Glow-worm FUELSAVER 65 Installation And Servicing Instruction

Hide thumbs

page of 40

/ 40
Bookmarks

Quick Links

Download this manual

Installation & Servicing Instructions

GC No. 41 319 21

Fanned Flue Sealed System Boiler

Reference in these instructions to British Standards and Statutory

Regulations/Requirements apply only to the United Kingdom.

One Contact Total Service

Supplied By www.heating spares.co Tel. 0161 620 6677

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

T h i s i s a C a t I

For Ireland the rules in force must be used.

Customer Services:

Tel: (01773) 828100

Fax: (01773) 828070

GC No. 41 319 18

a p p l i a n c e

2 H

Hepworth Heating Ltd.,

Nottingham Road, Belper, Derbyshire. DE56 1JT

General/Sales enquiries:

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

220678B.11.96

COSHH

BS 6332

BS 5258

Need help?

Do you have a question about the FUELSAVER 65 and is the answer not in the manual?

Questions and answers

Summary of Contents for Glow-worm FUELSAVER 65

Page 1 220678B.11.96 COSHH Installation & Servicing Instructions To b e l e f t w i t h t h e u s e r GC No. 41 319 21 GC No. 41 319 18 Fanned Flue Sealed System Boiler BS 6332 T h i s i s a C a t I a p p l i a n c e BS 5258...
Page 2 1 General All dimensions in millimetres SAFETY VALVE KEY: DISCHARGE 22mm COMPRESSION CENTRAL HEATING in. BSPT) GAS CONNECTION STD FLUE TERMINAL = 63 LONG FLUE TERMINAL = 61 Diagram 1.1 OVERALL DIMENSIONS 1.3 Statutory Requirements The instructions consist of two parts, Installation and Servicing Instructions and Instructions for Use, which The installation of the boiler MUST be carried out by a includes the Guarantee Registration Card.
Page 3 1 General CE Mark TABLE 1 The CE mark on this appliance shows compliance with: MODEL 1. Directive 90/396/EEC on the approximation of the 39.72kg 39.72kg LIFTING Laws of the Member States relating to appliances burning gaseous fuels. (87.57lb) (87.57lb) WEIGHT 2.
Page 4 2 Water System 2.1 General Notes WATER FLOW RATE AT 11 C (20 F) DIFFERENTIAL The installation of the boiler must comply with the requirements of the current issue of BS6798. UNIT litre/min. 24.9 30.6 2.2 Safety Valve gal/min. The safety valve, preset at 3bar, is an integral part of the boiler and cannot be adjusted.
Page 5 2 Water Systems 2.8 Water Make Up 2.14 Domestic Hot Water Cylinder Provision should be made for replacing water lost from SINGLE FEED INDIRECT CYLINDERS ARE NOT the system using a make up bottle mounted in a position SUITABLE AND SHOULD NOT BE USED. higher than the top point of the system, connected The domestic hot water cylinder must be of the indirect through a non-return valve to the return side of the...
Page 6 3 Boiler Location 3.1 General A compartment used to enclose the boiler must be designed and constructed specifically for this purpose. The boiler may be installed in any room although An existing cupboard or compartment modified for the particular attention is drawn to the requirements of the purpose may be used, refer to the current issue of current issue of the BS7671 with respect to the BS6798 for guidance.
Page 7 4 Flue The flue must be installed in accordance with the current STANDARD FLUE TERMINAL ILLUSTRATED issue of BS5440 Part 1. The air and flue ducting connect to the top of the boiler using an elbow which can be positioned to the left or right hand side or the rear.
Page 8 4 Flue 4.1 Terminal Position The minimum acceptable siting dimensions for the terminal from obstructions, other terminals and ventilation openings are shown in diagram 4.3. The terminal must be exposed to the external air, the position allowing free passage of air across it at all times.
Page 9 5 Preparation 5.1 Unpacking Remove the top carton from the boiler. To remove the outer case, slide the information plate up to access and remove the single securing screw, see diagram 5.1, unhook the case at the top and lift it off. Remove the cover of the inner case, secured with four screws, see diagram 5.2.
Page 10 5 Preparation Remove the two boiler securing screws, see diagram 5.4 BOILER then separate the boiler from the mounting frame, by SECURING SCREW (2) pulling the location studs/clips apart then unhook it at the top. BOILER LOCATION MOUNTING FRAME STUD(S) and CLIP(S) BOILER MOUNTING FRAME Diagram 5.4...
Page 11 6 Installing the Flue Make sure that the isolation valves are at the bottom facing forward and that the frame top is horizontal, then WALL mark the four wall fixing points through the holes in the SLEEVE two horizontal straps, do not drill the holes, see diagram 6.4.
