Glowworm Ultimate 30FF Instructions For Use Manual
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Glowworm Ultimate 30FF Instructions For Use Manual

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Installation and Servicing
30FF
G.C. No. 41 047 07
Fanned Flue Boiler
(SIT)
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
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
Instructions for Use
To b e l e f t w i t h t h e u s e r
BS 6332
BS 5258
Appliance
2H3P
Guarantee Registration
to offer our customers' a Comprehensive First Year Guarantee.
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
221518F.04.01

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  • Page 1 221518F.04.01 Instructions for Use Installation and Servicing To b e l e f t w i t h t h e u s e r 30FF G.C. No. 41 047 07 Fanned Flue Boiler (SIT) BS 6332 BS 5258 This is a Cat II Appliance 2H3P Reference in these instructions to British Standards and Statutory...

  • Page 2: Table Of Contents

    Important Information Testing and Certification This boiler is tested and certificated for safety and performance. It is therefore important that no alteration is made to the boiler, without permission, in writing, from Hepworth Heating Ltd. Any alteration not approved by Hepworth Heating Ltd., could invalidate the certification, boiler warranty and may also infringe the current issue of the Statutory Requirements, see Section 1.4.
  • Page 3 Instructions for Use Introduction To obtain service, please call your installer or Heatcall (Glow- worm’s own Service Organisation) using the telephone number WARNING. It is important that the case (not the controls tray) given on the controls tray. is not disturbed or removed other than for servicing by a Please be advised that the ‘Benchmark’...
  • Page 4 Instructions for Use Cleaning To Light the Boiler WARNING. This appliance contains metal parts (components) WARNING. Sealed Systems and care should be taken when handling and cleaning, with A sealed water system must be filled and pressurised by a particular regard to edges. competent person.

