Supplied By www.heating spares.co Tel. 0161 620 6677
Instructions for Use
Installation and Servicing
To be left with the user
COMPACT 80p
G.C. No. 47 047 04A
Fanned Flue Combination Boiler
221679H.11.00
6936
With Honeywell gas control
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:
to offer our customers' a Comprehensive First Year Guarantee.
return as soon as possible.
Service number 01773 828100.
✔
❑
✔
❑
✔
❑
One Contact Local Service
All replacement parts
All labour charges
All call-out charges
Customer Services:
Tel: (01773) 828100
Fax: (01773) 828070
REGISTER YOUR GLOW-WORM APPLIANCE
FOR 1ST YEAR GUARANTEE PROTECTION
CALL 0208 247 9857
Hepworth Heating Ltd.,
Nottingham Road, Belper, Derbyshire. DE56 1JT
General/Sales enquiries:
Tel: (01773) 824141 Fax: (01773) 820569
Supplied By www.heating spares.co Tel. 0161 620 6677
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.
CONTENTS DESCRIPTION SECTION PAGE No.
INSTRUCTIONS
FOR USE
Introduction 3
Clock Settings 4
Lighting the Boiler 5
General Data 1 7
INSTALLATION
INSTRUCTIONS
Boiler Location 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 14
Mounting the Boiler and Flue Fitting 8 16
Electrical Connections 9 18
Commissioning 10 20
SERVICING
INSTRUCTIONS
Servicing 12 23
Fault Finding 13 24
Replacement Parts 14 32
Spare Parts 15 43
General Data 11 23
221679H
2
Supplied By www.heating spares.co Tel. 0161 620 6677
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
0
P
AUTO
I
MT
P
DAY HR MIN
Digital timer
RUN
WThFSSu
R
12
11
13
14
15
16
17
18
19
20
21
10
9
8
7
6
5
4
3
22
2
1
23
24
Electro / mechanical
clock / timer
I
IMPORTANT NOTICE:
This boiler is for use only on G20 gas.
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 0.75mm
0.20mm) must be used within the boiler casing to connect to the
boiler.
6937
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.
If the power is off, except for short controlled periods, turn off the
pilot.
Note. The boiler safety cut-off 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.
.
2
(24/
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.
Domestic Hot Water Temperature
NOTE. The mains incoming water temperature in the winter is
lower than in the summer.
The water temperature is factory preset and can not be
adjusted.
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.
Boiler Safety Cut-off Device
The boiler is fitted with a safety cut-off device to prevent damage
through overheating.
Should the main burner and pilot go out, for no apparent
reason, during normal use, allow the boiler and system to
cool down (waiting at least a minimum of four minutes),
relight the boiler as described in "To light the boiler".
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
221679H
Supplied By www.heating spares.co Tel. 0161 620 6677
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
0
12
11
13
14
15
16
17
18
19
20
21
22
CONSTANT OFF
0
23
24
10
9
8
4
3
2
1
I
7
6
5
POINTER
TAPPETS
PROGRAMMED
CONSTANT ON
I
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
P
AUTO
I
MT
WTh
RUN
FS
Su
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.
6938
MON/FRI
ON - 06:30
OFF - 08:30
ON - 16:30
OFF - 22:30
SAT/SUN
ON - 07:00
OFF - 09:00
ON - 16:00
OFF - 23:00
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
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
central heating programme for the next available.
ON time programmes are indicated by the symbol
, this function will override the current
.
P
DAY HR MIN
R
Diagram 2
221679H
4
Supplied By www.heating spares.co Tel. 0161 620 6677
Instructions for Use
To Light the Boiler
1. Check that all four isolating valves are open, the levers in line
with the valve bodies, see diagram 3.
2. Open the controls cover door an familiarize yourself with the
controls, see diagram 4.
3. CAUTION. A sealed pressurised system must be filled and
pressurised by a competent person.
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.
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. Fully press and hold down the control knob “C”. Press and
release the piezo button “D” until the pilot burner lights, view
through window in the front case. When the pilot burner is lit,
keep control knob “C” pushed in for a further 15 seconds then
release. The pilot should remain alight.
7. IF THE PILOT GOES OUT NOW, OR ON ANY OTHER
OCCASION, A SAFETY DEVICE PREVENTS IMMEDIATE
RELIGHTING. WAIT AT LEAST FOUR MINUTES BEFORE
ATTEMPTING TO RELIGHT.
