Glow-worm Hideaway 80B FF Instructions For Use Installation And Servicing

2000225144B.09.03

Instructions for Use

Installation and Servicing

To be left with the user

Hideaway

80B FF

G.C. No. 41-047-35

Balanced

Fanned Flue Boiler

Hepworth Heating Ltd., Nottingham Road, Belper, Derbyshire. DE56 1JT

Guarantee Registration

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

Glow-worm appliances are manufactured to the very highest standard so we are pleased to offer our
customers a Comprehensive First Year Guarantee.

We recommend you complete and return as soon as possible your guarantee registration return
literature, supplied in the document envelope.

If your guarantee registration return literature is missing you can obtain a copy or record your registration
by telephoning the Heatcall Customer Service number 01773 828100.

For customer service call:

[phone]

Technical helpline: [phone]

For General and Sales enquiries:

Tel. [phone]

Fax: [phone]

To register your Glow-worm appliance call:

2000225144B

0208 247 9857

2

Contents

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

CONTENTS DESCRIPTION SECTION PAGE No.

Important Information 4

INSTRUCTIONS

FOR USE

INSTALLATION

INSTRUCTIONS

SERVICING

INSTRUCTIONS

Draining and Filling 5
Appliance Introduction 5
Appliance Safety Devices 5
Maintenance and Servicing 6
Instructions for Use 7

General Data 1 8
Water Systems 2 11
Flue and Ventilation 3 12
Installation 4 13
Electrical Wiring 5 20
Commissioning 6 21
Instructions to the User 7 23

Servicing 8 23
Fault Finding 9 26
Replacement of Parts 10 29
Spare Parts 11 31

3

2000225144B

Important Information

Gas safety (Installation and use) Regulations

In your interests and that of gas safety, it is the law that ALL gas
appliances are installed and serviced by a competent person in
accordance with the above regulations.

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. The
requirements are: 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. Manufacture's instructions supplied.
Manufacture's instructions must not be taken as overriding
statutory requirements.

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.

Control of 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

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.
The insulation is composed of non-combustible material.

Electrical Supply

WARNING: This boiler must be earthed.

All system components shall be of an approved type and shall
be connected in accordance with the current issue of BS7671
and any applicable local regulations.

All external wiring between the appliance and the electrical
supply and earthing requirements shall comply with the current
IEE 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 must be by a fused
double pole isolating switch, with a minimum contact separation
of 3mm on both poles. The switch should be readily accessible
and preferably adjacent to the appliance. It should supply the
appliance only and be easily identifiable as so doing.

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

Wiring to the boiler must be PVC 85
than 0.75mm2 (24/0.20mm).

o

C insulated cable, not less

Gas leak or fault

WARNING: If a gas leak or fault exists or is suspected, turn the

boiler off and consult the local gas supply company or your
installation/service company.

Sealed Components

WARNING: DO NOT interfere with any sealed components

within this appliance.

Manual Handling Guidance

During the appliance installation it will be necessary to employ
caution and assistance whilst lifting as the appliance exceeds
the recommended weight for a one man lift.

In certain situations it may be required to use a mechanical
handling aid.

Take care to avoid trip hazards, slippery or wet surfaces.

Heating System Controls

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

Thermostatic radiator valves may be installed, however they
must not be fitted in a room where the room thermostat is
located.

Note: For further information, see the current issue of the
Building Regulations, approved document L1, ( in the UK) and
the references:

1) GIL 59, 2000: Central heating system specification (CheSS)
and

2) GPG 302, 2001: Controls for domestic central heating
system and hot water. BRECSU.

2000225144B

4

Important Information

Air in the heating system

Persistent air in the heating system may indicate leaks in the
system or corrosion taking place. Call your Installation/Servicing
company.

Boilers Installed in a Compartment

If the boiler is fitted in a compartment, cupboard etc., do not
obstruct the purpose built compartment vents or the grill on the
boiler.

Do not use the compartment for storage purposes.

Draining and Filling

Draining and filling

Caution: The boiler must only be drained and filled by a
competent person.

If the boiler is to be out of use for any period of time during severe
weather conditions we recommend the whole system including
the boiler, be drained off to avoid the risk of freezing up. If an
immersion heater is fitted to the hot water cylinder make sure it
is switched off.

If in doubt, consult your servicing company.

Protection Against Freezing

If the boiler is to be out of use for any period of time during severe
weather conditions we recommend the whole system including
the boiler, be drained off to avoid the risk of freezing up. If an
immersion heater is fitted to the hot water cylinder make sure it
is switched off.

Appliance Introduction

Introduction

The Glow-worm Hideaway B FF series are Balanced fanned
flue boilers. They provide heating and if required, an indirect
domestic hot water supply.

The boiler is of the I
as distributed in the United Kingdom.

The boiler is automatic in operation, having only one user
control, the boiler temperature control.

category for use with Natural Gas (G20)

2H

Appliance Safety Devices

Air flow rate safety device

If the flue is obstructed, even partially, the built in safety system
will turn the boiler OFF, the fan will continue to run. The boiler
will be ready to operate when the fault has been cleared.

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

Manufacturer’s instructions must not be taken as overriding
statutory requirements.

These instructions should be carefully followed for the safe and
economical use of your boiler.

Note: The boiler serial number is marked on the data label
attached to the heat shield under the control box. The
'Instructions for Use' section describes how to safely use the
boiler.

Electrical supply failure

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

Reset any central heating system controls, to resume normal
operation.

If the boiler does not resume normal operation it is advisable to
consult your installation / servicing company.

5

2000225144B

Maintenance and Servicing

Cleaning

WARNING: This appliance contains metal parts (components)
and care should be taken when handling and cleaning with
particular regard to edges of sheet metal parts to avoid any
possibility of personal injury.

The boiler casing can be cleaned with a damp cloth, followed by
a dry cloth to polish.

Do not use abrasive or solvent cleaners.

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,
refer to guarantee registration with this literature.

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

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

To obtain service, please call your installer or Heatcall (Glow­worm’s own service organisation) using the telephone number
on the inside front cover of this literature.

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
benchmark Logbook. You can check your installer is CORGI
registered by calling CORGI direct on: 01256 372300.

Spare Parts

Remember, when replacing a part on this appliance, use only
spare parts that you can be assured conform to the safety and
performance specification that we require. Do not use
reconditioned or copy parts that have not been clearly authorised
by Hepworth Heating Ltd.

If a part is required contact Heatcall (Glow-worm’s own service
organisation) using the telephone number on the inside front
cover of this booklet.

Please quote the name of the appliance, this infomation will be
on the name badge on the front of the appliance.

If in doubt seek advice from the local gas company or Heatcall
(Glow-worm’s own service organisation) using the telephone
number on the inside front cover of this booklet.

Boiler casing

CAUTION. Do not remove or adjust the casing in any way, as

incorrect fitting may result in faulty operation. If in doubt, consult
your installation/service company.

2000225144B

6

Instructions for Use

To Turn the Appliance On

Turn the electrical supply on to the boiler and check that all
remote controls are calling for heat.

Turn the boiler temperature control clockwise to any position
between “0” and "Max", see diagram 1.

"Max" is approximately 82°C (180°F).

The boiler lighting operation is now automatic as follows:

The fan operates and after a short period of time, the spark
ignition operates, the solenoid opens, then the burner will light
shown by the burner ON indicator (green) on the control panel
lighting up.

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

Note: If the boiler is turned OFF at the boiler temperature
control, wait at least 30 seconds before switching on again.

When the boiler switches off, the burner will go out.