  • Page 5: General Data

    1 General Data WATER CONNECTIONS 22mm COPPER PIPE GAS CONNECTIONS in. BSPT) All dimensions are given in millimetres (except as noted) SIDE ELEVATION FRONT ELEVATION Diagram 1.1 Detailed recommendations are contained in the current issue of Important Notice the following British Standards and Codes of Practice:- This boiler is for use only on natural gas (G20), but may be BS4814, BS6798, BS5440 Part 1 and 2, BS5546 Part 1, BS5449, converted for use on L.P.G.
  • Page 6 1 General Data 1.5 Gas Supply 1.6 Electrical Supply The gas installation shall be in accordance with the current WARNING. This boiler must be earthed. issue of BS6891. All system components shall be of an approved type and shall The supply from the governed meter must be of adequate size be connected in accordance with the current issue of BS7671 to provide a steady inlet working pressure of 20mbar (8in wg) at and any applicable local regulations.
  • Page 7 1 General Data 1.12 Boiler Clearances Refer to diagram 1.2. This boiler must be positioned so that at least the minimum operational and servicing clearances are provided. Additional clearances may be required for installation. 500mm If fixtures are positioned next to the boiler they should be made removable for access to pipework.
  • Page 8 2 Flue and Ventilation Note: Detailed recommendations for flues are given in the current issue of BS5440 Part 1. 2.1 Terminal Position The minimum acceptable siting dimensions for the terminal from obstructions, other terminals and ventilation openings are shown in diagram 2.1. The terminal must be exposed to the external air, the position allowing free passage of air across it at all times.
  • Page 9 3 Water Systems The installation of the boiler must comply with the requirements of the current issue of BS6798. 1000 3.1 Frost Protection If the position of the boiler is such that it may be vulnerable to freezing it should be protected as specified in the current issue of BS5422.
  • Page 10 3 Water Systems OPEN VENTED FULLY PUMPED WATER SYSTEM FLOW RECOMMENDED RELATIONSHIP BETWEEN PUMP COLD FEED AND VENT RETURN 22mm 22mm VENT (MIN.) PIPE 450mm MIN. HEIGHT 15mm (MINIMUM) COLD FEED FEED AND EXPANSION CISTERN 1150mm MIN. PUMP 22mm VENT & 15mm COLD FEED TO BE FITTED IN ACCORDANCE There must always WITH BS 5449...
  • Page 11 3 Water Systems 3.12 Expansion Vessel 3.13 Pressure Gauge A diaphragm type expansion vessel, conforming to the current A pressure gauge with a set pointer and covering at least the issue of BS4814 (see also BS7074 Part 1 and 2) must be range of 0 to 4bar (0 to 60lb/in ) shall be permanently fitted to connected at a point close to the inlet side of the circulating...
  • Page 12 3 Water Systems 3.16 Filling a Sealed Water System 0051M METHOD 1 COMBINED Provision for filling the system at low level must be made. Three CHECK VALVE HEATING methods are shown in diagram 3.6. There must be no permanent TEMPORARY AND VACUUM SYSTEM connection to the mains water supply, even through a non-...
  • Page 13 4 Flue and Appliance Preparation 4.1 Unpacking Open the carton, check the items supplied against the boiler pack contents list on the flap and diagram 4.1. 4.2 Flue Position and Length Determine flue application, length and terminal position before starting. Refer to diagram 4.2 or 4.3.
  • Page 14 4 Flue and Appliance Preparation 4.3 Flue Preparation All flue assemblies are designed for internal installation (optional wall liner is required), given that there is sufficient clearances opposite to the flue for the installation of the flue. 115mm If there is insufficient clearance the flue can be installed from MINIMUM outside.
  • Page 15 4 Flue and Appliance Preparation 4.6 Wall Mounting Bracket Reposition the template, making sure of dimensional alignment with the flue hole. Mark the boiler fixing points and mounting bracket position, see diagram 4.5. Drill holes and plug, to suit No.12x2in wood screws, fit the screws allowing sufficient clearance, about 5mm, to accept the swing brackets, see diagram 4.5.