8. If the pilot burner fails to remain alight, repeat instruction 11.
but now hold down the control knob “C” for a little longer after the
pilot has lit.
9. Check the pilot is alight and stable.
10. Switch ON the electrical supply to the boiler at the external
isolator.
11. Set the switch “K” to ON 1 situated on the control fascia.
12. Check the light “E” is illuminated on the control fascia.
13. Set the summer / winter button “J”, light “H” or “F” will
illuminate.
SAFETY VALVE DISCHARGE
PIPE POSITION
HEATING
RETURN
HEATING
FLOW
HOT
WATER
OUT
GAS
SERVICE
COCK
COLD
WATER
SUPPLY IN
14. Set “B”, clock/timer (if fitted) and any remote controls as
required.
For central heating operation set button “J” to “On”. The main
burner will ignite. Light “F” will illuminate.
Close the controls cover door.
To Turn the Boiler Off
For short periods only set switch “K” to 0. Turn off pilot light.
To turn the boiler off, turn the control knob “C” in the direction
of the arrow clockwise.
To turn on again following the "To light the boiler" instructions.
Water Temperatures
NOTE. The mains incoming water temperature in the winter is
lower than in the 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.
Summer / Winter Selector Button
For central heating set button “J” to Winter light “F” will illuminate
as shown in diagram 4. The main burner will light.
When the heating is controlled by a room thermostat and/or a
time switch, button “J” must be set to Winter light “F” will
illuminate.
If a hot water tap is opened while the boiler is on for heating,
priority will be given to hot water.
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
7310
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
If the boiler is to be out of use for any long periods during severe
LEVER (OPEN)
HEATING
FLOW/ RETURN
LEVER (OPEN)
COLD WATER
SUPPLY IN/OUT
SLOT (OPEN)
GAS SERVICE
COCK
Diagram 3
weather, it is recommended that the whole system, including
the combination boiler, should be drained to avoid the risk of
freezing.
If in doubt, contact you installation/servicing company for advice.
5
221679H
Supplied By www.heating spares.co Tel. 0161 620 6677
Instructions for Use
7004
PRESSURE
GAUGE ‘A’
CONTROLS
FASCIA
CONTROL
‘C’
KNOB
PIEZO ‘D’
CONTROLS COVER
‘G’
‘E’
‘H’
SUMMER/ WINTER
BUTTON
‘J’
‘F’
CLOCK TIMER
IF FITTED
MAINS
ELECTRIC
SWITCH
‘B’
‘K’
7565
KEY TO NEON LIGHTS
‘G’ LOW WATER PRESSURE
‘H’ SUMMER SETTING (HOT WATER OPERATION ONLY)
‘F’ WINTER SETTING (HOT WATER AND CENTRAL HEATING OPERATION)
‘E’ POWER ‘ON’
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. The outlet should be kept clear
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.
Diagram 4
221679H
6
Supplied By www.heating spares.co Tel. 0161 620 6677
E
C
1 General Data
7029
A
G
D
F
M
C
L
C
L
FLUE
N
B
9mm
H
K
K
JL
ABCDEFGHJ KLMN
450 700 300 100 75 128 225 18 135 65 110 80 144
22mm COMPRESSION
CENTRAL HEATING
15mm COMPRESSION
DOMESTIC WATER
Rc 1/2 (1/2in. BSPT)
GAS CONNECTION
Diagram 1.1
TABLE 1
Lift Weight 33.4kg (73.63b)
Total Weight 42.8kg (94.36lb)
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 1.66 litres (0.37 gallon)
■ Expansion vessel capacity 6 litres (1.32 gallons)
Heating cold fill 0.7bar
pressure minimum (10.1lbf/in
❋ 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 154W fused 3A
Internal Fuse rating F1) Type T2A
F2) Type T315mA
❋ 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.
2
)
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
2
)
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 cover, 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
72.2%.
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
221679H
Supplied By www.heating spares.co Tel. 0161 620 6677
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.
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) .
2
(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
3212
7.6
17.6
457501
GB IE
MIN
1.2
10.720.09
COMPACT 80P
~
230V 50Hz 150W Fused a t 3A
For use on : -G20 - 20 mbar
This boiler is intended exclusively
to be installe d on a gas supply
with a gov erned meter
SPECIFIC WATER RATE 11.22 l/min.