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

It should be noted that this is a fanned flue appliance and fan
operation may be heard.

If the reset/standby indicator lights, turn the boiler temperature
control to "0" (off), wait 30 seconds, then repeat the lighting
instructions.

BOILER
TEMPERATURE
CONTROL

9857

To Turn the Appliance Off

For short periods, turn the boiler temperature control fully anti­clockwise to “0” (off), the reset/standby indicator will be on.

To relight, turn the boiler temperature control to any position
between “0” and “Max”.

For longer periods, turn the boiler temperature control fully anti­clockwise to “0” (off) and switch off the electrical supply to the
boiler.

To relight follow the lighting sequence given above.

"OFF"
POSITION

"BURNER ON"
INDICATOR

RESET/STANDBY

INDICATOR

Diagram 1

7

2000225144B

1 General Data

GAS CONNECTION

1

Rc

1

/

(

/

2

in. B.S.P.T.)

2

WATER CONNECTIONS

Rc1 (1in. B.S.P.T.)

WATER CONNECTIONS Rc1 reduced
with DISTRIBUTOR TUBE to

3

Rc

3

/

(

/

in. B.S.P.T.) (pumped return)

4

4

387

194

294

700

558

GENERAL DIMENSIONS - given in millimetres

Important Notice

This boiler is for use only on G20 gas.

The boiler is delivered in one pack and the flue pack is supplied
separately.

Wherever possible, all materials, appliances and components to
be used shall comply with the requirements of applicable British
Standards.

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

Refer to Manual Handling Operations, 1992 Regulations.

Sheet Metal Parts

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

1.1 Technical Data

See diagrams 1.1 and 1.2.

All dimensions are given in millimetres (except as noted)

Approximate weight of complete boiler and packaging
:131.5kg (290lb)

Water content : 5.76 litre (1.27gallons)

Gas connection : Rc

Water connection : Rc1 (1in BSPT)

Electrical supply : 230V~50Hz, fused 3A

Burner : Aeromatic

The Seasonal Efficiency Domestic Boilers UK (SEDBUK)
is 'D' 78.4%.

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

1

/2 (1/2in BSPT)

1.2 Range Rating

See diagram 1.2.

.

NOTE: The boiler casing can be

set at two heights,
MAX. and MIN.

555

300

MAX.

32

442

3

900

MIN.

860

364

Diagram 1.1

1.3 Statutory Requirements

The appliance is suitable only for installation in GB and IE and
should be installed in accordance with the rules in force.

In GB the installation of the boiler must be carried out by a
competent person as described in the following regulations:

The manufacturer’s instructions supplied.

The Gas Safety (Installation and Use) Regulations.

The appropriate Buildings Regulations either The Building
Regulations, The Building Regulations (Scotland),The Building
Regulations (Northern Ireland).

The Water Fittings Regulations or Water byelaws in Scotland.

The Health and Safety at Work Act, Control of Substances
Hazardous to Health (COSHH).

The Current I.E.E. Wiring Regulations.

Where no specific instructions are given, reference should be
made to the relevant British Standard Code of Practice.

In IE, the installation must be carried out by a competent person
and installed in accordance with the current edition of I.S.813
"Domestic Gas Installations", the current Building Regulations
and reference should be made to the current ETCI rules for
Electrical Installation.

In GB the following Codes of Practice apply:

BS4814, BS6798, BS5440 Part 1 and 2, BS5546 Part 1,
BS5449, BS6891, BS6700, BS7074 Part 1 and 2, BS7593,
BS7671.

In IE: I.S.813, BS5546, BS 5449, BS 7074, BS 7593.

Manufacturer’s instructions must not be taken as overriding
statutory requirements.

1.4 B.S.I Certification

This boiler is certificated by B.S.I., for safety and performance.
It is, therefore, important that no alteration is made to the boiler
unless agreed, in writing, by Hepworth Heating Ltd.

Any alteration not approved by Hepworth Heating Ltd., could
invalidate the B.S.I. certification, boiler warranty and could
infringe the current issue of the Statutory Requirements.

9921

2000225144B

8

1 General Data

1.5 Gas Supply

The gas installation shall be in accordance with the relevant
standards.

In GB this is BS6891.

In IE this is the current edition of I.S.813 "Domestic Gas
Installations".

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

On completion test the gas installation using the pressure drop
method and suitable leak detection fluid, purge in accordance
with the current issue of BS6891.

1.6 Electrical

WARNING. This boiler must be earthed.

The electrical installation must be carried out by a competent
person. All external components shall be of the approved type
and shall be connected in accordance with the current issue of
BS7671 and any local regulations which apply.

External wiring must be correctly earthed, polarised and in
accordance with the relevant standards.

In GB this is BS 6891.

In IE this is the current edition of I.S.813 "Domestic Gas
Installations".

Connection of the boiler and any system controls to the mains
supply through an unswitched shuttered socket outlet and 3A
fused 3 pin plug, both to the current issue of BS1363.
Alternatively, a 3A fused double pole isolating switch may be
used, having a minimum double pole contact separation of
3mm, serving only the boiler and system controls.

Heat resistant cable of at least 0.75mm
current issue of BS6500 Table 16, must be used for all
connections within the boiler casing, to the control box, pump
etc.

2

(24/0.20mm), to the

To floor
level

MAX.900
MIN. 860

BOILER CASING
ALTERNATIVE
HEIGHT
POSITIONS

MAX.

MIN.

FLOOR LEVEL

BOILER CASING HEIGHT(S)

WORKTOP

10

407 MIN.

BOILER

CUPBOARDS

MINIMUM CLEARANCES
LEVEL WITH WORKTOP

10

9922

Diagram 1.3

407 MIN.

9923

5

BOILER

Diagram 1.4

Diagram 1.2

WORKTOP OR FIXTURE

10121

10

10 10

CUPBOARD

CUPBOARD

MINIMUM CLEARANCES
UNDER WORKTOP, FIXTURES

9

10124

Diagram 1.5

2000225144B

1 General Data

1.7 Boiler Location

This boiler is not suitable for outside installation.

The boiler casing can be fitted at two heights. Refer to
diagram 1.3.

The boiler is assembled at the factory with the control box and
heat shield fitted in the lower position.

The boiler must stand on a level floor, conforming with local
authority requirements and building regulations.
The base temperature is within the requirements of the current
issue of BS5258. The boiler may stand on a wooden floor but
a metal base plate is required to protect plastic tiles and similar
floor coverings.

Suitable installation clearance needs to be available at the
sides of the boiler to facilitate direct connection of pipework and
making good around the flue assembly. The actual clearance
required will vary with site conditions.

When the boiler is to be installed level with work surfaces and
the like, minimum clearances should be provided as shown in
diagram 1.4. Work tops which overhang the cupboard sides,
almost in contact with the casing top, require a larger minimum
air gap. Flush sided fixtures require the same overall minimum
space but can have a reduced air gap on one side.

Boilers to be installed under work tops or fixtures, should be
positioned to provide minimum clearances as shown in diagram

1.5. To facilitate minimum clearances it may be necessary to
modify kitchen units and fixtures.

A front access clearance for servicing of 700mm, should be
provided.

The boiler can be installed within a cupboard, refer to minimum
ventilation and clearances as shown in diagram 1.6.

If the boiler is to be installed in a cupboard or compartment,
make sure that nothing will obstruct the openings/vents in the
compartment.

A compartment used to enclose the boiler must be designed
and constructed specifically for this purpose. An existing
cupboard or compartment modified for the purpose may be
used. Details of essential features of cupboard or compartment
design are given in the current issue of BS6798.