  • Page 16 4 Flue and Appliance Preparation 4.9 Air Duct/Terminal and Flue Duct Assembly Locate the flue duct into the air duct/terminal, see diagram 4.10. Take the flue manifold from the loose items pack together with the sealant. Place the sealant onto the flue manifold. Fully locate the flue manifold in to the air duct/terminal and flue duct assembly as shown in diagram 4.10, make sure the correct alignment of the “Top”s.
  • Page 17 4 Flue and Appliance Preparation 4.12 Flue Assembly - Installation If the boiler is not to be fitted for some time cover the hole in the wall. On limited access installations push the flue assembly into the hole such that it is within the wall and does not stick out into the room, see diagram 4.12.
  • Page 18 5 Boiler Installation 5.1 Boiler Preparation With the boiler still in the bottom tray, slide the controls cover upward and remove it as shown in diagram 5.1. CONTROLS COVER Remove the front cover by undoing the wing nut, nut and washer, lift the front cover off, see diagram 5.1.
  • Page 19 5 Boiler Installation 5.3 Water Circulation System The mains cable outer insulation must not be cut back external to the cable clamp. Complete the water connections to the boiler. Make sure the cable is suitably secured. Fill, vent and flush the system. When making connections, make sure that the earth conductor Check for any water leaks and put right.
  • Page 20 5 Boiler Installation SCREW SIDE REAR RIGHT 2.5mm dia.drill JUBILEE CLIP DUCT EXTENSION LEFT RIGHT REAR VERTICAL SIDE LEFT DUCT EXTENSION Cutting 'MARK' lengths. Lefthand flue does not require cutting. FLUE ELBOW Diagram 5.6 GASKET BLANKING (REAR FLUE OUTLET ILLUSTRATED) PLATE NUT (3) FLUE...
  • Page 21 5 Boiler Installation 5.10 External Controls Make sure that the supply cable and all external cables are SECURING secured and away from hot surfaces. SCREWS (2) GRAVITY DOMESTIC HOT WATER AND PUMPED CENTRAL HEATING, SEE DIAGRAM 5.9. FULLY PUMPED OPEN VENTED OR SEALED WATER SYSTEMS, SEE DIAGRAM 5.10.
  • Page 22 6 Commissioning Please ensure the “Benchmark” logbook is completed and left The pilot rate is preset and must not be adjusted.The step with the user. adjustment screw must not be touched. The pilot flame length should be as shown in diagram 6.4. 6.1 All Systems Turn the control thermostat knob to “O”...
  • Page 23 6 Commissioning Stick the self adhesive arrow indicator to the data label, against the rating that the boiler is going to be set to, for future reference. The arrow is in the loose items pack. Loosen the main burner pressure test point screw and connect SECURING a suitable pressure gauge, see diagram 6.2.
  • Page 24 6 Commissioning Turn the control thermostat knob fully anticlockwise to “Off”. Remove the pressure gauge from the test point and refit screw, SEAL making sure a gas tight seal is made. SIDE When the control thermostat is turned to the “Off” position, by SEAL hand, wait at least 30 seconds before turning “On”...
  • Page 25 7 Instructions to the User It is the Law that servicing is carried out by a competent person. Instruct and demonstrate the safe and efficient operation of the boiler, heating system and domestic hot water system. Advise the user of the precautions necessary to prevent damage to the system and building in the event of the heating system Advise the user, that to ensure the continued efficient and safe being out of use during frost and freezing conditions.
  • Page 26 8 Servicing Remove the main burner from the main injector at the rear. Raise the burner up and forward, easing the pilot pipe down, to clear, take care not to damage the combustion chamber insulation or the pilot burner assembly. Use a vacuum cleaner or suitable stiff brush to clean the burner thoroughly, making sure that all the burner ports are clear and unobstructed.
  • Page 27 9 Fault Finding 9.1 Electrical 9.2 Electrical Supply Failure Important. On completion of the Service/Fault Finding task Failure of the electrical supply will cause the burner to go out. which has required the breaking and remaking of the electrical Operation will normally resume on the restoration of the electrical connections the earth continuity, polarity, short circuit and supply.
