Glow-worm EnergySaver 80 User Manual

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Page 1

Instructions for Use

Installation and Servicing

T o be left with the user

221837B.11.00

Energysaver

70 80

Cat I

G.C. No. G.C. No.

41 319 92 41 319 84

High Efficiency Boiler

Reference in these instructions to British Standards and Statutory

Regulations/Requirements apply only to the United Kingdom.

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

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

For Ireland the rules in force must be used.

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

Cat II

2H3P

PAS010

4040S

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 center 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

✔

❏

One Contact Local Service

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

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

Nottingham Road, Belper, Derbyshire. DE56 1JT

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

Hepworth Heating Ltd.,

General/Sales enquiries:

Page 2

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

1.2.

CE MARK

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

Type test for purposes of Regulation 5 certified by: Notified body

0086. Product/productioncertifiedby: Notified body 0086. The CE mark on this appliance shows compliance with:

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

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

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

INFORMATION FOR THE INSTALLER AND SERVICE ENGINEER.

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

CERAMIC FIBRE/INSULATION PADS, GLASSYARN.

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

THERMOSTATS

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

CUT OFF DEVICES

Cut off devices with copper phial/bulb only. Bulb contains activated charcoal and very small amounts of

chloroddifludromethane in the sealed phial and capillary. If broken under normal circumstances the fluid does not cause a problem. If there is irritation to the eyes or skin then seek medical attention.

FLUE SEALANT

This contains cyclohexylaminosilane. It may cause irritation of skin of sensitive persons. Wash contact

area with soap and water, if irritation occurs, seek medical advice.

It will cause irritation on contact with eyes. If so, wash eye with large amounts of fresh water for at least 15 minutes. If irritation occurs, seek medical advice.

If swallowed drink plenty of milk and seek medical advice.

CONTENTS DESCRIPTION SECTION PAGE No.

INSTRUCTIONS

FOR USE

Introduction 3 Lighting the Boiler 5

General Data 1 6 Water System 2 8

INSTALLATION INSTRUCTIONS

Boiler Location 3 11 Flue 4 12 Preparation 5 14 Water and Condensate Connections 6 16 Flue Installation 7 17 Gas Connection 8 20 Electrical Connection 9 21 Commissioning 10 22 User Information 11 23

Servicing 12 24

SERVICING

INSTRUCTIONS

Fault Finding 13 26 Replacement Parts 14 33 Spare Parts 15 39

221837B

Page 3

Instructions for Use

GREEN

HIGH/LOW CONTROL KNOB LIGHT FOR HIGH FLAME

GREEN LIGHT FOR LOW FLAME

ORANGE DEMAND LIGHT

Introduction

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

This boiler is designed to provide central heating from a fully pumped open vented or sealed water system with a fully indirect cylinder.

The boiler is fully automatic in operation, having two user controls, high/low control on the left and the control thermostat on the right, see diagram 1.

The “high/low” control can set to “Low” during the summer months.

Important Notice

This boiler is for use on natural gas (G20) as distributed in the United Kingdom and Ireland, but may be converted for use on L.P.G. Propane (G31) with the use of a conversion kit, i.e.

Energysaver 80, Kit No.444758. If your boiler has been converted to use L.P.G. Propane the

following note applys: Propane cylinders are under pressure and should never be

stored or used indoors residentially. They should only be kept outside. Under no circumstances should LPG Propane cylinders be

fitted or stored in basement areas or boiler house.

CONTROL THERMOSTAT

0163M

KNOB

Diagram 1

Maintenance/Servicing

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

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

To obtain service, please call your installer or Heatcall (Glowworm’s own service organisation) using the telephone number given on the information plate, see diagram 2.

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.

7891

Gas Safety (Installation and Use) Regulations

In your interest and that of gas safety it is the Law that ALL gas appliances are installed by a competent person in accordance with the current issue of the above regulations.

Gas Leak or Fault

If a gas leak or fault exists or is suspected, the BOILER MUST BE TURNED OFF, including the electrical supply and MUST NOT BE USED UNTIL THE FAULT HAS BEEN PUT RIGHT. Advice/help should be obtained from your installation/servicing company or the local gas undertaking.

RESET BUTTON

INSTRUCTION LABEL

Diagram 2

221837B

Page 4

Instructions for Use

PERMANENT SURFACE

150

100

500

INCREASE THIS DIMENSION TO

25mm FROM COMBUSTIBLE MATERIAL

CLEARANCE OPPOSITE TO FLUE EXIT MUST BE ADEQUATE FOR THE INTERNAL INSTALLATION

0157M

Boiler Clearances

If fixtures are positioned close to the boiler, space must be left as shown in diagram 3. Enough space must also be left in front of the boiler to allow for servicing.

Boilers Installed in a Compartment or Cupboard

If the boiler is installed in a cupboard or compartment do not obstruct any ventilation openings.

Do not use the cupboard or compartment for storage. Regularly make sure that the air vent openings are clear of

obstructions.

Cleaning

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

Clean the casing occasionally by wiping it over with a damp soapy cloth or dry polishing duster.

Do not use an abrasive cleaner.

Protection Against Freezing

If the boiler is to be out of use for any long period of time during severe weather conditions we recommend that the whole of the system, including the boiler, be drained off to avoid the risk of freezing up. Make sure that, if fitted, the immersion heater in the cylinder is switched off.

If you have a sealed water system contact your installation/ servicing company as draining, refilling and pressurising must be carried out by a competent person.

Boiler Electrical Supply

WARNING. The boiler must be earthed. The boiler must only be connected to a 240V~50Hz supply,

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

BS7671. The colours of three core flexible cable are: Brown - live, Blue - neutral, green and yellow - earth. As the markings on your plug may not correspond with these

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

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

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

terminal marked “E”, “Green” or the earth symbol

Diagram 3

Electrical Supply Failure

Failure of the electrical supply will cause the burner to go out. Should this happen, operation of the boiler will normally resume

after the electrical supply is restored. If the burner does not relight after an electrical supply failure the

overheat device may need resetting, press the reset button on the underside of the boiler, see diagram 2.

221837B

Page 5

Instructions for Use

Overheat Safety Cutoff

If the cutoff operates on any other occasion than an electrical failure, press the reset button as stated in “Electrical Supply Failure”.

If the boiler fails to relight contact your installation/servicing company.

To Turn the Boiler On

Sealed Water Systems.

CAUTION A sealed water system must be filled and pressurised by a competent person.

Only light the boiler when you are sure that the system and boiler have been filled and pressurised.

The pressure gauge should show at least 0.7bar, anything less than this figure could indicate a leak and you MUST contact your installation/servicing company.

If there is any doubt about the boiler and system being full of water consult your installation/servicing company.

All Systems

Turn the electrical supply on to the boiler and check that any remote controls are set to your requirements (refer to manufacturer’s instructions for these items).

On demand, the orange light will come on. Turn the left hand switch to “high” flame. Turn the control thermostat knob, at the right, clockwise to any

position between “MIN” and “MAX., see diagram 1. The maximum setting is about 82

The boiler will not light between “O” and “MIN”. The boiler lighting operation is now automatic as follows: The fan operates, followed by an ignition spark until the burner

lights on low flame after a short period it will go to high flame and the green light will come on.

The burner will remain alight until switched off by the control thermostat or other remote control.

If the control thermostat is turned “Off”, by hand, wait at least 30 seconds before turning on again.

When the boiler thermostat is satisfied the burner and green light will go out.

When the system controls are satisfied the burner, orange and green lights will go out.

The automatic lighting sequence will operate again when heat is required.

The “high/low” switch should be set to “high” for winter use, but when domestic hot water only is required in the summer it can be turned to “low”.

If no light comes on you should contact your installation/ servicing company, to check the controls, although the system may be working.

C (180oF).

To Turn the Boiler Off

For short periods, turn thermostat control knob anti-clockwise until “O” is against the setting point. To relight the main burner, turn the thermostat knob clockwise to any setting between ”MIN” and “MAX”.

For longer periods, turn the thermostat control knob anticlockwise until “O” is against the setting point and switch off the electrical supply to the boiler.

To relight follow the sequence given above. Note: If the burner goes out for any reason, wait 30 seconds

before relighting.

Condensation Pluming

Like all condensing boilers this appliance will produce a plume of condensation from the flue terminal in cool weather. This is due to the high efficiency and hence low flue gas temperature of the boiler.

221837B

Page 6

1 General

119

660

500 370

722

300

124

CAPPED OFF

FLUE TERMINAL DETAIL

Ensure flue slopes 2˚ down towards the boiler i.e. 35mm fall per metre of flue length (2˚)

CONDENSATE DRAIN WATER CONNECTIONS

28mm COPPER GAS CONNECTION

4356

102

DRAIN CONNECTION

Diagram 1.1

Important Notice

This boiler is for use only on G20 gas, but the Energysaver 80 may be converted for use on G31 gas (L.P.G.) with an available conversion kit.