The boiler may be installed in any room, although particular
attention is drawn to the requirements of BS7671 with respect
to the installation of a boiler in a room containing a bath or
shower. Any electrical switch should be so positioned that it
cannot be touched by a person using the bath or shower. The
electrical provisions of the Building Standards (Scotland)
Regulations apply to such installations in Scotland.

Where the installation of the boiler will be in an unusual location,
special procedures are necessary the current issue of BS6798
gives detailed guidance on this aspect.

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, however they
must not be fitted in a room where the room thermostat is
located.

Note: For further information, see the current issue of the
Building Regulations, approved document L1, and the
references:

1) GIL 59, 2000: Central heating system specification (CheSS)
and

2) GPG 302, 2001: Controls for domestic central heating
system and hot water. BRECSU.

272cm2 FREE AREA

10mm

10mm

FOR VENTILATION

10mm

DOOR

CUPBOARD CUPBOARD

272cm2 FREE AREA
FOR VENTILATION

IMPORTANT

A CLEARANCE OF 10mm IS REQUIRED BETWEEN THE
FRONT OF THE APPLIANCE AND THE FITTED DOOR.

THE VENTILATION SLOTS ON THE FRONT
OF THE APPLIANCE MUST BE KEPT CLEAR.

THE FREE AREA FOR VENTILATION MUST
NOT BE REDUCED IF A GRILLE IS FITTED.

CUPBOARD MINIMUM
VENTILATION & CLEARANCE Diagram 1.6

2000225144B

10

2 Water Systems

The installation of the boiler must comply with the requirements
of the current issue of BS6798, in Ireland, refer also to the
current edition of I.S.813 "Domestic Gas Installations".

In GB it is necessary to comply with the Water Supply (Water
Fittings) Regulations 1999 (for Scotland, the Water Byelaws
2000, Scotland).

To comply with the Water regulations your attention is drawn to:
The Water Regulations guide published by the Water Regulations
Advisory Service (WRAS) gives full details of the requirements.

In IE the requirements given in the current edition of I.S.813
"Domestic Gas Installations" and the current Building Regulations
must be followed.

2.1 Water Pressure Head

The boiler shall only be connected to a cistern water supply with
a minimum head of 1metre (3ft3in) and a maximum head of
27metres (90ft) which has an open vent in the system.

The working pressure must be within the range 0.1bar to 2.7bar
(1.3 to 39lbftin

2

).

The boiler MUST NOT be connected to a sealed water system.

It is recommended that plastic pipes for primary pipework
should not be used for this boiler.

2.2 Inhibitor

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

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

REFER TO BS 5546

22mm VENT
15mm COLD FEED

INDIRECT
CYLINDER

(Shown with
27metres
Max.

recommended

thermostat and valve).

When using in an existing system take special care to drain the
entire system, including the radiators, then thoroughly clean out
before fitting the boiler whether or not adding an inhibitor.

2.3 Gravity Domestic and Pumped Heating

It is recommended that a cylinder thermostat is used to prevent
the stored water temperature becoming unnecessarily high
when the central heating pump is off.

The domestic primary flow and return must be 28mm o.d. The
installation must comply with the current issue of BS5546 and
BS6700, see diagram 2.1.

If the above conditions cannot be met, it is suggested that a fully
pumped system be used.

2.4 Pumped Heating and Hot Water

Where a single flow and return is taken from the boiler, a
minimum static head of 1metre (3ft3in) must be provided between
the water line of the feed tank and the centre of the waterway,
see diagram 2.2.

2.5 Circulation Pump

Normally the pump should be set to give a temperature difference
of 11oC (20oF) across the boiler. At the appropriate pumped flow
rate the pressure loss through the boiler can be found from the
graph, diagram 2.3.

Use a pump with integral valves or fit isolating valves as close
to the pump as possible.

2.6. Cylinder

For all systems supplying domestic hot water the cylinder must
be indirect.

2.7 Safety Valve

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

0869

2.8 Draining Tap

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

Draining taps should be to the current issue of BS2879.

BOILER
C

L

1 metre
MIN.
27metres
MAX.

BOILER
C

L

DRAIN OFF
COCK

15mm
COLD FEED

DRAIN OFF
COCK

28mm

PUMP

Distributor tube in
pumped return
connection

22mm VENT

PUMP

Distributor tube in
pumped return
connection

Heating
Circuit

TO INDIRECT
CYLINDER

Heating
Circuit

Diagram 2.1

Diagram 2.2

2.9 Thermostatic Radiator Valves

If thermostatic radiator valves are fitted care must be taken to
ensure that there is an adequate flow rate through the boiler
when they close, refer to the current issue of BS7478 for
guidance. If fitted to all radiators ensure a bypass is fitted and
adjust to achieve a temperature difference no greater than 20°C
between flow and return with the thermostatic valves closed.

FLOW RATE (GALLON/MINUTE)
0123456789

2.00

0870

1.75

1.50

1.25

1.00

0.75

0.50

WATER PRESSURE LOSS

(metre HEAD OF WATER)

0.25

0

6

0

12 18

FLOW RATE (LITRES/MINUTE)

24 30 36 42

1074

70

60

50

40

30

20

WATER PRESSURE LOSS

(INCHES HEAD OF WATER)

10

0

Diagram 2.3

11

2000225144B

3 Flue and Ventilation

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

3.1 Terminal Position

The minimum acceptable siting dimensions for the terminal
from obstruction, other terminals and ventilation openings are
shown in diagram 3.1. For Ireland the minimum distances for
flue terminal positioning must be those detailed in I.S.813
"Domestic Gas Installations".

A

E

L

F

UNDER CAR PORT etc.

B,C

G

A

H,I

B,C

K

F

G

J

C

D

F

K

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

Car ports or similar extensions of a roof only, or a 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 it is made of plastic sheeting. If the car port
consists of a roof and two or more walls, seek advice from the
local gas company before installing the boiler.

If the terminal is fitted within 600mm below plastic guttering or
painted soffit 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.

3.2 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 Terminal Guard

A terminal guard is required if persons 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

11508

be central over the terminal.

A suitable guard, reference Type “K3”, can be obtained from:

Tower Flue Components Ltd.,

Morley Road, Tonbridge,

Kent. TN9 1RA

MINIMUM SITING DIMENSIONS FOR
FANNED FLUE TERMINALS POSITION MM

HORIZONTAL FLUES

A DIRECTLY BELOW, ABOVE OR

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

OTHER VENTILATION OPENING 300
B BELOW GUTTER, DRAIN/SOIL PIPE 25
C BELOW EAVES 25
D BELOW A BALCONY OR CAR PORT 25
E FROM VERTICAL DRAIN PIPES AND

SOIL PIPES 25
F FROM INTERNAL/EXTERNAL CORNERS

OR TO A BOUNDARY ALONGSIDE THE

TERMINAL 25
G ABOVE ADJACENT GROUND OR

BALCONY LEVEL 300
H FROM SURFACE OR A BOUNDARY

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

Diagram 3.1

3.4 Room Ventilation

The boiler is room sealed and does not require the room or
space containing it to have permanent air vents.

3.5 Ventilation for Boilers installed in a
Cupboard

For minimum ventilation and clearances for cupboard installation
refer to section 1.7 and diagram 1.6.

3.6 Compartment Ventilation

Where the boiler is fitted in a compartment, the high and low
level permanent air vents must have effective areas, see
“Compartment Air Vent Table”.