  • Page 28 9 Fault Finding Before detailed checking of electrical components ensure that remote controls are calling for heat. Check the gas supply is free of obstructions and purged of air. Check the overheat cutoff has not operated, for fully pumped systems only. Isolate the electrical supply and physically check ALL cables, connections and the printed circuit board fuse.
  • Page 29 9 Fault Finding Pump Overrun Operation For Fully Pumped System Only The PCB has a timed pump overrun facility. The pump should run for several minutes after remote controls have stopped calling for heat. Before using the fault finding chart ensure all wiring is correct and in good condition, the pump is not faulty and check the PCB fuse F2 Does the pump run when SL is applied ? Faulty PCB.
  • Page 30 9 Fault Finding bk BLACK or ORANGE bk BLACK or ORANGE br BROWN w WHITE br BROWN w WHITE BLUE BLUE PURPLE y YELLOW PURLPLE YELLOW Red Link must be fitted between SL and 9. RED LINK LINK SPARK ELECTRODE PUMP SPARK ELECTRODE...
  • Page 31 9 Fault Finding KEY: GRAVITY DOMESTIC - BLUE HOT WATER AND bk - BLACK PUMPED CENTRAL - BROWN HEATING g/y - GREEN/YELLOW - ORANGE - PURPLE - RED MULTI-FUNCTIONAL - YELLOW CONTROL - WHITE ELECTRODE PRESSURE SWITCH CHASSIS CHASSIS EARTH EARTH SEQUENCE Yellow link fitted to bridge out the...
  • Page 32 9 Fault Finding KEY: FULLY PUMPED - BLUE OPEN VENTED bk - BLACK OR SEALED - BROWN WATER SYSTEM g/y - GREEN/YELLOW - ORANGE - PURPLE - RED MULTI-FUNCTIONAL - YELLOW CONTROL - WHITE ELECTRODE PRESSURE Remove red link between SWITCH 9 and SL when fitting a time control etc (If no switch is fitted,...
  • Page 33 10 Replacement of Parts Note. Replacement of parts must only be carried out by a CONTROL competent person. THERMOSTAT SHAKEPROOF Before replacing any parts isolate the boiler from the electrical WASHERS AND supply and turn the gas supply off at the gas service cock, SCREWS indicator slot to be vertical.
  • Page 34 10 Replacement of Parts ELECTRICAL PLUGS PHIAL RETAINING BOILER BRACKET THERMOSTAT SECURING ELECTRICAL SCREW CONNECTION NO.3 "YELLOW" OVERHEAT CABLE CUTOFF DEVICE PHIAL CHASSIS CONTROL EARTH THERMOSTAT CONNECTION PHIAL SUPPORT SECURING EARTH POST (4) SCREW (2) CONNECTION IGNITION SPLIT MAIN LEAD TERMINAL STRIP PLASTIC...
  • Page 35 10 Replacement of Parts 10.8 Solenoid - diagram 10.3 Remove the electrical plug from the multifunctional control. Remove the securing screw and then the solenoid Assembly. 10.9 Main Burner Remove the main burner as Section 8.3. RESTRICTOR 10.10 Main Injector EXTENDED Remove the main burner as Section 8.3.
  • Page 36 10 Replacement of Parts 10.11 Insulation - diagram 10.5 FRONT INSULATION Combustion Chamber Front Remove the retaining screw then the insulation. Sides Slide the insulation out. RETAINING SCREW Rear With the side insulation removed the rear insulation can be removed and replaced. 10.12 Viewing Window - diagram 10.6 Remove the old self adhesive aluminium foil gasket and the old mica window.
  • Page 37 10 Replacement of Parts 10.13 Air Pressure Switch - diagram 10.7 MICA WINDOW Release the control box as Section 5.6. Remove the air pressure tubes and electrical connections from the PCB, release the screws and remove the switch. When fitting the replacement make sure that the plastic tubes are fitted as shown in diagram 10.7 and that electrical connections are made as shown in diagrams 9.6 or 9.7.
  • Page 38 11 Spare Parts 11.1 Part Identification 11.2 Ordering The key number on the diagram and the list will help to identify When ordering any spare parts please quote the number and the part. description from the list together with the model name and serial number.
  • Page 39 11 Spare Parts Diagram 11.1 221518F...
  • Page 40 Because of our constant endeavour for improvement, details may vary slightly from those shown in these instructions. 221518F...
  • Page 41 221962A.11.01 Instructions for Use Installation and Servicing To b e l e f t w i t h t h e u s e r 40FF G.C. No. 41 047 54 Fanned Flue Boiler (SIT) BS 6332 BS 5258 This is a Cat I Appliance Reference in these instructions to British Standards and Statutory Regulations/Requirements apply only to the United Kingdom.