Energysaver 80, Kit No. 444758 The boiler is delivered in one pack. Wherever possible, all materials and components to be used

shall comply with the requirements of applicable British Standards.

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

This boiler must have fully pumped circuits, but is suitable for use with open vented or sealed water systems.

This boiler is not suitable for outdoor locations.

1.1 Sheet Metal Parts

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

1.2 Statutory Requirements

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

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

Building Regulations, The Building Standards (Scotland) Regulations (applicable in Scotland), local Water Company Bylaws, The Health and Safety at Work Act, Control of

Substances Hazardous to Health, The Electricity at Work Regulations and any applicable local regulations.

Detailed recommendations are contained in the current issue of the following British Standards and Codes of Practice, BS4814, BS5440 Part 1 and 2, BS5449, BS5546, BS6700, BS6798, BS6891 and BS7074 Part 1 and 2, BS7478, BS7593, BS7671.

We also suggest that you have to hand a copy of the British Gas publication, “Guidance Notes for the Installation of Domestic Condensing Boilers”.

Manufacturer’s notes must not be taken as overriding statutory obligations.

BSI Certification

The boiler is certificated to the current issue of P.A.S. 010 for performance and safety.

It is important that no alteration is made to the boiler, without permission, in writing, from Hepworth Heating Ltd.

Any alteration that is not approved by Hepworth Heating Ltd., could invalidate the warranty and could also infringe the current issue of the Statutory Requirements.

1.3 Range Rating

The boiler is range rated and is factory preset to maximum, but may be adjusted to suit individual system requirements, refer to Table 2.

1.4 General Data

The data label is positioned on the inner case, visible when the outer case is removed.

All dimensions on diagrams are given in millimetres (except as noted).

221837B

Page 7

1 General

The Seasonal Efficiency Domestic Boilers UK (SEDBUK) is 87.9%.

The value is used in the UK Government’s Standard Assessment Procedure (SAP) for energy rating of dwellings. The test data from which it has been calculated have been certified by B.S.I.

1.5 Gas Supply

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

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

On completion, test the gas installation for soundness using the pressure drop method and suitable leak detection fluid. Purge in accordance with the above standard.

1.6 Electrical Supply

WARNING. This boiler must be earthed. All system components shall be of the approved type and be

wired and connected in accordance with the requirements of the current issue of BS7671 and any applicable local regulations.

Connection of the boiler and system controls to the mains supply must be through a common isolator and must be fused 3A maximum. This method of connection should be, by a double pole isolating switch, which has a minimum contact separation of 3mm on both poles. This should be readily accessible and preferably adjacent to the appliance. It should supply the appliance only and be easily identifiable as so doing.

Wiring to the boiler must be PVC insulated type to the current issue of BS6500 Table 16.

Alternatively, an unswitched shuttered socket and 3 pin plug to the current issue of BS1363, fused 3A, may be used, provided it is not used in a room containing a bath or shower.

1.7 Condensate

The boiler condensate should, if possible, be discharged into the household internal draining system, that is, sink or washing machine drain. If this is not practicable, discharge can be external, into the household drainage system or a purpose designed soak away

The boiler is fitted with a safety device to prevent the boiler from working if the condensate pipe gets blocked by either ice or debris.

It is, therefore, recommended that any external condensate drain pipe is insulated to prevent it freezing up.

Alternatively, a larger diameter pipe can be used and insulated. The condensate drain pipe should be checked during any

servicing and any debris found removed. Refer to the British Gas publication “Guidance Note for the

Installation of Domestic Condensing Boilers” for further information.

1.8 Heating System Controls

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

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

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

1.9 Anti-theft Kits

Anti-theft kits are available for these appliances, contact Hepworth Heating Ltd. for further information.

DATA TABLE 1.

MODEL

TOTAL WEIGHT LIFT WEIGHT

WATER CONTENT

GAS CONNECTION

WATER CONNECTION

ELECTRICITY SUPPLY

TABLE 2.

RANGE RATING

NOMINAL

HEAT INPUT (GROSS)

NOMINAL

Btu/h

HEAT OUTPUT

NOMINAL

Btu/h

HEAT OUTPUT

Btu/h

CONDENSING BURNER

mbar

SETTING (HOT) PRESSURE

APPROX

in.w.g

m3h

GAS RATE

ft3h

BURNER INJECTOR MARKING: 80N

TABLE 2.

RANGE RATING

NOMINAL

HEAT INPUT

(GROSS) Btu/h

NOMINAL

HEAT OUTPUT

NOMINAL

Btu/h

HEAT OUTPUT

Btu/h

CONDENSING BURNER

mbar

SETTING (HOT) PRESSURE

APPROX

in.w.g

m3h

GAS RATE

ft3h

BURNER INJECTOR MARKING: 70N

70 and 80

51.0 kg

(112.5 lb)

35.5kg

(78.5 lb)

2.0 Litre

(0.44 gall)

/2 in.

28mm copper,

flow at right, return at left

240V ~ 50H

Z, fused 3A.

Energysaver 80

LOW MIN MID MAX

15.0 23.3 25.0 26.6

51,100 79,550 85,200 90,900

13.2 20.5 22.0 23.4

45,000 70,000 75,000 80,000

14.0 21.7 23.2 24.8

47,500 74,000 79,200 84,500

5.25 12.25 14.0 16.0

2.1 4.9 5.6 6.4

1.4 2.2 2.35 2.5

50.5 78.5 84.0 89.5

Energysaver 70

LOW MIN MID MAX

15.0 20.0 21.7 23.3

51,100 68,200 73,860 79,550

13.2 17.6 19.1 20.5

45,000 60,000 65,000 70,000

14.0 18.6 20.1 21.7

47,500 63,400 68,700 74,000

7.1 12.4 14.6 16.8

2.8 5.0 5.9 6.7

1.4 1.85 2.0 2.2

50.5 67.3 72.8 78.5

221837B

Page 8

2 Water System

2.1 Draining Tap

The boiler is provided with a draining point at the lower left hand side of the burner manifold, to be used for draining the boiler, see diagram 2.1.

A draining tap must be provided at the lowest points of the system which will allow the entire system and hot water cylinder to be drained.

Draining taps shall be to the current issue of BS2879.

2.2 Safety Valve

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

2.3 Pump

The pump should be fitted in the flow pipe from the boiler and have isolating valves each side, integral if possible.

A variable duty pump should be set to give a temperature difference of 11 thermostat set at “MAX”, which is about 82 design flow rate as shown in Table 3.

See chart for pressure drop of the boiler, diagram 2.2. The use of microbore systems is not recommended.

C (20oF) between the flow and return, with the

C (180oF), to give a

2.4 Bypass

A BYPASS MUST BE FITTED, see diagram 2.3 for a suitable position.

The flow rate through the boiler must not be allowed to fall below that given in Table 3.

Where the water system can allow the boiler and pump to operate on bypass only, the bypass

1.5m away from the boiler.

must be placed at least

2.5 Inhibitor

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

If an inhibitor is to be used, contact an inhibitor manufacturer for their recommendations as to the best product to use.

Note: This boiler has a totally copper water system and does not require a special inhibitor normally associated with other types of high efficiency (“condensing”) boilers.

If an existing system is to be reused take special care to drain the entire system, including the radiators, then thoroughly cleaning out before fitting the boiler whether or not adding an inhibitor.

Flow rate (gallons/minute)

0123

2.0

1.5

1.0

0.5

Water pressure loss

(metres head of water)

Energysaver 70 Energysaver 80

BOILER DRAIN POINT

Diagram 2.1

10 15

Flow rate (litres/minute)

20 25 30

70 60 50 40 30 20 10 0

35 40

Diagram 2.2

TABLE 3

Design Minimum

Flow Rate Flow Rate

26.8L/min 19.6L/m

30.5L/min 22.5L/m

4364 S

0164M

Water pressure loss

(inches head of water)

2.6 Open (Vented) Water System

The boiler must be supplied from an unrestricted water supply taken from a feed and expansion cistern situated at a maximum height of 27metres (90ft) above the boiler.

Maximum water pressure 3 Bar. The cold feed must be 15mm minimum size. The vent must rise continuously and be unrestricted. It is important that the relative positions of the pump, cold feed

and open vent are as shown in diagram 2.3.

2.7 Domestic Hot Water Cylinder

The domestic hot water cylinder must be of the double feed fully indirect type. Not the single feed self priming type.

221837B

Page 9

2 Water System

2.8 Domestic Hot Water System - Unvented

Where a storage system will not have a vent to atmosphere the installation must comply with the Building Regulations and local Water Company bylaws, see also the current issue of BS5546 and BS6700.