Page 12 6 Installing the Flue 6.6 Flue Preparation STANDARD FLUE TERMINAL ILLUSTRATED Rear Flue FLUE Mark and cut the air duct terminal assembly, see diagram DUCT 6.5 and the flue duct, diagram 6.6 to the lengths required, cutting square and removing any burrs. Refer to diagram 6.9, mark through the holes in the flue 'R' + 107 elbow assembly and drill the flue duct as shown.
Page 13 6 Installing the Flue Fix the self adhesive seal to the air duct, see diagram 6.11. Place the flue assembly into the flue hole. Make sure that the flue terminal is correctly positioned and sticking out the correct distance from the outside wall face, see diagram 6.11.
Page 14 6 Installing the Flue Locate the flue duct into the air flue elbow assembly and STD FLUE TERMINAL = 63 WALL SLEEVE secure with the screw provided. LONG FLUE TERMINAL = 61 Secure the air duct terminal to the flue elbow with the two self tapping screws supplied in the loose items pack, making sure that the flue duct is correctly located into FLUE...
Page 15 7 Gas, Water and Electrical Connections 7.4 Electrical Connections WARNING. The boiler must be earthed. Take the electrical connector from the loose items pack and remove the two screws and cover, see diagram 7.3. Using PVC insulated cable at least 0.75mm (24/0.2mm) to BS6500 Table 16 of a suitable length connect the mains supply cable to the appropriate terminals of the...
Page 16 8 Boiler and Flue Fixing 8.1 Mounting the Boiler After installing the boiler mounting frame, gas and water, making the electrical connections and preparing the flue components continue as below: Lift the boiler into position, hooking it onto the boiler mounting frame at the top, see diagram 8.1 then loosely fit the two, previously removed, boiler securing screws at the top, see diagram 5.4.
Page 17 8 Boiler and Flue Fixing 8.2 Flue Assembly to Boiler - Connection NOTE. The fan could be fittedwith transit clips, see diagram 8.6, which will need removing. Slacken but do not remove the fan securing screws and flue hood nuts, see diagram 8.4. Secure the flue assembly to the spigot on top of the boiler, see diagram 8.5.
Page 18 9 Completion and Commissioning 9.1 System Commissioning IMPORTANT THE CAP ON THIS Commissioning must only be carried out by a competent AIR VENT SHOULD person in accordance with the current issue of BS6798. NOT BE REMOVED OR REPLACED Check that the boiler is isolated from the electrical supply at the external isolator.
Page 19 9 Completion and Commissioning 9.2 Initial Lighting and Testing and Adjustment The set pointer on the pressure gauge should be set to coincide with the cold fill pressure. Refit the inner case, securing it with the four screws previously removed, see diagram 9.1. Make sure that the case is correctly fitted and sealed.
Page 20 9 Commissioning and Completion 9.4 Testing - Gas 9.3 Testing - Electrical Checks to ensure electrical safety should be carried out Test for gas soundness around the boiler gas by a competent person. components, using a suitable leak detection fluid. In the event of an electrical fault after installation of the Check the main burner gas pressure at least 10 minutes after the burner has lit, refer to Data label or Appliance...
Page 21 9 Commissioning and Completion 9.5 Heating System TABLE 4 Check that all remote controls are calling for heat. APPROX.GAS RATE Allow the system to reach maximum working temperature and examine for water leaks. The boiler MODEL 65 should then be turned off and the system drained as 67.4 73.4 79.2...
Page 22 11 Servicing 11.1 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 conditions and usage, but in general once a year should be enough. 12 to 14 FLAME LENGTH It is the Law that any servicing must be carried out by a competent person.
Page 23 11 Servicing 11.4 Main Burner ELECTRODE SECURING Slacken the flue hood securing angle nuts, SCREW see diagram 11.2. PILOT BURNER ASSEMBLY Remove the combustion chamber front panel, secured ELECTRODE SECURING with four screws and a wing nut, see diagram 11.2. SCREW (2) Disconnect the pilot pipe union connector and ignition lead, see diagram 11.3...
Page 24 11 Servicing 11.6 Cleaning Heat Exchanger. 11.7 Pilot Injector Disconnect the two electrical connections at the fan, see If the pilot flame is not burning correctly, it may be diagram 11.2. It is not necessary to disconnect the green necessary to remove the pilot injector. and yellow earth cable.
Page 25 12 Fault Finding Neon Indicators - An Aid to Fault Finding THE NEON INDICATORS ARE AN AID TO FAULT FINDING ONLY. FAILURE OF ANY OF THE NEON INDICATORS DOES NOT WARRANT THE REPLACEMENT OF AN OTHERWISE SATISFACTORY PRINTED CIRCUIT BOARD (PCB). IF RED NEON ON FASCIA IS ILLUMINATED FILL CENTRAL HEATING SYSTEM, PRESSURE 0.7bar MIN.
