Download
Share
Print this page
Glow-worm Energysaver 60 Instructions For Use Installation And Servicing
  1. Manuals
  2. Brands
  3. Glow-worm Manuals
  4. Boiler
  5. Energysaver 60
  6. Instructions for use installation and servicing

Glow-worm Energysaver 60 Instructions For Use Installation And Servicing

High efficiency boiler
Hide thumbs

Advertisement

Quick Links

Download this manual
Installation and Servicing
Energysaver
60
G.C. No. 41 319 71
High Efficiency Boiler
This is a Cat II
Reference in these instructions to British Standards and Statutory
Regulations/Requirements apply only to the United Kingdom.
For Ireland the rules in force must be used.
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.
Thank you for installing a new Glow-worm appliance in your home.
Glow-worm appliances' are manufactured to the very highest standard so we are pleased
to offer our customers' a Comprehensive First Year Guarantee.
In the 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
Supplied By www.heating spares.co Tel. 0161 620 6677
Instructions for Use
To b e l e f t w i t h t h e u s e r
PAS010
Appliance
2H3P
Guarantee Registration
return as soon as possible.
Service number 01773 828100.
REGISTER YOUR GLOW-WORM APPLIANCE
FOR 1ST YEAR GUARANTEE PROTECTION
CALL 0208 247 9857
Customer Services:
Tel: (01773) 828100
Fax: (01773) 828070
Hepworth Heating Ltd.,
Nottingham Road, Belper, Derbyshire. DE56 1JT
General/Sales enquiries:
Tel: (01773) 824141 Fax: (01773) 820569
221836B.11.00

Advertisement

loading
Need help?

Need help?

Do you have a question about the Energysaver 60 and is the answer not in the manual?