  • Page 42: Flue & Ventilation

    Important Information Testing and Certification This boiler is tested and certificated for safety and performance. It is therefore important that no alteration is made to the boiler, without permission, in writing, from Hepworth Heating Ltd. Any alteration not approved by Hepworth Heating Ltd., could invalidate the certification, boiler warranty and may also infringe the current issue of the Statutory Requirements, see Section 1.4.
  • Page 43 Instructions for Use Introduction Boiler Clearances WARNING. It is important that the case (not the controls tray) If fixtures are positioned close to the boiler space must be left as is not disturbed or removed other than for servicing by a shown in diagram 2.
  • Page 44 Instructions for Use Boiler Electrical Supply The pressure gauge should show at least 0.7bar, anything less than this figure could indicate a leak and you MUST contact your WARNING. This boiler must be earthed. installation/servicing company. The boiler must only be connected to a 230V~50Hz supply If there is any doubt about the boiler being full of water consult protected by a 3A fuse.

  • Page 45: General Data

    1 General Data ; ; ; ; ; ; ; ; WATER CONNECTIONS 22mm COPPER PIPE GAS CONNECTIONS in. BSPT) All dimensions are given in millimetres (except as noted) SIDE ELEVATION FRONT ELEVATION Diagram 1.1 Important Notice Detailed recommendations are contained in the current issue of the following British Standards and Codes of Practice:- This boiler is for use only on natural gas (G20) only.
  • Page 46 1 General Data DATA TABLE 1. TOTAL DRY WEIGHT 43.4kg (96lb) (Including Terminal) LIFT WEIGHT 37.7kg (83lb) WATER CONTENT 2.35L (0.52gal) GAS CONNECTION ELECTRICITY RATING Internal fuse Type F1A 4x22mm copper pipes from WATER top of case CONNECTION ELECTRICITY 230V~50Hz, fused 3A SUPPLY Diagram 1.2 DATA LABEL...
  • Page 47 1 General Data 1.13 Room Ventilation The boiler is room sealed and does not require the room or space containing it to have permanent air vents. 1.14 Boilers in a Compartment Where the installation of the boiler will be in an unusual position, 500mm special requirements are needed, the current issue of BS6798 gives detailed guidance on these requirements.
  • Page 48 2 Flue and Ventilation Note: Detailed recommendations for flues are given in the current issue of BS5440 Part 1. 2.1 Terminal Position The minimum acceptable siting dimensions for the terminal from obstructions, other terminals and ventilation openings are shown in diagram 2.1. The terminal must be exposed to the external air, the position allowing free passage of air across it at all times.

  • Page 49: Water Systems

    3 Water Systems The installation of the boiler must comply with the requirements of the current issue of BS6798. 1000 3.1 Frost Protection If the position of the boiler is such that it may be vulnerable to freezing it should be protected as specified in the current issue of BS5422.
  • Page 50 3 Water Systems OPEN VENTED FULLY PUMPED WATER SYSTEM FLOW RECOMMENDED RELATIONSHIP BETWEEN PUMP COLD FEED AND VENT RETURN 22mm 22mm VENT (MIN.) PIPE 450mm MIN. HEIGHT 15mm (MINIMUM) COLD FEED FEED AND EXPANSION CISTERN 1150mm MIN. PUMP 22mm VENT & 15mm COLD FEED TO BE FITTED IN ACCORDANCE There must always WITH BS 5449...
  • Page 51 3 Water Systems 3.12 Expansion Vessel 3.13 Pressure Gauge A diaphragm type expansion vessel, conforming to the current A pressure gauge with a set pointer and covering at least the issue of BS4814 (see also BS7074 Part 1 and 2) must be range of 0 to 4bar (0 to 60lb/in ) shall be permanently fitted to connected at a point close to the inlet side of the circulating...
  • Page 52 3 Water Systems 3.16 Filling a Sealed Water System 0051M METHOD 1 COMBINED Provision for filling the system at low level must be made. Three CHECK VALVE HEATING methods are shown in diagram 3.6. There must be no permanent TEMPORARY AND VACUUM SYSTEM connection to the mains water supply, even through a non-...

  • Page 53: Flue And Appliance Preparation

    4 Flue and Appliance Preparation 4.1 Unpacking Open the carton, check the items supplied against the boiler pack contents list on the flap and diagram 4.1. 4.2 Flue Position and Length Determine flue application, length and terminal position before starting. Refer to diagram 4.2 or 4.3.
  • Page 54 4 Flue and Appliance Preparation 4.3 Flue Preparation All flue assemblies are designed for internal installation (optional wall liner is required), given that there is sufficient clearances opposite to the flue for the installation of the flue. 115mm If there is insufficient clearance the flue can be installed from MINIMUM outside.
  • Page 55 4 Flue and Appliance Preparation 4.6 Wall Mounting Bracket Reposition the template, making sure of dimensional alignment with the flue hole. Mark the boiler fixing points and mounting bracket position, see diagram 4.5. Drill holes and plug, to suit No.12x2in wood screws, fit the screws allowing sufficient clearance, about 5mm, to accept the swing brackets, see diagram 4.5.
  • Page 56 4 Flue and Appliance Preparation 4.9 Air Duct/Terminal and Flue Duct Assembly Locate the flue duct into the air duct/terminal, see diagram 4.10. Take the flue manifold from the loose items pack together with the sealant. Place the sealant onto the flue manifold. Fully locate the flue manifold in to the air duct/terminal and flue duct assembly as shown in diagram 4.10, make sure the correct alignment of the “Top”s.
  • Page 57 4 Flue and Appliance Preparation 4.12 Flue Assembly - Installation If the boiler is not to be fitted for some time cover the hole in the wall. On limited access installations push the flue assembly into the hole such that it is within the wall and does not stick out into the room, see diagram 4.12.