Page 26 12 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. Isolate the elctrical supply, check all cables, connections and the printed circuit board (PCB) fuse.
Page 27 12 Fault Finding MAIN TERMINAL STRIP Is there 240V ~ between Replace thermostat yellow connection on thermostat and 2 ? Check yellow cable between Is there 240V~between N/c printed circuit board and air Is neon 3 lit ? on air pressure pressure switch.
Page 28 12 Fault Finding MAIN TERMINAL STRIP Is there 240V ~ between Inspect air tubes for leaks (N/o) on air pressure kink and correct fitting. switch and 2 ? If satisfactory replace faulty air pressure switch. Isolate supply, test harness Is there 240V~between continuity.
Page 29 12 Fault Finding INFORMATION MAIN TERMINAL STRIP CONNECTIONS PLATE CONTROL THERMOSTAT CONNECTIONS CONTROL BOARD CONNECTIONS LOW WATER PRESSURE SWITCH RESET BUTTON PUMP 3 POLE CONNECTOR NEON RESET BUTTON Diagram 12.4 INDICATOR SPARK ELECTRODE WATER DIFFERENTIAL PRESSURE SWITCH FUSE TYPE OVERHEAT CUT-OFF CONTROL THERMOSTAT...
Page 30 12 Fault Finding CIRCULATION BLUE PUMP FAN ASSEMBLY L N E GREEN/ YELLOW SPARK PURPLE CHASSIS FUSE ELCTRODE EARTH TYPE F1A WATER PRINTED 1 AMP PRESSURE CIRCUIT BOARD BLUE WARNING NEON BLUE B R O W N CHASSIS BLUE EARTH BROWN AIR PRESSURE BLUE...
Page 31 13 Replacement of Parts 13 Replacement of Parts 13.9 Pilot Injector 13.1 Replacement of parts must only be carried out by a Gain access as the relevant part of Section 11.4 and competent person. proceed as Section 11.7. Before replacing any part isolate the gas and electrical When relighting check that the flame length is as shown supplies.
Page 32 13 Replacement of Parts 13.10 Control Thermostat Gain access as Section 13.2. OVERHEAT Remove the control knob and fascia by removing the CUT-OFF screw, see diagram 8.2. CAPILLARY LOCKNUT Remove the thermostat securing nut, see diagram 13.1. SECURING (VIEWED CLAMP Remove the electrical connections from the thermostat FROM REAR) SCREW...
Page 33 13 Replacement of Parts 13.15 Water Differential Pressure Switch: diagram 13.4 Release water pressure as Section 13.3. Remove the two electrical connections and release the union connections and remove the pressure switch, complete with flexible tubing. Fit the flexible tubing to the new pressure switch. Refer to diagram 12.5 when remaking the electrical connections.
Page 34 13 Replacement of Parts 13.18 Multifunctional Control and Pilot Pilot Solenoid Solenoid: diagram 13.7 Disconnect the electrical connections at the solenoid, remove the retaining clip and solenoid. Disconnect all electrical connections at the multifunctional control. When reconnecting refer to diagram 12.5. Remove the four securing screws from the left hand side of the multifunctional control and pilot pipe, take care as 13.19 Pump: diagram 13.8...
Page 35 13 Replacement of Parts 13.20 Automatic Air Vent: diagram 13.9 AUTOMATIC Release the water pressure as Section 13.3. AIR VENT Remove the automatic air vent. Discard the sealing washer and use the new one supplied. HEAT Slacken the vent cap on the air vent of the new item. EXCHANGER This cap must not be re-tightened.
Page 36 13 Replacement of Parts 13.22 Combustion Chamber Insulation: INSULATION diagram 13.10 PANEL Remove the securing clip and insulation panel. Take care when sliding the replacement insulation into position securing it with the original clip. INSULATION RETAINING The rear insulation is in two pieces, after removal of the CLIP side insulation panels, the lower and upper rear insulation can be removed.
Page 37 13 Replacement of Parts 13.26 Air Pressure Switch: diagram 13.13 When refitting make sure that the coloured connection is fitted as shown and that the electrical connections are Remove the pressure and electrical connection. made as shown in diagram 12.5. Release the air pressure switch from its bracket by The polarity of the electrical connections is important.
Page 38 14 Spare Parts 14.1 Part Identification 14.2 Ordering The key number in diagram 14.1 and the first column of When ordering any spare part, please quote the part the list will help to identify the spare part. number and the description from the list together with the model name and serial number information from the data label.
Page 39 14 Spare Parts Diagram 14.1 220678B Supplied By www.heating spares.co Tel. 0161 620 6677...
Page 40 Control of Substances Hazardous to Health Information for the Installer and Service Engineer. Under Section 6 of The Health and Safety at Work Act 1974, we are required to provide infor- mation on substances hazardous to health. The adhesives and sealants used in this appliance are cured and give no known hazard in this state.

This manual is also suitable for:

Complheat 80 41 319 21 41 319 18