If fitting to an existing system the local authority should be informed.

2.9 Sealed Water Systems

The installation must comply with the appropriate requirements of the current issue of BS4814, BS5449, BS6759, BS6798 and BS7074 Part 1 and 2.

See diagram 2.4 for a suggested layout.

2.10 Safety Valve

A safety valve must be fitted to a sealed system. It shall be preset, nonadjustable with a lift pressure of 3bar,

incorporating seating of a resilient material, a test device and a connection for drain.

The drain from the safety valve must be routed clear of any electrical fittings and positioned so that any discharge can be seen.

450mm MIN. HEIGHT

1150mm MIN.

Open (vented) ststem. Recommended rellationship between pump,cold feed and vent.

22mm (MIN.) VENT FEED AND

EXPANSION CISTERN

15mm (MINIMUM) COLD FEED

22mm (MINIMUM) BYPASS WITH LOCKSHIELD VALVE

RET.

CYLINDER

PUMP

HEATING

0246M

FLOW

3 LITRES (0.66 gals) MAKE-UP BOTTLE (if required)

NON-RETURN VALVE

HEATING

CIRCUIT

AUTO AIR VENT

FLOW

RETURN

BOILER

22mm (min) BY-PASS WITH LOCKSHIELD VALVE

SAFETY VALVE

150mm

MAX

AIR RELEASE POINT

FILLING POINT

CIRCULATING PUMP

PRESSURE GAUGE

FLOW

Diagram 2.3

5814

(Make-up alternatives)

DRAIN COCK

BOILER

EXPANSION VESSEL

Diagram 2.4

221837B

Page 10

2 Water Sytem

2.11 Expansion Vessel

A diaphragm type expansion vessel, conforming to the current issue of BS4814 (see also BS7074 Part 1 and 2) must be connected at a point close to the inlet side of the circulating pump, see the diagrammatic layout, diagram 2.4 unless laid down differently by the manufacturer.

The expansion vessel volume depends on the total water system volume and the initial system design pressure. For any system an accurate calculation of vessel size is given in the current issue of BS7074 Part 1.

Example: For an initial system design pressure of 0.7bar, the minimum total vessel volume required is 0.063xTotal System volume.

Note: A higher initial design pressure requires a larger volume expansion vessel.

Guidance on vessel sizing is also given in the current issue of BS5449 and BS7074 Part 1.

The charge pressure must not be less than the static head of the system, that is, the height of the highest point of the system above the expansion vessel.

The water content of the boiler is given in the Data Table 1.

2.12 Pressure Gauge

A pressure gauge with a set pointer and covering at least 0 to 4bar (0 to 60lb/in a position where it can be seen when filling the system.

) shall be fitted permanently to the system in

2.13 Domestic Hot Water Cylinder

SINGLE FEED INDIRECT CYLINDERS ARE NOT SUITABLE. The hot water cylinder must be of the indirect coil type. It must

be suitable for working at a gauge pressure of 0.35bar above the safety valve setting.

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

PRESSURE REDUCING VALVE

0051

HEATING SYSTEM

2.14 Water Makeup

Provision should be made for replacing water loss from the system using a make up bottle or filling loop mounted in a position higher than the top point of the system, connected through a non-return valve to the return side of either the heating circuit or the hot water cylinder.

Alternatively, provision for make up can be made using a filling loop.

2.15 Filling a Sealed Water System

Provision for filling the system at low level must be made. Three methods are shown in diagram 2.5. There must be no permanent connection to the mains water supply, even through a nonreturn valve.

SUPPLY STOP VALVE

SUPPLY PIPE

HOSE UNIONS

DOUBLE CHECK VALVE ASSEMBLY

Diagram 2.5

221837B

Page 11

3 Boiler Location

NOTE:

The boiler may be installed in any room although particular attention is drawn to the requirements of the current issue of BS7671 with respect to the installation of a boiler in a room containing a bath or shower.

Any electrical switch or boiler control using mains electricity should be so situated that it cannot be touched by a person using the bath or shower. The electrical provisions of the Building Standards (Scotland) Regulations are applicable to such installations in Scotland.

The boiler must be mounted on a flat wall which is sufficiently robust to take its total weight, see Data Table 1.

3.1 Boiler Clearances

The boiler must be positioned so that at least the minimum operational and servicing clearances are as shown in diagram

3.1. Additional clearances may be required around the boiler for

installation purposes, dependent upon site conditions.

150

100

0157M

3.2 Timber Frame Buildings

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

3.3 Room Ventilation

The boiler is room sealed, so when installed in a room or space a permanent air vent is not required.

3.4 Cupboard or Compartment Ventilation

Where the boiler is fitted in a cupboard or compartment, permanent high and low level ventilation must be provided. The ventilation areas required are given in Table 4.

Where the installation of the boiler will be in an unusual location, special procedures are necessary, refer to the current issue of BS6798 for guidance.

Make sure that the cupboard or compartment air vents are positioned to be clear of obstructions at all times.

A compartment used to enclose the boiler must be designed and constructed specifically for this purpose.

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

INCREASE THIS DIMENSION TO

25mm FROM COMBUSTIBLE MATERIAL

500

PERMANENT SURFACE

CLEARANCE OPPOSITE TO FLUE EXIT MUST BE ADEQUATE FOR THE INTERNAL INSTALLATION

TABLE 4

ENERGYSAVER 70

Ventilation from room

Ventilation from outside

high level low level

cms in

210 32.6 210 32.6

105 16.3 105 16.3

cms in

Diagram 3.1

Ventilation from room

Ventilation from outside

TABLE 4

ENERGYSAVER 80

high level low level

cms in

240 37.2 240 37.2 120 18.6 120 18.6

cms in

221837B

Page 12

4 Flue

NOTE:

The flue must be installed in accordance with the current issue of BS5440 Part 1.

Important. The flue must be installed with a fall of: 35mm per metre (2

It is of no advantage to exceed the angle of 2 of the fan to the flue elbow may become more difficult as the angle is increased.

The air and flue duct connect to the top of the boiler using an elbow which can be positioned to the side or rear.

The rear and side flue assemblies are designed for internal installation, but if necessary, due to insufficient clearances (boiler/flue terminal location) they can be installed from the outside.

For a wall thickness up to 300mm the flue can be fully installed from the inside.

For a wall thickness over 300mm the external cut hole will need to be made good from the outside.

The standard flue is able to provide the duct lengths as shown in diagram 4.2 for a rear flue and diagram 4.3 for a side flue.

If a longer flue duct is required, do not extend the ductings. A 1, 2 or 3metre flue and terminal can be supplied.

See diagrams 4.2 and 4.3

) TOWARDS the boiler, see diagram 4.1.

, indeed sealing

6860

'R'

Make sure flue slopes 2

down towards

the boiler that is 35mm fall per metre of flue length (2

)

300mm

REAR FLUE

SIDE VIEW

Make sure flue slopes

down

towards the boiler that is 35mm fall per metre of flue length (2

)

REAR FLUE LENGTHS

R = Wall Thickness

STD Flue pack 75mm to 442mm 1m Flue pack 75mm to 953mm

2m Flue pack 75mm to 1953mm

0158M(a)

3m Flue pack 75mm to 2933mm

Diagram 4.2

'S'

6861

10.5mm

35mm

SIDE FLUE LENGTHS

S = "External wall face" to "boiler casing"

STD Flue pack 80mm to 311mm

221837B

SIDE FLUE

FRONT VIEW

1metre

Diagram 4.1

1m Flue pack 80mm to 821mm

2m Flue pack 80mm to 1821mm 3m Flue pack 80mm to 2801mm

Diagram 4.3

Page 13

4 Flue

4.1 Terminal Position

The minimum acceptable spacings from the terminal to obstructions and ventilation openings are as shown in diagram

4.4. The boiler must be installed so that the terminal is exposed to

the external air. It is important that the position of the terminal allows the free

passage of air across it at all times. Note: The flue will produce a plume of condensation in cold

weather, so special care must be taken in the siting of the flue terminal so as not to cause a nuisance to adjacent property.

Where the terminal is fitted within 600mm (24in) below plastic guttering an aluminium shield 1500mm (5ft) long should be fitted to the underside and immediately beneath the guttering or eaves.

Where the terminal is fitted within 450mm (18in) below eaves or painted guttering an aluminium shield 750mm (2ft6in) long should be fitted to the underside and immediately beneath the guttering or eaves.

0103 M

B,C

4.2 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, see diagram 4.4.

A suitable terminal guard can be obtained from:

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

their reference CGD K3 BL

4.3 Flue Collar Kit

A flue collar kit, part No. 443286 (with instructions) is available. Please note, the use of this collar will mean that the flue lengths

will need to be altered, full instructions are given in the kit.