Both the high and level air vents must communicate with the
same room or must both be on the same wall to outside air.

COMPARTMENT AIR VENT TABLE

COMPARTMENT
VENTILATION
REQUIREMENTS

VENTILATION
FROM ROOM
OR SPACE

FROM
OUTSIDE

HIGH LEVEL LOW LEVEL

VENT AREA VENT AREA

272cm2 42in2 272cm2 42in

136cm2 21in2 272cm2 42in

2

2

2000225144B

12

9867

4 Installation

* INCREASE TO 30mm IF A FLUE COLLAR IS ADDED

*

FLUE & AIR DUCT LENGTH = A + 15 + 3

General Installation Notes

The appliance pack contains :-

Boiler

Fan connector

Casing panels, packed seperately.

Loose items fittings pack, see list in pack.

The flue is supplied seperately.

NOTE: The rear flue option kit Part No. 425861 is available,
which consists of wall cover plates, for replacement Hideaway
balanced flue appliances.

Before installation of the boiler make sure that the location
selected is in accordance with the requirements of Section 1.7.

FLUE

PACKS

REAR STD.

REAR 75 95 510

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

MINIMUM

WALL

THICKNESS

MINIMUM

FLUE

LENGTH

MAXIMUM

FLUE

LENGTH

Diagram 4.1

4.2 Flue Position and Length

Select the boiler location, with due regard to the flue length and
terminal position, see diagrams 3.1 and 4.1.

For a wall thickness up to 300mm, provided that the optional
wall liner kit is used, the flue can be fully 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.

387

9868

10051

4.1 Unpacking

The boiler casing panels are packed separately within the main
carton and are designed to enable gas and water connections
to be made before fitting the casing panels.

The casing brackets, flue restrictor, distributor tube and other
loose items, are in the fittings pack.

NOTE:

To make a neat finish to the flue outlet a flue collar kit, part No.
900850, with instructions, is available, see diagram 4.4.

If required an optional wall liner kit, part no. 900862, is available
complete with instructions.

All flue assemblies are designed for internal installation.

Make sure that the ductings do not slope down towards the
boiler.

13

115

194

BOILER
OUTLINE

700

FRONT VIEW

Diagram 4.2

2000225144B

4 Installation

4.3 Flue Hole Cutting

Mark out the flue centre, see diagram 4.2, then cut a hole for the
flue using, preferably, a 115mm minimum core drill.

4.4 Rear Flue Option Kit - 425861

Fit the wall cover plates as described in the instructions supplied
with the kit.

(if applicable)

4.5 Flue Preparation

Note: If the flue collar kit, see diagram 4.4, is to be used

increase the 15mm projection to 30mm.

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 minimum beyond wall face, see diagram

4.1.

If it is necessary to cut the flue ensure that the overlap is as
stated in diagram 4.1.

Carefully drill though air duct pilot hole and secure with self
tapping screw provided in fittings pack, see diagram 4.3.

Seal the joint with the tape provided.

Note: Should any one of the flue sections require cutting to
obtain desired flue system length make sure that the overlaps
are as follows:-

The overlap for air duct = 25mm

The overlap for flue duct = 50mm.

Take the terminal restrictor and position the clamping bracket
making sure the clamping bracket nib protrudes in the slot of the
terminal restrictor and secure with locking screw, but do not
tighten, see diagram 4.5.

Engage the terminal restrictor on the flue terminal by hooking it
over the terminal end and engaging the clamping bracket
behind the inner ring of the terminal securing it by tightening the
locking screw, see diagram 4.5.

Fit the self adhesive foam seal provided in the flue pack around
the air duct at the position shown in diagram 4.1.

Make sure that the ductings do not slope down towards the
boiler.

Make good around the flue outside after installation of the boiler.

Important: If the wall liner kit is used, the self adhesive foam seal
included in the wall liner kit must be used in place of the one
supplied with the flue pack, see diagram 4.6 for position of self
adhesive seal.

Push the flue assembly into and through the hole such that it is
within the wall, and does not stick out into the room. Do not push
the flue assembly too far into the hole as it has to be pulled back
into the boiler and secured.

If the boiler is not to be fitted for some time cover the hole in the
wall.

7148

OPTIONAL
FLUE
COLLAR

Diagram 4.4

STANDARD 510mm REAR

FLUE
TERMINAL

CLAMPING
BRACKET

7323

FLUE
SPIGOT

2000225144B

BAYONET
CONNECTION

SCREW
AND TAPE

GASKET

SCREW (4)

FLUE

Diagram 4.3

9869

14

RESTRICTOR

7332

TERMINAL RESTRICTOR
SHOWN FITTED

LOCKING
SCREW

CLAMPING
BRACKET NIB

Diagram 4.5

4 Installation

4.6 Water Connections - Gravity Domestic and
Pumped Heating

Fit suitable fittings into the boiler tappings, see diagram 4.7.
Make sure that all pipes are taken backwards and will clear the
casings, see diagram 1.1.

NOTE: It is recommended that plastic pipes for primary
pipework should not be used for this boiler.

Heating flow: Any one of the four upper connections may be
used.

Domestic flow: Any one of the three remaining upper connections
may be used.

Heating return: The water distributor tube must be fitted into
either of the front lower connections on all installations, see
diagram 4.8. This tube is in the fittings pack.

Domestic return: Any one of the three remaining lower
connections may be used for the gravity domestic hot water
return.

Fit plugs into any unused boiler tappings.

4.7 Water Connections - Fully Pumped
Systems

Fit suitable fittings into the boiler tappings as required, see
diagram 4.9. Make sure that all pipes are taken backwards and
will clear the casings, see diagram 1.1.

NOTE: It is recommended that plastic pipes for primary
pipework should not be used for this boiler.

It is important that all connections are made as shown in
diagram 4.9.

Fit the water distributor tube into the return connection, see
diagram 4.8. This tube is in the fittings pack.

Fit plugs into any unused boiler tappings.

WITH WALL LINER KIT ONLY

WALL THICKNESS­UP TO 300mm

SELF

ADHESIVE

FOAM SEAL

7102

9859

GRAVITY
DOMESTIC
RETURN TO
ANY OF THE
3 REMAINING
LOWER CONNECTIONS

WATER CONNECTIONS - GRAVITY
DOMESTIC, PUMPED HEATING

UPPER MARKER
must lie between the
two outer NOTCHES

UPPER
MARKER

DISTRIBUTOR TUBE

ALTERNATIVE
HEATING OR
DOMESTIC
HOT WATER
FLOW

ALTERNATIVE
HEATING
RETURN
With distributor
tube (not shown)

Diagram 4.7

1076

DISTRIBUTOR
TUBE
must be in
pumped return
connection

Diagram 4.8

Q

Q-35mm

WALL THICKNESS­OVER 300mm

15mm

SELF

ADHESIVE

FOAM SEAL

Q

Diagram 4.6

WATER CONNECTIONS FULLY
PUMPED SYSTEMS

15

ALTERNATIVE
FLOW
POSITIONS

ALTERNATIVE
RETURN
POSITIONS
With distributor
tube (not shown)

Diagram 4.9

2000225144B

9859

4 Installation

4.8 Pipework

When the front tappings are used, it is essential that any
pipework or fittings do not project more than shown in diagram

4.10.

When using a rear tapping with Rc (1in BSP) fitting for 28mm od
pipework, it is recommended that a short nipple and an Rc
thread (BSP) to copper elbow is used. If the pipework is required
to run back to the wall, make sure that it will clear the boiler air
duct and, if working to minimum clearance, does not project too
far from the boiler, see diagram 4.11.