DOMESTIC CIRCUIT PMW = 10 bar
HEATING CIRCUIT PMS = 2.5 bar
G20
HOT BURNER PRESSURE
HEAT
HEAT
SERIAL
I
INPUT NETT
OUTPUT
No.
2H
Q =
=
P
TYPE : C - C
NO Class 5
x
DHW MAX.
mbar
13.0
kW
25.5
kW
23.45 8.79
INJECTOR: 4.2mm 205766
GC No. 47-047-04A
0086
86/AU/582
CH MAX.
7507
EXPANSION
VESSEL
FLOW
SENSOR
OVERHEAT
CUT-OFF
LOW WATER
PRESSURE
SWITCH
TEMP.
SENSOR
D.H.W.
COLD
INLET
FANNED
FLUE
GAS VALVE
BYPASS
VALVE
C.H.
FLOW
HEAT EXCHANGER
MAIN BURNER
PUMP
SAFETY
VALVE
GAS
C.H.
RETURN
AUTOMATIC
AIR VENT
SAFETY
VALVE
DISCHARGE
Diagram 1.2
7643
PILOT
BURNER
OVERHEAT
CUT-OFF
TEMP.
SENSOR
D.H.W.
HOT
OUTLET
Diagram 1.3
221679H
8
Supplied By www.heating spares.co Tel. 0161 620 6677
2 Boiler Location
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 outdoor installation.
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 doorway 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 FLUE ELBOW
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
6944
5
Diagram 2.1
2.4 Timber Frame Buildings
If the boiler is to be installed in a timber frame building it should
be fitted in accorandce 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.
9
221679H
Supplied By www.heating spares.co Tel. 0161 620 6677
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
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.
o
45
Flue Bend Pack - Pt. No. 230485
o
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.
3.6 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.
3.6 Cupboard/Compartment Ventilation
If the boiler is to be fitted in a cupboard or compartment. Refer
to Section 2.2.
K
L
D
F
C
K
L
K
G
MINIMUM
SPACING
mm
A
B,C
K
F
F
G
J
A
F
G
UNDER CAR PORT etc.
B,C
G
A
E
G
H,I
MINIMUM SITING DIMENSIONS FOR
FANNED FLUE TERMINALS
POSITION
A DIRECTLY BELOW AN OPENABLE
WINDOW, 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
2816
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 .
221679H
10
TERMINAL GUARD TYPE K3
SUPPLIED BY :
Tower Flue Components Ltd.
Morley Road
Tonbridge
Kent
TN9 1RA
Diagram 3.1
Supplied By www.heating spares.co Tel. 0161 620 6677
4 Heating System
5.00
O)
2
4.00
3.00
2.00
1.00
Remaining conveying capacity (m H
0.00
0 5 10 15 20 25
Circuit flow rate (l/min)
Dt at 60000 btu output
Dp (MH2O)
50
7487
40
30
Dt (°C)
20
10
0
Diagram 4.1
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.
4.5 Expansion Vessel
The boiler has an integral expansion vessel with a capacity of
6Litres, (1.32gall). 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 pressure shall not be less than 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
If required a valve can 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.
4.7 Bypass
The bypass is an integral part of the boiler and cannot be
adjusted.
No external system bypass is required.
4.8 Filling Sealed Systems
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
221679H
Supplied By www.heating spares.co Tel. 0161 620 6677
4 Heating System
ADDITIONAL
EXPANSION
VESSEL
(if required)
HEATING
CIRCUIT
RETURN
BOILER
’A’
FLOW
CONTROL
VALVE
DOMESTIC
WATER
FILLING
POINT
DRAIN
POINT
HOT
COLD SUPPLY
Diagram 4.2
7650
METHOD 1
TEMPORARY
HOSE
SUPPLY
PIPE
METHOD 2
TEMPORARY
HOSE
SUPPLY
PIPE
METHOD 3
CISTERN
HOSE
UNIONS
SUPPLY STOP
VALVE
DOUBLE CHECK
VALVE ASSEMBLY
HOSE
UNIONS
SUPPLY STOP
VALVE
OVERFLOW
SERVICING
VALVE
COMBINED
CHECK VALVE
AND VACUUM
BREAKER
SERVICING
VALVE
SERVICING
VALVE
PRESSURE
REDUCING
VALVE
HEATING
SYSTEM
3132
HEATING
SYSTEM
HEATING
SYSTEM
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.