H,I

MINIMUM SITING DIMENSIONS FOR FANNED FLUE TERMINALS POSITION

MINIMUM

SPACING

in mm

A DIRECTLY BELOW AN OPENABLE

WINDOW, AIR VENT, OR ANY OTHER

VENTILATION OPENING 300 B BELOW GUTTER, DRAIN/SOIL PIPE 75 C BELOW EAVES 200 E FROM VERTICAL DRAIN PIPES AND

SOIL PIPES 75

F FROM INTERNAL OR EXTERNAL

CORNERS 300 G ABOVE ADJACENT GROUND OR

BALCONY LEVEL 300 H FROM A SURFACE FACING THE

TERMINAL 600

I FACING TERMINALS 1200

K VERTICAL FROM A TERMINAL 1500

L HORIZONTALLY FROM A TERMINAL 300

* It may be necessary to increase this dimension to prevent

staining of adjacent walls depending on weather conditions.

0161M

Diagram 4.4

221837B

Page 14

5 Preparation

5.1 Unpacking - refer diagram 5.1

Open carton top, remove top fitting, wall template, loose items pack and boiler mounting bracket. Remove carton wrap and packing pieces.

Lift off white outer case front. Remove protective packing piece. Remove the cover of the inner case, see diagram 5.3.

INSTRUCTIONS

TOP FITTING

6289

LOOSE ITEMS PACK

No.10 x 3/

SELF TAPPER

➁

BOILER MOUNTING BRACKET

M5x10mm

PACKING PIECE

6294

➀

WALL TEMPLATE

BASE TRAY

BOILER

TOP CARTON WRAP

CONTROLS FITTING

Note: Casing securing screws supplied in loose items pack. Fit in order of numerical sequence.

SECURING SCREW(4)

INNER CASE

Diagram 5.2

6295

221837B

Diagram 5.1 Diagram 5.3

Page 15

5 Preparation

5.2 Rear and Side Flue Application

Having selected the location and flue application, with due regard to the terminal position.

Take the template from the boiler pack and temporarily position it on the wall, see diagram 5.4, making sure that the minimum clearances are maintained.

For a rear flue, mark the position of the flue as diagram 5.4. For a side flue, extend the centre line horizontally (taking into

account the required fall towards the boiler) left or right to the corner of the adjacent surface where the flue is required to exit to the outside.

Alternatively, the increase in the centre line height over a distance “x” is given by H=0.035x. Mark the position of the centre of the flue, as diagram 5.4.

5.3 Flue Hole Cutting

Having marked out the flue centre cut a hole for the flue see diagram 5.4A for minimum core drill size for various wall thicknesses.

This will allow for the 35mm per metre (2o) fall towards the boiler. Note: If required, an optional Wall Liner Kit, part No.900862, is

available, complete with fixing instructions.

5.4 Wall Mounting Bracket

Reposition the template, making sure of dimensional alignment with the flue centre lines.

Mark the boiler securing screws and mounting plate position, see diagram 5.5.

Drill holes and plug, fit the securing screws, allowing sufficient clearance to accept the keyhole fixing brackets and secure the boiler mounting bracket to the wall.

115 Minimum hole 125 up to 300mm wall 135 up to 680mm wall

REAR FLUE

56.5mm MIN

"x"

124mm

'H'=

0.035x

2˚

SIDE FLUE

0248 M

0249M

300

125 DIAMETER

2°

115 DIAMETER

See template for centre line positions

Diagram 5.4

135 DIAMETER

WALL THICKNESS

680

Diagram 5.4A

221837B

Page 16

5 Preparation

TEMPLATE

BOILER TOP FIXING POINTS

7Ø

3/16Ø PLUG

7Ø

3/16Ø PLUG

5mm

MOUNTING BRACKET FIXING POINT(S)

BOILER MOUNTING BRACKET

0170M

No. 12x2in.

5.5 Boiler Preparation

Lift the boiler into position above the boiler mounting bracket, lowering the boiler into position at the same time locating the key hole slots of the boiler on to the securing screws, when located secure the screws, see diagram 5.5.

AIR PRESSURE TUBES

4043 S

RED TUBE

CLEAR TUBES

Diagram 5.5

6 Water Connections and Condensate

6.1 Water Connections

The water connections to the heating system must be as shown in diagram 6.1.

UNION NUT

28mm O.D. COPPER TUBING

FLUE GAS SAMPLE POINT

WATER CONNECTIONS

OLIVE

SECURING

SCREWS (3)

ELECTRICAL CONNECTIONS

6.2 Condensate Connection

The condensate drain connection is at the bottom right of the boiler.

The drain ends in a spigot which is suitable for push-fit 22mm

(

in.) plastic overflow pipe, for example, Hepworth Polypipe,

Uponor, Osma, Oracstar. If using Marley, Terrain or Hunter tubing, which is slightly larger, use the silicone sealent provided

4O37 S

in the fittings pack to make a leak proof joint to the drain connection on the boiler.

The condensate discharge pipe should have a fall of 2 The boiler is fitted with a safety device to prevent the boiler from

working if the condensate pipe gets blocked by either ice or debris.

It is, therefore, recommended that any external condensate drain pipe is insulated to prevent it freezing up.

Alternatively, a larger diameter pipe can be used and insulated. The condensate pipe should be checked during any servicing

and any debris found removed. It is not necessary to provide air breaks, or traps in the discharge

pipe since the boiler has an integral 50mm trap and siphon. Refer to the British Gas publication “Guidance Notes for the

Installation of Domestic Condensing Boilers” for advice on the disposal of the boiler condensate.

Diagram 5.6

221837B

Diagram 6.1

Page 17

7 Flue Installation

7.1 Rear Flue

Mark and cut the air duct terminal assembly, see diagram 7.3 and the flue duct, diagram 7.4 to the lengths required, cutting square and removing any burrs.

Refer to diagram 7.5, mark through the holes in the flue elbow assembly and drill the duct as shown, making sure of the correct alignment of the “Top”.

7.2 Side Flue

Mark and cut the air duct terminal assembly, see diagram 7.6 and flue duct, diagram 7.7 to the lengths required, cutting square and removing any burrs.

Refer to diagram 7.5 mark through the holes in the flue elbow assembly and drill the flue duct as shown, making sure of the correct alignment of the “Top”.

7.3 Internal Flue Assembly

If access to the outside wall is not practical, the flue system can be installed from inside. Use of the optional wall liner kit recommended.

Apply sealant to the flue duct, locate into the air duct terminal, see diagram 7.8.

Apply sealant to the flue elbow spigot and then locate the flue and air duct terminal assembly to the flue elbow as shown in diagram 7.5, making sure of the alignment of the “Top”.

Secure the air duct/terminal assembly to the flue elbow and flue duct assembly with the two self tapping screws supplied in the loose items pack and then seal with the tape provided.

Place the flue assembly into the flue hole. Make sure that the flue terminal is correctly positioned and

projecting the correct distance from the outside wall face, see diagram 7.11.

FAN BRACKET

FAN SECURING SCREW (3)

FAN BRACKET SECURING SCREW (2)

Diagram 7.2

4444

LABEL

SECURING SCREWS (2)

TRANSIT BRACKET

Diagram 7.1

4368 S

LONG FLUE TERMINAL

STANDARD FLUE TERMINAL

4045 S

"Q" plus 67mm

"Q"

Diagram 7.3

221837B

Page 18

7 Flue Installation

7.4 External Flue Installation

Locate the air duct/terminal assembly into the flue elbow assembly as shown in diagram 7.5, making sure of correct terminal alignment of the “TOP”.

Mark the position of the air duct terminal assembly securing holes and drill two 2.8mm diameter holes through the air duct/ terminal assembly.

Apply sealant to the flue duct and locate into air duct terminal, see diagram 7.8.

From outside, place the air duct/terminal assembly and flue duct into the flue hole.

Make sure that the flue terminal is correctly positioned and projecting the correct distance from the outside wall face, see diagram 7.11.

Apply sealant to the flue elbow spigot and then locate the flue and air duct terminal assembly as shown in diagram 7.5, make sure of the correct alignment of the “Top”.

Secure the air duct terminal to the flue elbow with the two self tapping screws supplied in the loose items pack, then seal with the tape provided.