Do not route any pipework, water or gas, across the front
of the combustion chamber cover.

The gas pipework must be along the left hand side of the
boiler.

9860

4.9 Casing Brackets

Fit the two upper and two front casing brackets shown in
diagram 4.12, using the No.8 screws provided.

NOTE: The screws will already be fitted.

Push the captive nuts, supplied loose, on to the casing brackets
as shown in diagram 4.12.

PIPEWORK CASING
CLEARANCES

REAR CONNECTION
PIPEWORK (28mm)

Diagram 4.10

FOR MINIMUM
CLEARANCE

Diagram 4.11

9861

UPPER CASING
BRACKET

No.8
SCREW
(4)

CAPTIVE
NUT

No.8
SCREW
(4)

FRONT

CAPTIVE
NUT

CASING
BRACKET

CASING BRACKETS FITTING

9858

Diagram 4.12

2000225144B

16

4 Installation

4.10 Side In-fill Panel (if required)

A side in-fill panel is supplied with the boiler, which can be fitted
at the rear of the left or right hand side casing but can be
discarded if the water connections are made on both sides of
the boiler or if the boiler is screened by fixtures. The in-fill panel
will usually be fitted on the side where there no pipework
connections.

Insert the push fit plastic location peg, supplied, through the in­fill panel and side casing holes and secure with the spring clips,
see diagram 4.13.

NOTE

The boiler is assembled at the factory with the control box and
heat shield fitted in the lower casing height position.

SIDE CASING
(R.H.SHOWN)

SPRING
CLIP

IN-FILL
PANEL

12082

4.11 Side Casings

Fit the side casings by locating their lugs into the appropriate
slot in the boiler plinth, see diagram 4.13, depending on the
required height, there are two options, see section 1.7.

Secure the casing sides to the front and rear upper casing
brackets with self-tapping screws supplied, see diagrams 4.13
and 4.15.

FRONT
CASING
BRACKET

MAX.

MIN.

SIDE
CASING
(R.H.)

LOCATING
SLOTS

No. 8
SCREW
(4)

9863

UPPER VIEW

SIDE CASING
(R.H. SHOWN)

IN-FILL
PANEL

PLASTIC
PEG

SPRING
CLIP

PLASTIC
PEG

LOWER VIEW

Diagram 4.13

BOILER
PLINTH

SIDE CASINGS FITTING

SCREW

SIDE CASING
(R.H. SHOWN)

Diagram 4.14

12081

UPPER
CASING
BRACKET

Diagram 4.15

17

2000225144B

4 Installation

4.12 Flue / Boiler Connection

Remove the three self-tapping screws from the lower part of the
control box support bracket, see diagram 4.16.

Undo the wing nut that secures the top of the heat shield and
carefully hinge down control box and heat shield, see diagram

4.16.

Release the two toggle latches that secure the boiler access
door and remove, see diagram 4.17.

Remove the electrical connections from the fan by pulling the
insulation boots onlyand disconnect the two air pressure tubes
from the fan taking note of their positions, see diagram 4.18.

Remove the fan assembly from the flue hood by removing the
securing screw, pull forward and lift up to release the 3 hooked
securing lugs underneath the fan, see diagrams 4.18 and 4.19.

From the flue pack take the flue spigot,the gasket is supplied in
the fittings pack.

Connect the flue spigot and gasket to the rear flue outlet of the
boiler using the self tapping screws provided, see diagram 4.3.

IMPORTANT. With regards to the Manual Handling Operations,
1992 Regulations, the following operation, exceeds the
recommended weight for one man lift.

Place the boiler in position taking care not to damage the casing
panels.

With access to the flue system through the boiler, pull the flue
on to the spigot bayonet connection, twist anti-clockwise to lock
into position.

Take the flue duct extension from the boiler and slide on to the
fan duct until it will go no further, see diagram 4.20.

Fit fan and engage the flue duct extension into the flue duct,
secure fan, replace electrical connections and air pressure
tubes.

The polarity of the electrical connections is not important.

Make sure that the air pressure tubes are fitted as before, see
diagram 4.18 and that the fan duct engages fully into the flue
duct extension piece.

10259

FAN ELECTRICAL
CONNECTORS

AIR
PRESSURE
TUBE (RED)

TOGGLE
LATCHES

FRONT AIR PRESSURE
SWITCH TUBE (CLEAR)

12083

FAN
ACCESS
DOOR

Diagram 4.17

"LOW"
position

"HIGH"
position

"LOW"
position

"HIGH"
position

SELF
TAPPING
SCREWS
(3)

WING NUT

(3) SELF
TAPPING
SCREWS
(for height
adjustment
only)

CONTROL BOX
SUPPORT
BRACKET

Diagram 4.16

0886

FAN
SECURING
SCREW

REAR AIR PRESSURE
SWITCH TUBE (RED)

Diagram 4.18

2000225144B

18

4 Installation

4.13 Water and Gas connections

Replace fan access door, heat shield and control box.

Note: When replacing the fan access door make sure the lip at
the top of door fits into and behind the slotted bracket located at
the top of the boiler.

As there are two casing height options, the control box height
and the heat shield may have to be adjusted to suit your
requirements.

Complete the water connections to the boiler.

Fill, vent and flush the system.

Check for any water leaks and put right.

Make the gas connection to the service cock, at the lower left
hand side of the boiler, see diagram 1.1.

The whole of the gas installation, including the meter, should be
inspected, tested for soundness and purged in accordance with
the current issue of BS6891 and in IE the current edition of I.S.
813 "Domestic Gas Installations".

SECURING
LUGS (3 OFF)

12084

Diagram 4.19

4.14 Top Casing

Refer to diagram 4.21.

Fit two plastic pegs, one on each side, in the holes on the top
casing. The plastic pegs are a tight fit and are best pushed home
with a flat faced tool.

Secure front of top casing with the screws provided.

FLUE DUCT
EXTENSION PIECE

TOP CASING

10149

FAN

Diagram 4.20

9865

PLASTIC
PEG (2)

19

SCREW (2)

Diagram 4.21

2000225144B

5 Electrical Wiring

SECURING
SCREWS

TERMINAL
BLOCK

CONTROL
BOX

BOILER
TEMPERATURE
CONTROL

5.1 Control Box Access

Remove control box cover by undoing the four securing screws
(two on control box, two on the heat shield) and lift off, see
diagram 5.1.

5.2 Electrical Connections

WARNING. This boiler must be earthed.

Take care not to damage any internal wiring.

Using heat resistant (85oC) cable of at least 0.75mm2 (24/

0.2mm) and of a suitable length, route as shown in diagram 5.3.
Thread through the grommet at the bottom rear of the control
box, through the cable clamp and connect to appropriate
terminals. Tighten cable clamp screws, see diagram 5.2.

Standard colours are, brown - live (L), blue - neutral (N) and
green/yellow - earth

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

Make sure the cable is suitably secured.

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.

.

CONTROL
BOX
COVER

CABLE
CLAMP
SCREW

MAINS INLET
CONNECTOR

HEAT RESISTANT
CABLE

9905

bk

TERMINAL BLOCK
CONNECTIONS

Diagram 5.1

12086

CABLE
CLAMP

Diagram 5.2

12085

5.3 Pump Connection

The pump must be connected to the external controls.

5.4 Testing - Electrical

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

After installation of the system, preliminary electrical system
checks as below should be carried out.

1. Test insulation resistance to earth.

2. Test 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.

Replace the control box cover.