  • Page 58: Boiler Installation

    5 Boiler Installation 5.1 Boiler Preparation With the boiler still in the bottom tray, slide the controls cover CONTROLS upward and remove it as shown in diagram 5.1. COVER Remove the front cover by undoing the wing nut, nut and washer, lift the front cover off, see diagram 5.1.
  • Page 59 5 Boiler Installation 5.3 Water Circulation System The mains cable outer insulation must not be cut back external to the cable clamp. Complete the water connections to the boiler. Make sure the cable is suitably secured. Fill, vent and flush the system. When making connections, make sure that the earth conductor Check for any water leaks and put right.
  • Page 60 5 Boiler Installation SCREW SIDE REAR RIGHT 2.5mm dia.drill JUBILEE CLIP DUCT EXTENSION LEFT RIGHT REAR VERTICAL SIDE LEFT DUCT EXTENSION Cutting 'MARK' lengths. Lefthand flue does not require cutting. FLUE ELBOW Diagram 5.6 GASKET BLANKING (REAR FLUE OUTLET ILLUSTRATED) PLATE NUT (3) FLUE...
  • Page 61 5 Boiler Installation 5.10 External Controls SECURING SCREWS (2) Make sure that the supply cable and all external cables are secured and away from hot surfaces. GRAVITY DOMESTIC HOT WATER AND PUMPED CENTRAL HEATING, SEE DIAGRAM 5.9. FULLY PUMPED OPEN VENTED OR SEALED WATER SYSTEMS, SEE DIAGRAM 5.10.

  • Page 62: Commissioning

    6 Commissioning Please ensure the “Benchmark” logbook is completed and left The pilot flame length should be as shown in diagram 6.4. with the user. Turn the control thermostat knob to “O” and isolate the boiler from the electrical supply. 6.1 All Systems Fit the combustion chamber front.
  • Page 63 6 Commissioning Loosen the main burner pressure test point screw and connect When the control thermostat is turned to the “Off” position, by a suitable pressure gauge, see diagram 6.2. hand, wait at least 30 seconds before turning “On” again. Make sure that any remote controls are calling for heat.
  • Page 64 6 Commissioning 6.6 Testing - Open Vented System SEAL Allow the system to reach maximum working temperature and examine for water leaks. SIDE There should be no undue noise in the system and no pumping SEAL over of water or entry of air at the open vent above the feed and expansion cistern.

  • Page 65: Instructions To User

    7 Instructions to the User Instruct and demonstrate the safe and efficient operation of the It is the Law that servicing is carried out by a competent person. boiler, heating system and domestic hot water system. Advise the user of the precautions necessary to prevent damage Advise the user, that to ensure the continued efficient and safe to the system and building in the event of the heating system operation of the boiler it is recommended that it is checked and...
  • Page 66 8 Servicing Remove the main burner from the main injector at the rear. Raise the burner up and forward, easing the pilot pipe down, to clear, take care not to damage the combustion chamber insulation or the pilot burner assembly. Use a vacuum cleaner or suitable stiff brush to clean the burner thoroughly, making sure that all the burner ports are clear and unobstructed.