SUPPLY
STOP VALVE
SUPPLY
PIPE
HOSE
UNIONS
DOUBLE CHECK
VALVE ASSEMBLY
Diagram 4.3
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.
221679H
12
Supplied By www.heating spares.co Tel. 0161 620 6677
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 carton the wall template, then follow the
instructions given on the template.
Note: It is important that the wall hanging bracket and the
service cock bracket are fitted to a flat and true wall area for
correct alignment with the boiler. Where this cannot be achieved
it is acceptable to pack out the service cock bracket 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. Purge the gas supply.
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 piping kit 457160 is available and is
recommended. 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 screw heads on the isolating valves are
accessible.
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, see diagram 6.2. (THE
DISCHARGE PIPE MUST BE FITTED BEFORE THE BOILER
IS MOUNTED ON THE WALL).
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.
HOT
HEATING
FLOW
SLOT (OPEN)
HEATING
FLOW/ RETURN
WATER
OUT
REAR VIEW
OF BOILER
DISCHARGE
PIPE
UNION
CONNECTION
SAFETY DISCHARGE
PIPE ROUTING POSITION
GAS
SERVICE
COCK
SLOT (OPEN)
COLD WATER
SUPPLY IN/OUT
COLD
WATER
SUPPLY
IN
SAFETY
VALVE
DISCHARGE
6956
HEATING
RETURN
SLOT (OPEN)
GAS SERVICE
COCK
Diagram 6.1
7028
SEALING
WASHER
Diagram 6.2
13
221679H
Supplied By www.heating spares.co Tel. 0161 620 6677
7 Flue Preparation
TOP OUTLET FLUE PACK
FLUE LENGTH
MAX 840mm (extd.)
MAX 570mm (std)
C
L
15mm
117mm
SCREW
’X’
SIDE FLUE
& TAPE
’X’ plus 132mm = FLUE LENGTH
STD./EXTD. TOP OUTLET FLUE PACK & 1 METRE EXTENSION KIT
3 x 1 metre extension kits may be joined together.
C
L
VIEW ’B’
36mm
REAR FLUE
15mm
7508
FLUE LENGTH
MAX 840mm (extd.)
MAX 570mm (std)
15mm
SCREW
& TAPE
’Y’
’Y’ plus 50mm = FLUE LENGTH
SCREW
& TAPE
SCREW
& TAPE
’X’
’Y’
SCREW
& TAPE
VIEW ’B’
SIDE FLUE ’X’ plus 132mm = FLUE LENGTH REAR FLUE ’Y’ plus 50mm = FLUE LENGTH
FLUE
PACKS
TOP STD.
REAR
SIDE
TOP EXTD.
REAR
SIDE
MINIMUM
WALL
THICKNESS
75
75
75
75
MINIMUM
FLUE
LENGTH
126
212
126
212
MAXIMUM
FLUE
LENGTH
570
570
840
840
MAXIMUM DISTANCE FROM
BOILER MOUNTING FACE
TO EXTERNAL WALL FACE
"Y"
519
-
789
-
7.1 Flue Position and Length
Determine flue application, length and terminal position before
starting, refer to diagram 7.1.
Note: The Standard Top Outlet Flue Pack and the Extended
Top Outlet Flue Pack contains a flue duct extension piece
complete with "O" rings, this should be discarded.
If you are using a Flue Bend or a Vertical Flue Kit, please follow
the instructions supplied with the kit.
To make a neat finish to the flue outlet a flue collar kit, part No.
443286, with instructions, is available, see diagram 7.2.
Note: If required an optional wall liner kit, part no. 900862, is
available complete with instructions.
"X"
BOILER CASING TO
EXTERNAL WALL FACE
-
438
-
708
7.2 Flue Assembly
Extend the telescopic flue to the required length, making sure
that the minimum overlap is no less than 25mm, and that the flue
terminal projects 15mm minmum beyond wall face, see diagram
7.1.
Carefully drill though air duct pilot hole and secure with self
tapping screw provided in fittings pack, see diagram 7.1.
Seal the joint with the tape provided.
If the flue system requires the addition of flue extension kits,
drill, seal and secure them with the self tapping screw and tape
provided.
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 3 METRES WITH THE USE
OF THE 1 METRE EXTENSION KITS.
NOTE :THIS APPLIES TO STANDARD KITS ONLY.
7506
Diagram 7.1
221679H
14
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