2000225144B

CABLE
CLIPS

CABLE
CLIPS

Diagram 5.3

20

6 Commissioning

IMPORTANT NOTE

The WARNING NOTICE attached to the front casing
be removed by the user

Please ensure the “Benchmark” logbook is completed and left
with the user, and the magnetic lighting instruction label is
placed on the surface of the boiler casing.

must only

6.1 All Systems

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

UNDER ALL CIRCUMTANCES the case must be correctly
fitted and sealed, unless fault finding.

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, ensuring that all the
air is properly vented from the system and pump.

6.2 Initial Lighting and Testing

CAUTION. This work must be carried out by a competent

person, in accordance with the current issue of BS6798.

Make sure that all naked lights and cigarettes are extinguished.

Refer to ‘Instructions for Use’ and identify the controls.

Check that the boiler is isolated from the electrical supply.

Turn the gas service cock “On” , see diagram 6.1.

Purge in accordance with the current issue of BS6891.

WARNING. The multifunctional control and fan operate on
mains voltage, terminals will become live.

If programmer control is fitted, make sure it is in the ON mode.

Make sure that any remote controls are calling for heat.

Turn the boiler temperature control clockwise to “Max”.

The control will conduct a purge before the ignition system will

operate to light the boiler. After a pre-set time if ignition has not
taken place the boiler will shutdown.

To re-start the lighting sequence, turn the boiler temperature
control to “O”, then fully clockwise to “Max”.

"Max" is approximately 82°C (180°F).

After the burner has lit, the “Burner on” indicator on the control
panel will come on.

Isolate the boiler from the electrical supply.

Loosen the burner pressure test point screw and connect a
suitable pressure gauge, see diagram 6.1.

Switch on the electrical supply to the boiler.

WARNING. The multifunctional control and fan operate on
mains voltage, terminals will become live.

6.3 Testing - Electrical

Turn the boiler temperature control knob fully clockwise to the
maximum setting, which is approx. 82oC (180oF).

The lighting sequence is automatic as follows:

The fan will operate for 10 seconds prior to the start of the
ignition sparks, the gas valve solenoids will open and the burner
will light. This is shown by the ‘Burner On’ indicator on the
control panel lighting up.

The burner will stay alight until switched off, either by the
temperature control or remote system control. At this point the
fan will overrun by 5 seconds.

To make sure that the flame supervision device is working
correctly the following should be done.

With the burner alight, turn the gas service cock ‘OFF’, see
diagram 6.1.

After a short period the burner will go out and fan will overrun for
5 seconds.

The correct working of the flame supervision device is shown by

12087

BOILER
COMPONENTS

12163

A

10052

B

A

F

E

G

D

A CONTROL BOX
B PHIAL POCKET
C GAS SERVICE COCK
D "BURNER ON" INDICATOR

J

E RESET/STANDBY INDICATOR

C

H

F TEMPERATURE CONTROL
G BURNER PRESSURE TEST POINT
H GAS PRESSURE ADJUSTMENT SCREW
J DATA LABEL

Diagram 6.1

21

2000225144B

6 Commissioning

the ‘Burner On’ indicator going out and the lighting sequence
starting up, as follows:

1. Fan starts.

2. Spark ignition operates for 10 seconds.

3. Fan will overrun for 5 seconds.

4. The fan will start again.

5. After 10 seconds the spark ignition operates, this continues
for a further 10 seconds.

6. Fan will overrun for 5 seconds.

This sequence is repeated TWICE more and the boiler will shut
down. The following illumination will happen with the indicators
on the front of the control panel, ‘Reset/Standby indicator’
permanently ON and ‘Burner On indicator’ flashing fast (8 Hz).

If the above lighting sequence fails, refer to section 9 - Fault
Finding.

To continue, turn the gas service cock ‘On’, see diagram 6.1.

To restart the lighting sequence, turn the temperature control
knob to ‘O’ then fully clockwise to ‘Max’.

During Normal Operation when the boiler switches ‘Off’, the
burner will go out. The automatic lighting sequence will work
again when heat is required.

6.4 Testing - Gas

With the boiler on proceed 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 gas pressure at least 10 minutes after boiler
has lit, refer to Data Label, see diagram 1.2.

If necessary adjust the gas pressure to obtain the required
setting turning screw clockwise, to decrease pressure, see
diagram 6.1.

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

Gas rate: Hideaway 80B FF : 2.7m

is for guidance only, dependent on the heat setting.

Turn the boiler temperature control fully anti-clockwise to “0”.

Isolate from the electrical supply.

Remove the pressure gauge from the test point and refit screw,
making sure a gas tight seal is made.

When the boiler temperature control is turned to the “0” position,
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.

3

/h (94ft3/h)

6.7 Adjustment - Fully Pumped Open Vented
System

When commissioning the system the boiler should first be fired
on full service, that is, central heating and domestic hot water.
Adjust the pump to the system design setting, then balance the
system, making adjustments as necessary.

6.8 Completion

Adjust the boiler temperature control and any system controls
to their required settings. In addition it is necessary to complete
the "Benchmark" logbook.

For IE, it is necessary to complete a "Declaration of Conformity"
to indicate compliance to I.S.813. An example of this is given in
the current edition of I.S.813.

Fit the bottom plinth panel and secure with two dog point
screws, see diagram 6.2.

Finally fit the front panel by hooking under front of top panel
locating on the two studs and securing at the bottom on to the
bottom plinth panel with two screws, see diagram 6.3.

SECURING SCREWS

BOTTOM PLINTH PANEL

Diagram 6.2

LOCATE
UNDER LIP

LOCATING
STUDS

FRONT
PANEL

12089

12164

6.5 Testing - All Water Systems

Allow the system to reach maximum working temperature and
examine for water leaks.

There should be no undue noise in the system.

The boiler should then be turned off and the system drained off
as rapidly as possible, whilst still hot.

Refill system.

6.6 Open Vented System

Ensure there is no pumping over of water or entry of air at the
open vent above the feed and expansion cistern.

2000225144B

FRONT PANEL
SECURING SCREWS

22

Diagram 6.3

7 Instructions to the User

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

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 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 in the UK.

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

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.

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

8 Servicing

REMEMBER, When replacing a part on this appliance, use only
spare parts that you can be assured conform to the safety and
performance specification that we require. Do not use
reconditioned or copy parts that have not been clearly authorised
by Hepworth Heating Ltd.

Products of Combustion Check

Note: To obtain a products of combustion reading, remove the
front panel, see diagram 6.3 and remove the control box as
descibed in the relevant paragraphs of section 4.12. Next,
remove the cap from the sampling point, located on the top of
the left hand side of the inner casing, see diagram 8.1.

Connect the analyser tube on to the nipple.

WARNING. The multifunctional control and fan operate on
mains voltage, terminals will become live.

Switch on the electrical supply and gas supply then operate the
boiler.

On completion of the test switch off the electrical supply and gas
supply, remove analyser tube and replace sampling point cap.

Servicing

Before servicing turn off the gas and isolate the electrical supply
to the boiler.

After completing a service always test for gas soundness, make
electrical checks and carry out functional check on controls.

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

8.1 Access

Remove the boiler front casing panel, refer to paragraph 6.8.

Remove the bottom plinth panel by unscrewing the two dog
point screws securing the panel to the boiler plinth, see diagram

8.4.

Disconnect gas valve from gas service cock and unplug electrical
plug from gas valve, firstly removing electrical plug securing
screw, see diagram 8.2.

Unclip electrical wires from control box support bracket, see
diagram 8.3.