Questions and answers

Related Manuals for Glow-worm Energysaver 60

Summary of Contents for Glow-worm Energysaver 60

  • Page 1 Guarantee Registration Thank you for installing a new Glow-worm appliance in your home. Glow-worm appliances' are manufactured to the very highest standard so we are pleased to offer our customers' a Comprehensive First Year Guarantee. In the center pages are to be found your Guarantee Registration Card, which we recommend you complete and return as soon as possible.
  • Page 2 Important Information TESTING AND CERTIFICATION CERAMIC FIBRE/INSULATION PADS, GLASSYARN. This boiler is tested and certificated for safety and performance. It is therefore important that no alteration is made to the boiler, These can cause irritation to skin, eyes and the respiratory tract. without permission, in writing, from Hepworth Heating Ltd.
  • Page 3 All CORGI Registered Installers carry a CORGI ID card, and have a registration number. Both should be recorded in your Energysaver 60, Kit No.444509. boiler Logbook. You can check your installer is CORGI registered If your boiler has been converted to use L.P.G. Propane the by calling CORGI direct on :- 01256 372300.
  • Page 4 Instructions for Use 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.
  • Page 5 Instructions for Use Overheat Safety Cutoff To Turn the Boiler Off If the cutoff operates on any other occasion than an electrical For short periods, turn thermostat control knob anti-clockwise failure, press the reset button as stated in “Electrical Supply until “O”...
  • Page 6 G31 gas (L.P.G.) with an available conversion kit. BS6891 and BS7074 Part 1 and 2, BS7478, BS7593, BS7671. Energysaver 60, Kit No. 444509. We also suggest that you have to hand a copy of the British Gas publication, “Guidance Notes for the Installation of Domestic The boiler is delivered in one pack.
  • Page 7 Connection of the boiler and system controls to the mains supply must be through a common isolator and must be fused TABLE 2. Energysaver 60 3A maximum. This method of connection should be, preferably, by a double pole isolating switch, provided it has a minimum RANGE RATING contact separation of 3mm on both poles.
  • Page 8 2 Water System Note. The boiler has 28mm copper connections which must be used for the Energysaver 60. 2.1 Draining Tap BOILER DRAIN 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, POINT see diagram 2.1.
  • Page 9 2 Water System 2.10 Safety Valve Open (vented) system. Recommended A safety valve must be fitted to a sealed system. relationship between It shall be preset, nonadjustable with a lift pressure of 3bar, pump, cold feed and incorporating seating of a resilient material, a test device and a 450mm vent.
  • Page 10 2 Water Sytem 2.12 Pressure Gauge 0051M METHOD 1 COMBINED A pressure gauge with a set pointer and covering at least 0 to CHECK VALVE HEATING 4bar (0 to 60lb/in ) shall be fitted permanently to the system is TEMPORARY AND VACUUM SYSTEM a position where it can be seen when filling the system.
  • Page 11 Diagram 3.1 The doorway opening should be of sufficient size to allow for easy removal of the boiler. TABLE 4 Ventilation high level level From Room Energysaver 60 29.5 29.5 Ventilation From Outside Energysaver 60 14.3 14.3 221836B Supplied By www.heating spares.co Tel. 0161 620 6677...
  • 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 ) towards the boiler, see diagram 4.1. It is of no advantage to exceed this angle (2 ) indeed sealing of the fan to flue elbow may become more difficult as the angle is increased.
  • 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.
  • Page 14 5 Preparation 5.1 Unpacking: diagram 5.1 For a side flue, extend the centre line horizontally (taking into account the required fall towards the boiler) left or right to the Open top carton, remove top fitting, wall template, loose items corner of the adjacent surface where the flue is required to exit fittings pack and boiler mounting bracket.
  • Page 15 5 Preparation 5.3 Flue Hole Cutting Having marked out the flue centre cut a hole for the flue see 115 Minimum hole diagram 5.5 for minimum core drill size for various wall thicknesses. 125 up to 300mm wall 135 up to 680mm wall This will allow for the 35mm per metre (2 ) fall towards the boiler.
  • Page 16 Refer to the British Gas publication “Guidance Notes for the Installation of Domestic Condensing Boiler” for advice on the The 28mm connections must be used for the Energysaver 60. disposal of boiler condensate. The right hand connection is the flow from the boiler.
  • Page 17 7 Flue Installation Complete assembly by fully tightening the two fan bracket 7.1 Rear Flue securing screws. Mark and cut the air duct terminal assembly, see diagram 7.1 Finally tighten the three fan securing screws. and the flue duct, diagram 7.2 to the lengths required, cutting Fit the inner case door.
  • Page 18 7 Flue Installation FLUE DUCT LONG FLUE TERMINAL STANDARD FLUE TERMINAL "Q" plus 82mm "N" minus 57mm FLUE DUCT BOILER CENTRE LINE "N" "Q" Diagram 7.2 Diagram 7.4 DRILL SIZE AIR DUCT/TERMINAL AND FLUE DUCT SEAL WITH ASSEMBLY TAPE SUPPLIED "N"...
  • Page 19 7 Flue Installation FLUE DUCT FOAM SEAL SEALANT "Q" minus 25mm "Q" AIR DUCT/ TERMINAL FLUE DUCT ASSEMBLY Diagram 7.6 Diagram 7.8 STD FLUE TERMINAL = 63 FOAM SEAL LONG FLUE TERMINAL = 61 FLUE TERMINAL 10mm FLUE DUCT Diagram 7.9 7.6 Wall Liner If a wall liner is used, fit self adhesive seal as follows : For wall thicknesses up to 300mm fit the self adhesive seal to...