SEAL WITH TAPE SUPPLIED

FLUE ELBOW ASSEMBLY

2.8mm

DRILL SIZE

4079 S

AIR DUCT/TERMINAL AND FLUE DUCT ASSEMBLY

FLUE DUCT

"Q" plus 82mm

6863

BOILER CENTRE LINE

SEALANT

LONG FLUE TERMINAL

STANDARD FLUE TERMINAL

AIR DUCT/ TERMINAL AND FLUE DUCT ASSEMBLY

Diagram 7.5

6864

"N" minus 57mm

221837B

"Q"

Diagram 7.4

"N"

Diagram 7.6

Page 19

7 Flue Installation

7.5 Flue Elbow

Remove transit bracket and label, see diagram 7.1. Fit the flue elbow gasket, from the fittings pack, to the casing

top. The two fan bracket securing screws should be loosened, but

not removed, before slackening the three fan securing screws. After locating the flue elbow into the outlet of the fan, secure the

flue elbow onto the top panel with the four M4x14 screws provided.

Then push fan upwards, making sure that the flue elbow spigot engages inside the fan outlet and compresses the gasket. Complete assembly by fully tightening the two fan bracket securing screws.

Finally tighten the three fan securing screws. Fit the inner case door.

7.6 Wall Liner

If a wall liner is used : For wall thicknesses up to 300mm fit the self adhesive seal to

the air duct, see diagram 7.9, make sure the joint is on top. For wall thicknesses over 300mm see diagram 7.10.

SEALANT

FLUE DUCT

4080 S

FLUE DUCT

BOILER CENTRE LINE

"N" minus 42mm

6865

AIR DUCT/ TERMINAL ASSEMBLY

FOAM SEAL

FLUE DUCT

Diagram 7.8

6866

10mm

"N"

Diagram 7.7

"Q"

Diagram 7.9

221837B

Page 20

7 Flue Installation

FOAM SEAL

"Q" minus 25mm

"Q"

6867

✽ STD FLUE TERMINAL = 63 ✽ STD FLUE TERMINAL = 61

✽

FLUE TERMINAL

FLUE DUCT

SEAL (joint to be at top)

6868

Diagram 7.11

Diagram 7.10

8 Gas Connection

Make the gas connection to the gas service cock, see diagram 8.1.

MULTI-FUNCTIONAL CONTROL

SECURING SCREWS (4)

SOLENOID SECURING SCREW

SUPPORT BRACKET SECURING SCREW

GAS SERVICE COCK (SHOWN OFF)

9022

221837B

BURNER PRESSURE TEST POINT

SECURING SCREW

PLUGS

SECURING SCREW

UNION CONNECTOR

Diagram 8.1

Page 21

9 Electrical Connection

NOTE:

WARNING: This boiler must be earthed. Remove the screws as diagram 9.1. Pull the control box forward to release from the rear slot, allow

to pivot and place into position as shown in diagram 9.1. Using PVC insulated cable to the current issue of BS6500 Table

16, and of a suitable length, thread the cable through the small cable clamp and connect to the appropriate terminals, see diagram 9.2.

Standard colours are, brown - live (L),

blue -neutral(N), green/yellow - earth (E) .

The mains cable outer insulation must not be cut back external to the cable clamp.

When making connections, make sure that the earth conductor is made of a greater length than the current carrying conductors, so that if the cable is strained the earth conductor would be the last to become disconnected.

It is essential that the polarity is correct.

9.1 Pump and External Controls Connection

The pump must be connected directly to the control box, as shown in diagram 9.2.

Any external controls must only be connected to terminals 1 and SL. after removing red link.

Thread the cable(s) through the large cable clamp in the side of the control box.

9.2 Testing - Electrical

Checks to ensure electrical safety should be carried out by a competent person.

In the event of an electrical fault after installation of the system, preliminary electrical system checks as below should be carried out:

1. Test insulation resistance to earth of mains cable.

2. Test the earth continuity and short circuit of all

cables.

3. Test the polarity of the mains. The installer is requested to advise and give guidance to the

user of the controls scheme used with the boiler.

MAINS SUPPLY CABLE GROMMET

4052 S

CONTROL BOX

PULL SLIGHTLY FORWARDS AND UP

SECURING SCREW (2)

PUSH DOWN

LOCATING SLOTS

Diagram 9.1

4370 S

PUMP AND REMOTE CONTROLS GROMMET

PUMP CABLE

MAINS SUPPLY CABLE

CHASSIS EARTH POST

✽

SL PL PN 1 L N

✽ RED LINK SL TO 1 REMOTE CONTROLS

Diagram 9.2

221837B

Page 22

10 Commissioning

Please ensure the “Benchmark” logbook is completed and left with the user.

10.1 Preliminaries - All Systems

Commissioning should be carried out by a competent person in accordance with current issue of BS6798.

Make sure that the system has been thoroughly flushed out with cold water without the pump in place.

Refit the pump, fill the system with water, making sure that all the air is properly vented from the system and pump.

Before operating the boiler check that all external controls are calling for heat.

10.2 Sealed Systems

Fill the system until the pressure gauge registers 2.7bar (40lbf/

). Clear any air locks and check for leakage.

in Check the operation of the safety valve, preferably by allowing

the water pressure to rise until the valve lifts. This should be within +/-0.3bar (+/-4.3lbf/in

), of the preset pressure. Where

this is not possible a manual check should be carried out. Release the cold water to initial design pressure.

10.3 Initial Lighting, Testing and Adjustment

WARNING: The multifunctional control, fan and control box operate on MAINS voltage, terminals will become live.

Check that the mains electrical supply to the boiler is switched off and that the control thermostat is turned to “O”, see diagram

10.1. For future reference stick the self adhesive arrow indicator, from

the loose items pack, to the data label against the rating that the boiler is going to be set to.

Turn on the supply at the gas service cock. Loosen the burner pressure test point screw and fit a suitable

pressure gauge, see diagram 8.1. Turn the electrical supply on to the boiler and check that all

remote controls are calling for heat. The orange demand light will come on, see diagram 10.1. Turn the left hand switch to “High” flame. Turn the control thermostat knob, at the right, clockwise to any

position between “MIN” and “MAX”, see diagram 10.1. The maximum setting is about 82

C (180oF). The boiler will not light between “O” and “MIN”. The boiler lighting operation is now automatic. The fan operates, followed by an ignition spark until the burner

lights on “Low” flame after a short period it will go to “High” flame the green light is on.

The burner will remain alight until switched off by the control thermostat or other remote control.

The automatic lighting sequence will operate again when heat is required.

10.4 Testing - Gas

With the boiler on carry on as follows: Test for gas soundness around the boiler gas components

using a suitable leak detection fluid, in accordance with the current issue of BS6891.

Check the burner pressure at least 10 minutes after the burner has lit, refer to Data label.

If the main burner pressure requires adjustment, see diagram

10.2. The brass nut, controls the main (high) burner pressure.

221837B

The centre, plastic posidrive screw controls the “Low” burner pressure.

The centre, plastic posidrive screw must be held in position whilst adjusting the main (high) burner pressure, brass nut.

After adjustment the low pressure must be checked, by turning the “high/low” to “low” setting.

Should any doubt exist about the gas rate, check it using the gas meter test dial and a stop watch, at least 10 minutes after the burner has lit, make sure that all other gas burning appliances are off.

The rates are as shown in Table 2. Turn the control thermostat knob to “Off”. Remove the pressure gauge from the test point and refit the

screw, making sure that a gas tight seal is made. When the control thermostat is turned to “Off”, by hand, wait at

least 30 seconds before turning “On” again. There may be an initial smell given off from the boiler when new,

this is quite normal and it will disappear after a short period of time.

Refit the electrical controls box.

GREEN LIGHT FOR HIGH FLAME

CONTROL THERMOSTAT KNOB

HIGH/LOW CONTROL KNOB

GREEN LIGHT FOR LOW FLAME

ORANGE DEMAND LIGHT

Diagram 10.1

HIGH SETTING ADJUSTMENT (BRASS NUT)

LOWER SETTING ADJUSTMENT (INNER SCREW)

Diagram 10.2

0163 M

9023

Page 23

10 Commissioning

10.5 Heating System

Check that all remote controls are calling for heat. Allow the system to reach maximum temperature and examine

for water leaks. The boiler should then be turned off and the system drained off

as rapidly as possible whilst still hot. Refill the system, vent and again check for water soundness. For sealed water systems adjust to initial design pressure. The

set pointer on the pressure gauge should be set to coincide with the indicating pointer.

The overrun thermostat will keep the pump running when the boiler shuts down, so long as the temperature within the boiler is above a predetermined level.

When commissioning the system the boiler should be fired with the bypass fully closed on full service, that is, central heating and domestic hot water.

The system should then be balanced, adjusting the pump and lockshield valves as necessary to achieve flow rates, refer to Section 2.4.

Having achieved a satisfactory condition, operate the boiler with the bypass closed on minimum load, normally central heating only with one radiator operating in the main living area. The valve should be opened gradually to achieve the appropriate flow rate as quoted in Section 2.4. If necessary readjust the pump.