Undo the four self-tapping screws that secure the combustion
chamber front and carefully withdraw it together with the burner
and gas valve assembly, taking care not to strain the ignition
and earth wire, see diagram 8.5.

Note: When replacing burner in combustion chamber make
sure it fits correctly on the guides.

Disconnect the ignition and earth leads from the burner and
remove by drawing the leads though the grommet, see diagram

8.5.

Remove the three self-tapping screws from the lower part of the
control box support bracket, see diagram 8.6.

Undo the wing nut that secures the top of the heat shield and
carefully hinge down control box and heat shield, see diagram

8.6.

Release the two toggle latches that secure the boiler access
door and remove, see diagram 4.17.

SAMPLE POINT

Diagram 8.1

ELECTRICAL
PLUG

SECURING
SCREW

GAS
SERVICE
COCK
UNION

Diagram 8.2

12091

12088

23

2000225144B

8 Servicing

Note: When replacing the fan access door make sure the lip at
the top of door fits into and behind the slotted bracket located at
the top of the boiler.

Refer to diagram 8.7.

Remove the electrical connections from the fan by pulling the
insulation boots only.

Disconnect the two air pressure tubes from the air pressure
switch and the red air pressure tube from the fan taking note of
their positions.

Remove the flue hood and fan assembly by sliding back to
disengage the retaining lugs then lift up.

When replacing the flue hood ensure that it rests on the guides
and that the rear of flue hood is located under the pegs at the
rear and pushed down and back fully.

IMPORTANT: When re-fitting fan check that it fits fully into the
flue duct extension piece.

GROMMET

COMBUSTION
CHAMBER COVER

12029

IGNITION AND
EARTH LEADS

Diagram 8.5

CONTROL BOX
SUPPORT
BRACKET

ELECTRICAL
WIRE
RETAINING
CLIPS

SECURING SCREWS

Diagram 8.3

12159

12164

AIR PRESSURE
TUB (RED)

WING NUT

SELF
TAPPING
SCREWS
(3)

FAN
ELECTRICAL
CONNECTIONS

0886

CONTROL BOX
SUPPORT
BRACKET

Diagram 8.6

AIR
PRESSURE
SWITCH

2000225144B

BOTTOM PLINTH
PANEL

Diagram 8.4

AIR PRESSURE
TUB (RED)

24

AIR PRESSURE
TUB (CLEAR)

10259

FLUE HOOD

Diagram 8.7

8 Servicing

8.2 Boiler Flueways

Remove flueway baffles noting that there are 2 centre and 2
side flueway baffles, see diagram 8.8.

Place a sheet of paper in the combustion chamber to catch any
flue debris.

Thoroughly clean boiler flueways and fins with a suitable stiff
brush.

Replace in reverse order, after completing the relevant
instructions in sections 8.3 and 8.4.

8.3 Burner and Injector

Remove the two screws and nuts securing the burner support
bracket to the combustion chamber cover, see diagram 8.9.

Remove the graphite coated nuts on the supply feed pipe at the
rear of the burner to release the burner, see diagram 8.10.

Clean the burner. Use a vacuum cleaner or suitable stiff brush
(not wire) to clean the burner thoroughly, making sure that all
the burner ports are clear and unobstructed.

Check the burner injector for blockage or damage and replace
if necessary, see diagram 8.11.

With the burner removed the injector can be inspected and
cleaned as necessary.

For cleaning do not use a wire or sharp instrument on the hole.

If removed, use a little suitable sealant on the external thread
when refitting to make sure a gas tight seal is made.

8.4 Service Checks

Inspect the spark electrode and clean and replace as necessary,
see diagram 8.12.

Check the condition of the side and rear insulation panels in the
combustion chamber.

Check the condition of the seals on the boiler access door and
the combustion chamber cover.

Examine the flue hood and terminal to make sure they are clean
and clear of obstructions.

Refit all parts.

Light the boiler and carry out functional tests as described in
section 6.

BURNER
SUPPORT
BRACKET

SCREWS &
NUTS (2)

12158

SIDE
FLUEWAY
BAFFLE

HEAT
EXCHANGER

HEAT
EXCHANGER

FLUEWAY
BAFFLE

12157

12027

Diagram 8.9

12028

GRAPHITE
COATED
NUT(2)

MAIN
BURNER

Diagram 8.8

25

SUPPLY
FEED
PIPE

Diagram 8.10

2000225144B

8 Servicing

ELECTRODE

SECURING
SCREW

Diagram 8.12

GRAPHITE
COATED
NUT(2)

BURNER
INJECTOR

Diagram 8.11

0939

SPARK GAP

+

= 3.6 1.1

-

9 Fault Finding

IMPORTANT. On completion of the Fault Finding task which has required the breaking and remaking of the electrical connections,

the continuity, polarity, short circuit and resistance to earth checks must be repeated using a suitable multimeter.

WARNING. The multifunctional control and fan operate on mains voltage, the terminal will be live.

Before carrying out fault finding, ensure that gas, electricity and water are available to the boiler.
Ensure that any external controls are calling for heat and circuit water is cold.
If Reset/Standby indicator is lit - check water system for overheating, reset by turning temperature
control knob off and on. If the indicator coding is showing an ignition failure, reset the boiler by
turning the control knob off and on. Do not operate the boiler without combustion chamber front fitted.

12062

12026

Control Knob at '0'

Ye s

Power ON at isolation switch

Ye s

Does the fan run for 10 seconds with RESET/STANDBY INDICATOR lit

Ye s

Apply heating demand
(turn potentiometer clockwise)

Ye s

Does the fan start

Ye s

Does the unit begin to spark

Ye s

Does the burner light

Ye s

Correct Operation

No

Is there an INDICATOR sequence

Ye s

Refer to table

No

Are the HT & Earth
connections made

Ye s

Refer to table

No

Ye s

Is there an INDICATOR sequence

Ye s

Refer to table

No

No

No

No

No

No

Replace fuse

Replace PCB

Switch OFF
Remake connections
Restart diagnosis

Replace PCB

Turn Gas ONIs the Gas turned ON

Replace PCB

ELECTRICAL FAULT FINDING

2000225144B

Diagram 9.1

26

9 Fault Finding

BOILER TEMPERATURE
CONTROL

0900

Diagram 9.2

9.1 Electrical

Gain access to the control box, refer to the relevant paragraph
in section 8.1, then remove the control box cover, refer to
section 5.1.

Refer to: Boiler Fault Finding, see diagram 9.1, Fault Finding
Wiring Diagram, see diagram 9.3, Pictorial Wiring Diagram, see
diagram 9.4.

9.2 Electrical Supply Failure

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

If the burner does not relight after an electrical supply failure and
the reset/standby indicator on the control panel is lit, turn the
burner temperature control to “0”, wait 30 seconds, then fully
clockwise to “Max.” see diagram 9.2.

SL

bk

FUSE

TYPE 3.15A

MAINS SUPPLY
230v ~ 50Hz

bk BLACK
br BROWN
b BLUE
p PURLPLE

br

br

p

r

g

AIR
PRESSURE
SWITCH

br

bk

EV2

KEY

FAN

(N/O)

(N/C)

r RED
y YELLOW
g GREY

b

b

(C)

b

b

EV1

12001

N

9.3 INDICATOR Fault Coding

Refer to fault coding table below.