  • Page 20 8 Gas Connection Make the gas connection to the gas service cock, see diagram 8.1. SOLENOID SUPPORT BRACKET MULTI-FUNCTIONAL SECURING SCREW SECURING SCREW CONTROL GAS SERVICE SECURING COCK (SHOWN SCREWS OFF) BURNER SECURING UNION PRESSURE SCREW CONNECTOR TEST POINT SECURING PLUGS SCREW Diagram 8.1...
  • Page 21 9 Electrical Connection 9.1 Pump and External Controls Connection MAINS SUPPLY The pump must be connected directly to the control box, as CABLE GROMMET shown in diagram 9.2. Any external controls must only be connected to interrupt the Red Link between terminals 1 and SL. Thread the cable(s) through the large cable clamp in the side of the control box.
  • Page 22 10 Commissioning Please ensure the “Benchmark” logbook is completed and left The centre, plastic posidrive screw controls the “Low” burner with the user. pressure. The centre, plastic posidrive screw must be held in position 10.1 Preliminaries-All Systems whilst adjusting the main (high) burner pressure, brass nut. Commissioning should be carried out by a competent person in After adjustment the low pressure must be checked, by turning accordance with current issue of BS6798.
  • Page 23 10 Commissioning 10.5 Heating System 10.7 Operational Checks Check that all remote controls are calling for heat. Adjust the control thermostat and any system controls to their required settings and set “high/low” switch to “high”. Allow the system to reach maximum temperature and examine for water leaks.
  • 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.
  • Page 25 12 Servicing Brush from back to front NOT left to right. 12.6 Operational Checks Do not use a brush with metallic bristles. After completing a service, before fitting the casing, check the inner case seal to ensure that it is in good condition, renew if Remove the paper and any debris.
  • Page 26 12 Servicing SECURING SCREW (2) INJECTOR MANIFOLD SILICONE SLEEVING SECURING SCREW (3) IGNITION SENSING LEAD SECURING SCREW (2) SPARK ELECTRODE Diagram 12.7 GASKET SECURING SCREW (3) SPARK GAP 3mm to 4mm CONDENSE DRAIN TRAP Diagram 12.9 WASTE OUTLET Diagram 12.8 13 Fault Finding 13.1 Electrical Important.
  • 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.
  • 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.
  • Page 29 13 Fault Finding Reconnect supply Is APS neon lit ? Is fan running ? Replace APS Is there 240V at the fan ? Has boiler been operating for 10 Is there 240V Replace ignition seconds yet ? at C ? Switch High/Low Switch Will flue hood to 'low'...
  • Page 30 13 Fault Finding Does the burner remain alight ? Is the low gas pressure Is condense drain setting correct (see Data blocked, repair. Tables) at the test point Does burner remain on the gas valve ? alight ? Is the low gas pressure setting correct (see data tables)? Adjust as necessary.
  • Page 31 13 Fault Finding AIR PRESSURE SWITCH HIGH FLAME PLASTIC NEON OVERHEAT DEMAND FLAME NEON NEON HIGH/LOW (FLAME) SWITCH EARTH LAMP INTER- POST CONNECTION P.C.B. LAMP LINK REMOTE PUMP SWITCH SUPPLY MAINS 240VAC 50Hz STAT EARTH POST MULTI-FUNCTIONAL CONTROL MAIN PLUG CONDENSE CUT-OFF CHASSIS...
  • Page 32 13 Fault Finding RED LINK PUMP DEMAND OVERRUN NEON Stat(2) Stat(4) Lamp(3) Lamp Stat(3) N(3) CONTROL THERMOSTAT PUMP OVERHEAT THERMOSTAT P.C.B.(2) Stat(1) FUSE P.C.B.(1) TYPE F2A PLASTIC OVERHEAT IGNITION P.C.B.(4) CM1(1) CM1(2) P.C.B. AIR PRESSURE SWITCH P.C.B.(3) GV1(1) GV1(3) GV1(2) LOW FLAME NEON Amp Con Lamp N(2)
  • Page 33 13 Fault Finding RESET BUTTON FLUE HOOD RESET BUTTON OVERHEAT THERMOSTAT INSTRUCTION LABEL Diagram 13.5 Diagram 13.4 14 Replacement of Parts Notes: CONDENSATE FLEXIBLE SECURING Replacement of parts must be carried out by a competent SCREW (2) TUBE 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.
  • Page 34 14 Replacement of Parts 14.3 Printed Circuit Boards (PCBs): diagram 14.3 Release the control box as Section 9. Control PCB: diagram 14.3 (top) Disconnect the electrical plug on the board. Release from its two support post and carefully pull the board away noting that the ignition lead is still connected.
  • Page 35 14 Replacement of Parts CONTROL THERMOSTAT SECURING SCREW (2) RETAINING OVERHEAT CUT OFF PHIAL ELECTRICAL CONNECTION (5) CONTROL OVERHEAT THERMOSTAT CUT OFF PHIAL LOCKNUT Diagram 14.4 HIGH/LOW CONTROL CONTROLS CONTROL THERMOSTAT FASCIA KNOB KNOB SECURING CONTROLS SCREW (3) FASCIA ELECTRICAL CONNECTIONS RESET FLUE HOOD...
  • Page 36 14 Replacement of Parts 14.7 Multifunctional Control: diagram 8.1. Release the flexible tube from the condense drain trap, this is a push-fit. Disconnect the screws and electrical plugs at the multifunctional Release union connections and the six securing screws, then control.
  • Page 37 14 Replacement of Parts Heat Exchanger - Primary - diagram 14.10 REAR Disconnect the three union connections. INSULATION 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.
  • Page 38 14 Replacement of Parts 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. CONDENSATE 14.13 Insulation: Combustion Chamber Front SENSOR Panel: diagram 14.11 SCREW Remove the two screws from the viewing window then slide the...
  • Page 39 15 Spare Parts 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 the British Gas also quote the GC number of the part. Description GC Part No.
  • Page 40 15 Spare Parts Diagram 15.1 Because of our constant endeavour for improvement details may vary slightly from those in the instructions. 221836B Supplied By www.heating spares.co Tel. 0161 620 6677...