Under NO circumstances should this valve be left in the FULLY Closed position.

10.7 Operational Checks

Adjust the control thermostat and any system controls to their required settings and set “high/low” switch to “high”.

Do not attempt to adjust the thermostat calibration screw. Operate the boiler again on full service and check that the

balancing is satisfactory, making further adjustments as necessary to the system, radiator valves and bypass.

There must be no pumping over of water or entry of air at the vent above the feed and expansion cistern.

If thermostatic radiator valves are fitted care must be taken to make sure that there is an adequate flow rate through the boiler and bypass when the valves are closed. For guidance on the use of thermostatic radiator valves refer to the current issue of BS7478 and British Gas Publication “Guidance Notes for Installation of Domestic Condensing Boilers”.

To check the operation of the flame supervision device, with the burner alight, turn gas service cock to “Off” the burner will go out. There will be one attempt to relight, indicated by a 5 second ignition phase.

Wait 30 seconds. Turn the gas cock to “ON” and the burner should NOT relight. Turn the control thermostat knob to “OFF” and then “ON” again

and the burner WILL now relight. Turn “high/low” switch to “low” and observe low flame, then

return switch to “high”. Refit the outer case, see diagram 5.2 and secure the case with

the screws from the fittings pack.

10.6 Condensate Check

After 30 minutes of running, turn the boiler off and remove the inner case.

Check that there are no condensate leaks from the fan outlet/ flue elbow or fan inlet/flue hood joints. Also check for leaks from the condensate drainage system.

11 User Information

NOTES:

Instruct and demonstrate the efficient and safe operation of the boiler, heating system and if fitted the domestic hot water system.

Advise the user that, like all condensing boilers this appliance will produce a plume of condensation from the flue terminal in cool weather. This is due to the high efficiency and hence low flue gas temperature of the boiler.

Show the user the position of “Lighting Instructions” - refer to Instructions for Use.

Advise the user that for summer use the “high/low” switch can be turned to “low”.

Advise the user of the precautions necessary to prevent damage to the system and building in the event of the heating system being out of use during frost and freezing conditions.

Advise the user, that to ensure the continued efficient and safe operation of the boiler it is recommended that it is checked and serviced 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.

Draw attention, if applicable, to the current issue of the Gas Safety (Installation and Use) Regulations, Section 35, which imposes a duty of care on all persons who let out any property containing a gas appliance.

It is the Law that servicing is a carried out by a competent person.

Reminder - Leave these instructions and the “Benchmark” logbook with the user.

221837B

Page 24

12 Servicing

NOTES:

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

It is the Law that any servicing is carried out by a competent person.

Note. To get a products of combustion reading use the connection on top of the boiler, see diagram 6.1.

Should the gas pressure need adjusting refer to Section 10.4. Isolate the boiler from the electrical supply. Before starting a service, remove the casing, refer to diagram

5.1. Turn the gas supply off at the gas service cock, see diagram 8.1. Unless stated otherwise, parts removed for servicing should be

replaced in the reverse order to removal. After completing any servicing of gas carrying components,

ALWAYS test for gas soundness and carry out functional check of controls.

Also check for condensate leaks at fan outlet/flue elbow and fan inlet/flue hood joints.

It should be noted that the burner is water cooled and a system drain down is necessary if the burner is removed.

SECURING SCREW(2)

AIR BAFFLE

BYPASS HEAT SHIELD

SECURING SCREW(2)

SECURING SCREW (2)

RED TUBE

AIR PRESSURE TUBES

4372 S

Diagram 12.1

4043 S

12.1 Heat Exchanger Cleaning

Remove the inner case cover, see diagram 5.3. Remove the bypass heat shield and air baffle, see diagram

12.1. Note. The flue hood top will “spring” up. Disconnect the fan air pressure tubes, combustion sampling

tube, electrical connections and remove the three fan securing screws, fan securing bracket, then fan and the flue hood.

Note. On reassembly it is suggested that the two top securing screws for the bypass heat shield and the flue hood be partially engaged before fitting of the bypass heat shield, see diagram

12.3. Carefully remove the combustion chamber front panel, see

diagram 12.4. Remove the loose baffle from the condensing section, see

diagram 12.5.

Place a container under condense drain trap, see diagram

12.8, and remove red cap. Flush loose debris from secondary heat exchanger with

water poured from above, and allow the water to drain through the flexible condensate tube at the right hand side of heat exchanger into the container.

Check that this tube is not partially blocked and the water runs freely.

If there is any build up of debris in the condensate trap, the trap should be removed and flushed out.

Important: With use a white oxide coating will form on the aluminium parts - this should only be removed if the coating is blocking the gaps between the fins.

When cleaning take care that the water does not overflow the condensate catchment tray.

Place a sheet of paper over the burner, see diagram 12.6. Clean the primary heat exchanger, with a suitable soft brush,

see diagram 12.6. Brush from back to front NOT left to right. Do not use a brush with metallic bristles. Remove the paper and any debris.

221837B

CLEAR TUBES

SECURING SCREWS (3)

ELECTRICAL CONNECTIONS

FLUE HOOD SECURING SCREW (2)

FLUE HOOD

Diagram 12.3

12.2 Burner

Clean the fins of the burner with a suitable soft brush, any debris can be allowed to fall into the mixing chamber.

Do not use a brush with metallic bristles. Note: The burner is water cooled and a system drain down is

required if removing.

4055 S

Page 25

12 Servicing

12.3 Injector

Remove the injector by releasing the three screws at the injector manifold burner box, the two screws at the inner case base sealing plate, see diagram 12.7, and the four screws at the multifunctional valve, see diagram 8.1.

Make sure that the “O” ring is in place in the flanged connection when refitting.

Clean the holes by blowing through. Do not use a wire or sharp instrument on the holes.

12.4 Spark Electrode

Remove the silicone sleeving and disconnect the ignition lead, see diagram 12.9.

Remove the two securing screws. Withdraw the electrode taking care not to damage the insulation

material. Inspect and clean taking care not to damage the ceramic body.

When replacing make sure that the spark gap is as shown.

COMBUSTION CHAMBER FRONT PANEL

LOCATION SLOT

VIEWING WINDOW

SECURING SCREW (2)

Diagram 12.4

4376S

SECONDARY HEAT EXCHANGER

4371 S

CONDENSATE TRAY

PRIMARY HEAT EXCHANGER

BURNER

Diagram 12.6

BAFFLE

Diagram 12.5

4373 S

4374 S

INJECTOR MANIFOLD

SECURING SCREW (3)

SECURING SCREW (2)

Diagram 12.7

221837B

Page 26

12 Servicing

12.5 Condensate Drain

Remove the cap at the base of the condensate drain trap, see diagram 12.8 and carefully flush through, from the condensate collecting tray, diagram 12.6, taking care not to allow any water to overflow the tray.

When refitting the cap make sure a water tight seal is made.

12.6 Operational Checks

After completing a service, before fitting the casing, check the inner case seal to ensure that it is in good condition, renew if necessary.

GASKET

SECURING SCREW (3)

CONDENSATE DRAIN TRAP

4060 S

SECURING SCREW (2)

IGNITION AND SENSING LEAD

SPARK ELECTRODE

4375 S

SILICONE SLEEVING

WASTE

CAP

OUTLET

Diagram 12.8

13 Fault Finding

13.1 Electrical

Important. On completion of the Service/Fault Finding task which has required the breaking and remaking of the electrical connections the earth continuity, polarity, short circuit and resistance to earth checks must be repeated using a suitable multimeter.

Refer to Fault Finding, Wiring diagram 13.2 and Functional Flow diagram 13.3.

Note. Failure of an indicator light does not warrant the replacement of an otherwise satisfactory part.

13.2 Electrical Supply Failure

Failure of the electrical supply will cause the burner to go out. Operation will normally resume on restoration of the electrical

supply. If the boiler does not relight after an electrical supply failure the overheat device may need resetting.

To reset, press the reset button on the underside of the boiler, see diagram 13.4.

If the cutoff operates at any other time press the reset button and the burner should relight. If the fault persists refer to Fault Finding Chart.

There is a further cutoff mounted on the flue hood, see diagram

13.5 which also may need resetting.

SPARK GAP 3mm to 4mm

Diagram 12.9

13.3 Condensate Sensor

Refer to fault finding chart. The boiler is fitted with a safety device to prevent the boiler from

working if the condensate drain pipe gets blocked. Remove the condensate drain cap, diagram 14.2.

If condensate is backing up to the sensor position, the drain is blocked and it must be cleared before the boiler will work. Inspect external condensate drain pipe and clear away any debris or ice. Release ice blockage by using warm cloths on the pipe.

