
	G
UNDER CAR PORT etc.
			D
			J
			F
	H,I		K

MINIMUM SITING DIMENSIONS FOR	MINIMUM
FANNED FLUE TERMINALS	SPACING
POSITION
	mm

ADIRECTLY BELOW, ABOVE OR HORIZONTALLY TO AN OPENING, AIR BRICK,

	OPENING WINDOWS, AIR VENT OR ANY	300
	OTHER VENTILATION OPENING.
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

221895A

10

4 Heating System

	6.0																	30
0)														Dt at 75000 btu output
														Dp (M H2O)
2
(mH	5.0																	25
capacity	4.0																	20
conveying
	3.0																	15
Remaining	2.0																	10
	1.0																	5
	0.0																	0.0
	0			5		10		15		20				25		30
							Circuit flow (l/min)
4.1 General Notes										4.7 Bypass
The boiler is intended for use in a sealed system only.										The bypass is an integral part of the boiler.

9093

Diagram 4.1

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.

4.6 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.

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.

11

221895A

4 Heating System

DOMESTIC

WATER

6951

	BOILER	COLD SUPPLY
ADDITIONAL	HOT
EXPANSION
VESSEL
(if required)
	OPTIONAL FILLING
	KIT AVAILABLE
	No. 457120
	FILLING
	POINT

RETURN

HEATING

CIRCUIT ’A’

FLOW DRAIN

CONTROL POINT

VALVE

Diagram 4.2

ALTERNATIVE METHODS OF FILLING

	METHOD 1		COMBINED
	TEMPORARY		CHECK VALVE		HEATING
			AND VACUUM		SYSTEM
	HOSE		BREAKER
		HOSE	SERVICING
			VALVE
		UNIONS
	SUPPLY	SUPPLY STOP			3132
		VALVE
	PIPE
	METHOD 2				HEATING
	TEMPORARY		DOUBLE CHECK
					SYSTEM
	HOSE		VALVE ASSEMBLY
		HOSE	SERVICING
			VALVE
		UNIONS
		SUPPLY STOP
	SUPPLY	VALVE
	PIPE
	METHOD 3
	CISTERN	OVERFLOW			HEATING
		SERVICING		PRESSURE SYSTEM
		VALVE		REDUCING
				VALVE
	SUPPLY
	STOP VALVE
		HOSE		DOUBLE CHECK
	SUPPLY	UNIONS
				VALVE ASSEMBLY
	PIPE
					Diagram 4.3

5 Domestic Hot Water System

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.

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.

221895A

12

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	6956
ROUTING POSITION

	HEATING	HOT	GAS	COLD	HEATING
		WATER
			SERVICE	WATER	RETURN
	FLOW	OUT
			COCK	SUPPLY
				IN

	LEVER (OPEN)	LEVER (OPEN)	SLOT (OPEN)
			GAS SERVICE
	HEATING	COLD WATER
			COCK
	FLOW/ RETURN	SUPPLY IN/OUT
			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.

13

221895A

7 Flue Preparation

TOP OUTLET FLUE PACK

FLUE LENGTH

MAX 840mm (extd.)

MAX 570mm (std/easyfit)

5mm*					15mm

239mm*

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 (must include 50mm min.

side clearance)

FLUE LENGTH

MAX 840mm (extd.)

MAX 570mm (std/easyfit)

15mm 54mm*

9377

					SCREW
					& TAPE
TOP OUTLET/			'X'
SIDE FLUE

*STD/EXTD flue only

								SCREW
TOP OUTLET/
								& TAPE
REAR FLUE
				'Y'

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

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

2 x 1 metre extension kits may be joined together.

SCREW

& TAPE

VIEW 'B'

15mm

SCREW

SCREW

& TAPE

'Y'

& TAPE

'X'

SIDE FLUE

VIEW 'B'

STD/EXTD

'X' plus 254mm (RH) = flue length

REAR FLUE

'X' plus 10mm (LH) = flue length

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

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

EASYFIT

'Y' plus 97mm = flue length

REAR OUTLET FLUE PACK

REAR OUTLET FLUE PACK & 1 METRE EXTENSION KIT

FLUE LENGTH

2 x 1 metre extension kits may be joined together.

510mm MAX.

		15mm		SCREW	15mm
				& TAPE
80mm			80mm
FOAM			FOAM
SEAL	'Y'	SCREW	SEAL	'Y'	SCREW
		& TAPE			& TAPE

'Y' plus 95mm = FLUE LENGTH				'Y' plus 95mm = FLUE LENGTH			9358
						NOTE :
	MINIMUM	MINIMUM	MAXIMUM	MAXIMUM DISTANCE FROM
FLUE						IF IT IS NECESSARY TO CUT THE DUCTS
				"Y"	"X"
PACKS	WALL	FLUE	FLUE			TO ACHIEVE THE "FLUE LENGTH" MAKE SURE
				BOILER MOUNTING FACE	BOILER CASING TO
	THICKNESS	LENGTH	LENGTH			THAT THE OVERLAPS ARE AS FOLLOWS :-
				TO EXTERNAL WALL FACE	EXTERNAL WALL FACE
						THE OVERLAP FOR AIR DUCT = 25mm
TOP STD/
						THE OVERLAP FOR FLUE DUCT = 50mm
EASYFIT	75	144	570	500	-
REAR						THE MAXIMUM LENGTHS CAN BE INCREASED
SIDE R.H.	75	334	570	-	316	BY AN ADDITIONAL 2 METRES WITH THE USE
SIDE L.H.	75	90	570	-	560	OF THE 1 METRE EXTENSION KITS.
TOP EXTD.						NOTE :THIS APPLIES TO STANDARD KITS ONLY.
REAR	75	144	840	770	-
SIDE R.H.	75	334	840	-	586
SIDE L.H.	75	90	840	-	830
REAR STD.
REAR	75	170	510	415	-	Diagram 7.1

221895A

14