INDICATOR 1 INDICATOR 2 INDICATOR CONDITION REMARK
(RESET) (BURNER LIT) STATUS

Reset O/H or in
'standby' mode

Correct operation

Transpose Live & Neutral

Check Earth

Check connection

& value

Check connection

& operation

Simultaneous

Simultaneous

Simultaneous

Alternating

Non - Volatile Lockout

Burner Lit

PCB Failure

Other Errors

Reversed Polarity

Lighting Sequence-Thermistor

Lighting Sequence-Fan/APS

Software Sequence Error

Software Error

Ignition Lockout

SPARK
ELECTRODE

AIR PRESSURE SWITCH CONNECTIONS

MAIN TERMINAL STRIP CONNECTIONS

PRINTED CIRCUIT BOARD CONNECTIONS

Diagram 9.3

N

Slow Flashing (2Hz)

Fast Flashing (8Hz)

27

2000225144B

9 Fault Finding

12000

BOILER PILOT FAULT FINDING

2000225144B

Diagram 9.4

28

10 Replacement of Parts

IMPORTANT NOTES

REMEMBER, When replacing a part on this appliance, use only
spare parts that you can be assured conform to the safety and
performance specification that we require. Do not use
reconditioned or copy parts that have not been clearly authorised
by Hepworth Heating Ltd.

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

Before removing or replacing any parts, turn off the gas supply
at the gas service cock, see diagram 8.2 and isolate the
electrical supply to the appliance.

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.

10.1 Electrical Thermistor

Remove front panel to gain access, see section 6.8.

Remove control box cover by undoing the four securing screws
(two on control box, two on the heat shield) and lift off, see
diagram 10.1.

Remove thermistor lead from retaining clip, located on the
control box support bracket, see diagram 8.3.

Release strain relief grommet securing thermistor lead at the
side of control box.

SECURING
SCREWS

CONTROL
BOX
COVER

Disconnect the thermistor electrical plug from the control board
(P.C.B) slightly bending back the retaining latch to allow
withdrawal, see diagram 10.2.

Withdraw the electrical thermistor from its phial, see diagram

10.3.

Draw the thermistor lead followed by the thermistor out though
the control box case.

Re-assembly note. When fitting the thermistor make sure it is
fully inserted into the phial and secured using the grommet
moulded to the cable, see diagram 10.3.

10.2 Control Board (P.C.B)

Remove front panel to gain access, see section 6.8.

Remove control box lid by undoing the four securing screws
(two on control box, two on the heat shield) and lift off, see
diagram 10.1.

Carefully pull the boiler temperature control knob away from the
P.C.B.

Disconnect the electrical plugs from the control board (PCB)
slightly bending back the retaining latches to allow withdrawal,
see diagram 10.2.

Disconnect ignition lead.

Carefully pull the board away from its supports bending back
slightly the retaining latches.

When refitting refer to wiring diagram 9.4.

Take care when replacing the burner temperature control knob
by supporting the potentiometer on the P.C.B.

NOTE: Ensure jumper is in position 'A', refer to wiring diagram

9.4.

9905

TERMINAL
BLOCK

BOILER
TEMPERATURE
CONTROL

PCB

CONTROL
BOX

Diagram 10.1

12100

ELECTRICAL
PLUG

GAS
SERVICE
COCK
UNION

SECURING
SCREW

PHIAL

12099

POCKET

THERMISTOR

Diagram 10.3

12168

SHORT
SCREWS (2)

LONG
SCREWS
(2)

EARTH LEAD

ELECTRICAL PLUGS

Diagram 10.2

29

SOLENOID
ASSEMBLY

Diagram 10.4

2000225144B

10 Replacement of Parts

10.3 Electrode

Refer to the relevant paragraphs of Section 8 servicing to
remove the burner from combustion chamber.

To remove the electrode, unscrew from the retaining bracket,
see diagram 8.12.

Take the electrode out from below and remove the ignition lead.

When removing and replacing the electrode take care not to
damage it.

When refitting, check spark gap, see diagram 8.12.

10.4 Multifunctional Control

Remove front panel to gain access, see section 6.8.

Remove the securing screw and disconnect the electrical plug,
see diagram 10.4.

Disconnect the gas cock, on the left hand side.

Support the multifunctional control, remove the four screws (2
long, 2 short) from the flanged connection at the right hand side.

Remove and discard the original “O” ring from the flanged
connection and fit the new “O” ring supplied, into recess, before
fitting the replacement multifunctional control.

After assembly test for gas soundness and purge in accordance
with the current issue of BS6891 or IE, the current edition of
I.S.813 "Domestic Gas Installations".

10.5 Solenoid

Remove the electrical plug from the multifunctional control and
remove the securing screw and then the solenoid assembly,
see diagram 10.4.

10.6 Burner

Refer to the relevant paragraphs of Section 8 servicing to
remove the burner from combustion chamber.

10.7 Injector

Refer to the relevant paragraphs of Section 8 servicing to
remove the burner from combustion chamber.

The injector can then be unscrewed from the manifold.

When replacing use a little jointing compound on the external
thread only, to ensure a gas tight seal.

FRONT AIR PRESSURE
SWITCH TUBE (CLEAR)

AIR
PRESSURE
SWITCH

10.8 Air Pressure Switch

Remove front panel to gain access, see section 6.8.

Refer to the relevant paragraphs of Section 8 servicing to
remove the burner from combustion chamber.

Remove the air pressure tubes and electrical connections from
the switch, release the securing screws and remove the switch,
see diagram 10.5.

When fitting the replacement make sure that the air pressure
tubes are fitted with the clear tube from the air pressure switch
to the front fan connection, as shown in diagram 10.5 and the
electrical connections are made as shown in wiring diagram

9.4.

10.9 Fan

Remove front panel to gain access, see section 6.8.

Refer to the relevant paragraphs of Section 8 servicing to
remove the burner from combustion chamber.

Remove the electrical connections and air pressure tubes from
the fan.

Note: Remove the electrical connections by pulling insulation
boots only.

Undo the screw securing the fan to the flue hood and disengage
fan from flue hood.

When re-assembling, make sure that the air pressure tubes are
fitted as before and that the fan duct engages fully into the flue
duct extension piece.

The polarity of the electrical connections is not important.

10.10 Insulation

Refer to the relevant paragraphs of Section 8 servicing to
remove the burner from combustion chamber.

Sides

Undo the burner support bracket nuts and remove support
bracket and insulation, see diagram 10.6.

Refit support bracket with new side insulation.

Rear

Bend forward rear insulation securing nibs, one on each side,
to release insulation.

Fit new insulation and bend back securing nibs.

10259

BURNER SUPPORT
BRACKET

NUTS

REAR
INSULATION
PANEL

12108

2000225144B

REAR AIR PRESSURE
SWITCH TUBES (RED)

ELECTRICAL
CONNECTORS

Diagram 10.5

SIDE INSULATION

30

Diagram 10.6

11 Spare Parts

11.1 Part Identification

The key number in diagram 11.1 and the first column of the list
will help identify the spare part.

1

2

8

5

4

10

11.2 Ordering

When ordering any spare part please quote the part number
and the description from the list together with the model name
and serial number information from the data label.

The data label is positioned on the heat shield, see diagram 6.1.

12008

3

6

7

9

Diagram 11.1

Key No. Part No. Description GC Part No.

1 2000461752 Multifunctional control ******

2 227132 Fan ******

3 2000463496 Air pressure switch ******

4 2000461793 Electrical thermistor ******

5 202635 Spark electrode ******

6 2000461714 Boiler temperature control knob ******

7 2000461924 Injector ******

8 202240 Fuse ******

9 2000227134 Control board ******

10 205656 Burner ******

31

2000225144B

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

2000225144B

32