221837B

Page 27

13 Fault Finding

PUMP OVERRUN OPERATION

The control thermostat has a pump overrun facility built into it, when the control thermostat is

set at maximum only, the pump overrun will keep the pump running to allow the boiler to cool

down after which it will stop, providing the remote controls are NOT calling for heat.

FAULT FINDING

Turn boiler control thermostat to maximum, with the remote controls calling for heat, does the

pump continue to run after the appliance has shut down on boiler control thermostat ?

YES

Turn off remote controls,

does pump stop after a short

period of time

Faulty pump overrun.

YES

Replace control thermostat

Pump overrun in order

Is there 240V~ on L ?

YES

Is there 240V ~on

9 connection on thermostat ?

Faulty permanent

live feed.

Replace

YES

Is there 240V ~ on PL for pump ?

YES

Faulty pump/wiring ? Replace or repair as necessary

Faulty

connections

between

thermostat and

interconnection

PCB. Repair

Faulty

connections

between

thermostat and

interconnection

PCB. Repair

221837B

Page 28

13 Fault Finding

Before detailed checking of electrical components ensure that remote controls are calling for heat. Check that the gas supply is free of obstructions and purged of air. Check the overheat thermostat and fluehood thermostat have not operated. Isolate the electrical supply and physically check ALL cables, connections and the printed circuit board (PCB) fuse. Check the air tubes to air pressure switch.

Is there 240V between L + N

YES

Is thermostat

neon on ?

YES

Isolate supply

Correct power supply problem

Isolate supply

Check continuity

of overheat thermostat.

Thermostat ok ?

YES

Check continuity of

control thermostat

between 3 and 6

ok ?

Replace

overheat

thermostat

Replace control

thermostat

Is there

continuity

between

and

C on APS

YES

Check wiring

and IC PCB

'stat' plug for

defects.

Repair or

replace wiring/

PCB if

necessary

Replace APS

Diagram 13.1

221837B

Page 29

Reconnect supply

13 Fault Finding

YES

Replace APS

Replace ignition

PCB

Is APS neon lit ?

YES

Has boiler been operating for 10

seconds yet ?

Is fan running ?

Is there 240V at the fan ?

Is there 240V

at C ?

YES

Switch High/Low Switch

to 'low'

Is there a spark at

electrode ?

Will flue hood

thermostat reset?

- is there 240V at the fan?

Replace flue hood

thermostat

YES

Does gas ignite ?

Replace fan

Flue hood overheating-

blocked secondary heat

exchanger (clean/replace)

Isolate supply

Check continuity of

both main coils

Coils ok?

YES

Replace

ignition

Replace as

necessary

PCB

Can the “low” gas

pressure be set

(see data tables)

at test point on gas

valve?

Does gas

ignite?

Faulty injector

Replace

YES

Does discharge tube on

ignition PCB flash ?

YES

Examine electrode and

leads. Repair/replace

as necessary

YES

Replace PCB

Diagram 13.1

221837B

Page 30

13 Fault Finding

Does the burner

remain alight ?

Is condense drain

blocked, repair.

Does burner remain

alight ?

Is the low gas pressure setting

correct (see data tables)?

Adjust as necessary.

Does burner remain alight?

Will burner remain alight if gas

pressure is temporarily

increased?

YES

Is the low gas pressure

setting correct (see Data

Tables) at the test point

on the gas valve ?

Turn High/Low switch to

“High”.

Check and adjust “High”

gas pressure

(see data tables)

Is gas pressure OK?

NOYES

Adjust gas

pressure

Faulty injector - Replace

(Reset pressure)

Faulty PCB flame detection -

Replace PCB

(Reset pressure)

Boiler satisfactory

Does “High” neon light ?

Isolate supply

Check continuity

between 4 and 1 on

High/Low switch.

Switch ok ?

YES

Replace gas valve

YES

Replace

High/Low

switch

221837B

Diagram 13.1

Page 31

13 Fault Finding

9024

FAN

g/y

REMOTE SWITCH

HIGH/LOW (FLAME) SWITCH

PUMP SUPPLY

MAINS 240VAC 50Hz

EARTH POST

g/y

EARTH POST

PLASTIC OVERHEAT

RED LINK

TB1

1 L

LOW FLAME NEON

LAMP 2

CM1

PCB

4 3

STAT

2 1

HIGH FLAME NEON

3 2

LAMP

GV2

4 3 2 1

DEMAND NEON

GV1

2 1

AIR PRESSURE SWITCH

INTER-

CONNECTION

P.C.B.

MULTI-FUNCTIONAL CONTROL

HIGH/LOW (FLAME) PLUG

KEY:

b - BLUE bk - BLACK br - BROWN g/y- GREEN/ YELLOW g - GREY

REMOVE RED LINK IF REMOTE

SWITCH IS TO BE FITTED

r - RED y - YELLOW p - PURPLE w - WHITE o - ORANGE

g/y

MAIN PLUG

OVERHEAT CUT-OFF

12345678910

y g/y

2 AMP FUSE

CONTROL P.C.B.

BOILER CONTROL THERMOSTAT

CONDENSE CUT-OFF

CHASSIS EARTH

SPARK ELECTRODE

Diagram 13.2

221837B

Page 32

13 Fault Finding

FUSE TYPE F2A

IGNITION P.C.B.

OVERRUN

P.C.B.(4) CM1(1)

CONDENSE CUT-OFF

PUMP

Stat(3)

PUMP

Stat(1)P.C.B.(2)

NO C

P.C.B.(3) GV1(1)

HIGH/LOW SWITCH

Stat(2)

Stat(4) Lamp(3)

PLASTIC

OVERHEAT

AIR PRESSURE SWITCH

GV1(2)

Amp Con

✽ RED LINK

CONTROL THERMOSTAT

OVERHEAT THERMOSTAT

bk bk

FAN

CM1(3)

HIGH FLAME

DEMAND

NEON

bbk

Lamp N(3)

P.C.B.(1)

CM1(2)

GV1(3)

LOW FLAME NEON

Lamp N(2)

NEON

Lamp N(1)

554

221837B

KEY:

r - RED br - BROWN p - PURPLE b - BLUE bk - BLACK y - YELLOW w - WHITE g - GREY

Lamp(1)

br b

GV2(1 ) GV2(2)

I.C. P.C.B. CONNECTIONS: ie STAT (Pin No. from bottom) MAIN TERMINAL STRIP CONNECTIONS CONTROL THERMOSTAT CONNECTIONS PRINTED CIRCUIT BOARD CONNECTIONS

✽ RED LINK MAY HAVE BEEN REMOVED TO FIT REMOTE CONTROLS

Diagram 13.3

Page 33

13 Fault Finding

RESET BUTTON

INSTRUCTION LABEL

7891

RESET BUTTON

FLUE HOOD OVERHEAT

Diagram 13.4

THERMOSTAT

14 Replacement of Parts

4067 S

Diagram 13.5

Notes:

Replacement of parts must be carried out by a competent person.

Before replacing any parts isolate the boiler from the electrical supply and turn the gas supply off at the gas service cock, see diagram 8.1.

Unless stated otherwise, all parts are replaced in the reverse order to removal.

After replacing any parts always test for gas soundness and if necessary carry out functional check of controls.

For the following the front case and inner case cover will need to be removed, diagrams 5.2 and 5.3.

14.1 Spark Electrode

Replace as described in Section 12.4.

14.2 Ignition Lead: diagram 14.2

Release the control box as Section 9. To disconnect the ignition lead from the control board, remove

the PCB from the mounting pegs, the front two have detachable grips, the rear two are plain supports.

When refitting lead make sure that there is enough length through the gland plate assembly.

Condensate Sensor - diagram 14.2

Refer to the relevant parts of Section 14.2 to remove the screw. The sensing screw is fitted to a push fit cap which can be levered

off for easy access. Note. The condensate flexible tube is a push fit and can be

removed from the condensate drain trap to improve access to the screw.

When replacing the cap make sure that it is firmly in place and that the ring tag is pointing away from the casing side.

SECURING SCREW (2)

CONDENSATE SENSOR SCREW

5549

CONDENSATE FLEXIBLE TUBE

SPARK ELECTRODE

CONDENSATE DRAIN CAP

IGNITION SENSING LEAD

Diagram 14.2

221837B

Page 34

14 Replacement of Parts

Control PCB: diagram 14.3 (top)

Disconnect the electrical plug on the board. Release from its two support posts and carefully pull the board

away noting that the ignition lead is still connected. It may be necessary to hold some of the wires above the PCB

clear with an electrical screwdriver on removal or refitting. Release and carefully pull the board away from its supports,

noting that the ignition lead is still connected. Disconnect the ignition lead.

Interconnecting PCB: (ICB) diagram 14.3 (bottom)

Disconnect the electrical plugs and cables from the terminal strip.

Release and carefully pull the board away from its supports. When refitting refer to wiring diagram 13.2.

14.4 Control Thermostat and Overheat Cutoff

Release the control box, see Section 9.

Control Thermostat: diagram 14.4A and 14.4

Pull off the control thermostat and High/Low knobs. Remove the three fascia securing screws and fascia. Remove the electrical connections from the control thermostat

body. Remove the two control thermostat securing screws. Release and remove the control thermostat phial from the

pocket. Withdraw the capillary through the controls box grommet. Slide control thermostat body away from control box. On replacement smear the phials with the heat sink compound

supplied before replacing in the phial pocket. When refitting refer to wiring diagram 13.2.

ELECTRICAL PLUG

IGNITION LEAD

SUPPORT POST (2)

4065 S

CONTROL P.C.B.

Overheat Cutoff: diagram 14.4A and 14.4

Remove the electrical connections. Remove the locking nut. Release and remove the overheat cutoff phial from the pocket. Withdraw the capillary through the controls box grommet. On replacement smear the phials with the heat sink compound

supplied before replacing in the phial pocket. When refitting refer to wiring diagram 13.2. Neatly secure any surplus capillary.

Flue Hood Overheat Cutoff: diagram 14.5

Remove electrical connections and unfasten the screws to release.

Note: the polarity of the connections is not important.

SUPPORT POST (4)

TERMINAL STRIP

I.C.B

ELECTRICAL PLUG (5)

Diagram 14.3

221837B

Page 35

14 Replacement of Parts

4078 S

CONTROL THERMOSTAT SECURING SCREW (2)

OVERHEAT CUT OFF LOCKNUT

ELECTRICAL CONNECTION (5)

4377 S

RETAINING PIN

OVERHEAT CUT OFF PHIAL

CONTROL THERMOSTAT PHIAL

Diagram 14.4

CONTROLS FASCIA SECURING

HIGH/LOW CONTROL KNOB

CONTROL THERMOSTAT KNOB

SCREW (3)

CONTROLS FASCIA

Diagram 14.4A

14.5 “High/Low” Control: diagram 14.4 and

14.6

Remove the fascia as described in Section 14.4. Remove the four screws securing the lights bracket. Remove the locknut to release the “High/Low” control. Disconnect the three in-line electrical connectors. When refitting refer to wiring diagram 13.2.

4066 S

RESET BUTTON

PLASTIC OVERHEAT THERMOSTAT

Diagram 14.5

14.6 Air Pressure Switch: diagram 14.7.

Remove the air pressure tubes and electrical connections. Remove the two securing screws to release the air pressure

switch. When fitting the replacement make sure that all the air pressure

tubes and electrical connections are made as shown.

4067 S

221837B

Page 36

14 Replacement of Parts

14.7 Multifunctional Control: diagram 8.1.

Disconnect the screws and electrical plugs at the multifunctional control.

Support the multifunctional control and remove the four screws from the flanged connection, undo the union at the gas service cock and remove the support bracket securing screw.

Remove the multifunctional control by easing the flange and service cock apart.

Remove the union half and refit to the replacement multifunctional valve.

Use a little jointing compound on the external thread only, to ensure gas soundness.

Make sure that the new “O” ring is in place in the flanged connection is replaced.

It will be necessary to purge the pipework and multifunctional control before relighting and checking the pressure, refer to “Commissioning”.

14.8 Fan

Refer to Section 12.1 “Heat Exchanger Cleaning”. Make sure that the earth connection is remade onto the

replacement fan. The polarity of the electrical connections is not important.

14.9 Injector

Refer to Servicing Section 12.3. Fit new injector as shown. Note: The replacement injector manifold is supplied complete

with the gas supply pipe manifold.

14.10 Heat Exchanger: diagram 14.8

Note: To carryout the following operations it will be found more convenient if the whole of the heat exchanger and burner are removed as a unit.

Follow the relevant parts of Servicing Section and remove the bypass heat shield, fan/flue hood, combustion chamber front panel, heat exchanger baffle, spark electrode, injector manifold and thermostat phials.

Release the flexible tube from the condense drain trap, this is a push-fit.

Release union connections and the six securing screws, then remove the complete assembly.

SECURING SCREW (2)

AIR PRESSURE SWITCH

ELECTRICAL CONNECTIONS (3)

GREY

BROWN

CLEAR

RED

AIR PRESSURE SWITCH TUBES

GREY

YELLOW

Diagram 14.7

4378 S

LOCKNUT

SECURING SCREW (4)

LIGHTS BRACKET

HIGH/LOW CONTROL

4068 S

Diagram 14.6

UNION CONNECTION

SECURING SCREWS (6)

SPARK ELECTRODE

INJECTOR MANIFOLD

4379 S

CONDENSATE TUBE

Diagram 14.8

221837B

Page 37

14 Replacement of Parts

Heat Exchanger: Secondary - diagram 14.9

Disconnect the union connector. Remove and fit the flexible hose to the replacement.

Heat Exchanger - Primary - diagram 14.10

Disconnect the three union connections.

14.11 Burner: diagram 14.9

Note: To carryout the following operations it will be found more convenient if the whole of the heat exchanger and burner are removed as a unit.

SECONDARY HEAT EXCHANGER

Release the flexible tube from the condense drain trap, this is a push-fit.

Release union connections and the six securing screws, then remove the complete assembly.

Remove the insulation as Section 14.14 and retain for use in the replacement part.

Disconnect the two union connections. Fit the insulation.

14.12 Insulation - Rear - diagram 14.10

With the heat exchangers and burner assembly removed, as Sections 14.10 and 14.11, the rear insulation pad can be removed as shown.

14.13 Insulation: Combustion Chamber Front Panel: diagram 14.11

Remove the two screws from the viewing window then slide the

4380 S

insulation pad out.

REAR INSULATION

4381 S

UNION CONNECTION

PRIMARY HEAT EXCHANGER

UNION CONNECTION

LOCATING SLOT

UNION CONNECTION

BURNER

Diagram 14.9

COMBUSTION CHAMBER FRONT PANEL

INSULATION

PILOT VIEWING WINDOW

Diagram 14.10

4073 S

SECURING SCREW (2)

Diagram 14.11

221837B

Page 38

14 Replacement of Parts

14.14 Insulation - Sides - diagram 14.12

Remove the spark electrode refer to Section 12.4. Remove the insulation by sliding it out.

14.15 Condensate Sensor: diagram 14.13

Refer to the relevant parts of Section 14.2 to remove the screw. The sensing screwis fitted to a push fit cap which can be levered

off for easy access. Note. The condensate flexible tube is a push fit and can be

removed from the condensate drain trap to improve access to screw.

When replacing the cap make sure that the ring tag is pointing away from th casing side.

14.16 Viewing Window Glass: diagram 14.14

Remove the two screws to release the frame and glass. When replacing take care not to damage the gasket.

14.17 Inner Case Cover Seal

When removing seal make sure that all the old adhesive is removed.

When fitting the new seal make sure that it fits correctly and has not buckled.

SIDE INSULATION

CONDENSATE SENSOR SCREW

4382 S

Diagram 14.12

5549

14.18 Fascia and Lights Assembly

Release the control box as Section 9. Refer to the relevant parts of Section 14.5 to remove the fascia

and lights bracket.

FRAME

SECURING SCREW (2)

GLASS

VIEWING WINDOW/INNER CASE FRAME

Diagram 14.13

4076 S

GASKET

221837B

SECURING SCREW (2)

VIEWING WINDOW/COMBUSTION CHAMBER FRONT PANEL

GLASS

GASKET

Diagram 14.14

Page 39

15 Spare Parts

When ordering spare parts, please quote the appliance name and serial number, to be found on the data label, visible when the outer casing is removed.

If ordering from Birtish Gas also quote the GC number of the part.

Key No.

1 230530 Multifunctional control 2 800476 Thermostat - control 278 094 3 800477 Thermostat - over heat cutoff 278 095

4 800466 Overheat Thermostat 278047

5 450260 High/low control 278 276 6 800467 Thermostat control knob 278 049 7 202135 Air pressure switch 313 303 8 203157P Gas manifold assembly - 80 - NAT 278 262 8 203160P Gas manifold assembly - 70 - NAT 278 519 9 202231 Fuse 10 208302 Sight glass 312 419

11 800840 Ignition lead E00335 12 202211 Control board (PCB) 379 239

Part No.

208093 Gasket-sight glass (not illustrated) 312 420

Description

GC Part No.

13 800659 Fan 278 263 14 202625 Electrode 278 096 15 202210 Interconnection board 379 238

221837B

Page 40

15 Spare Parts

6291

221837B

Diagram 15.1

Because of our constant endeavour for improvement details may vary slightly from those in the instructions.