  • Page 67: Fault Finding

    9 Fault Finding 9.1 Electrical 9.2 Electrical Supply Failure Important. On completion of the Service/Fault Finding task Failure of the electrical supply will cause the burner to go out. which has required the breaking and remaking of the electrical Operation will normally resume on the restoration of the electrical connections the earth continuity, polarity, short circuit and supply.
  • Page 68 9 Fault Finding Before detailed checking of electrical components ensure that remote controls are calling for heat. Check the gas supply is free of obstructions and purged of air. Check the overheat cutoff has not operated, for fully pumped systems only. Isolate the electrical supply and physically check ALL cables, connections and the printed circuit board fuse.
  • Page 69 9 Fault Finding Pump Overrun Operation For Fully Pumped System Only The PCB has a timed pump overrun facility. The pump should run for several minutes after remote controls have stopped calling for heat. Before using the fault finding chart ensure all wiring is correct and in good condition, the pump is not faulty and check the PCB fuse F2 Does the pump run when SL is applied ? Faulty PCB.
  • Page 70 9 Fault Finding bk BLACK or ORANGE bk BLACK or ORANGE br BROWN w WHITE br BROWN w WHITE BLUE BLUE PURPLE y YELLOW PURLPLE YELLOW Red Link must be fitted between SL and 9. RED LINK LINK SPARK ELECTRODE PUMP SPARK ELECTRODE...
  • Page 71 9 Fault Finding KEY: GRAVITY DOMESTIC - BLUE HOT WATER AND bk - BLACK PUMPED CENTRAL - BROWN HEATING g/y - GREEN/YELLOW - ORANGE - PURPLE - RED MULTI-FUNCTIONAL - YELLOW CONTROL - WHITE ELECTRODE PRESSURE SWITCH CHASSIS CHASSIS EARTH EARTH SEQUENCE Yellow link fitted to bridge out the...
  • Page 72 9 Fault Finding KEY: FULLY PUMPED - BLUE OPEN VENTED bk - BLACK OR SEALED - BROWN WATER SYSTEM g/y - GREEN/YELLOW - ORANGE - PURPLE - RED MULTI-FUNCTIONAL - YELLOW CONTROL - WHITE ELECTRODE PRESSURE Remove red link between SWITCH 9 and SL when fitting a time control etc (If no switch is fitted,...

  • Page 73: Replacement Parts

    10 Replacement of Parts Note. Replacement of parts must only be carried out by a CONTROL competent person. THERMOSTAT Before replacing any parts isolate the boiler from the electrical SHAKEPROOF supply and turn the gas supply off at the gas service cock, WASHERS AND indicator slot to be vertical.
  • Page 74 10 Replacement of Parts ELECTRICAL PLUGS PHIAL RETAINING BOILER BRACKET THERMOSTAT SECURING ELECTRICAL SCREW CONNECTION NO.3 "YELLOW" OVERHEAT CABLE CUTOFF DEVICE PHIAL CHASSIS CONTROL EARTH THERMOSTAT CONNECTION PHIAL SUPPORT SECURING EARTH POST (4) SCREW (2) CONNECTION IGNITION SPLIT MAIN LEAD TERMINAL STRIP PLASTIC...
  • Page 75 10 Replacement of Parts 10.8 Solenoid - diagram 10.3 Remove the electrical plug from the multifunctional control. Remove the securing screw and then the solenoid Assembly. 10.9 Main Burner Remove the main burner as Section 8.3. RESTRICTOR 10.10 Main Injector EXTENDED Remove the main burner as Section 8.3.
  • Page 76 10 Replacement of Parts 10.11 Insulation - diagram 10.5 Combustion Chamber Front Remove the retaining screw then the insulation. Sides Slide the insulation out. Rear With the side insulation removed the rear insulation can be removed and replaced. 10.12 Viewing Window - diagram 10.6 Remove the old self adhesive aluminium foil gasket and the old mica window.
  • Page 77 10 Replacement of Parts 10.13 Air Pressure Switch - diagram 10.7 Release the control box as Section 5.6. MICA WINDOW Remove the air pressure tubes and electrical connections from the PCB, release the screws and remove the switch. When fitting the replacement make sure that the plastic tubes are fitted as shown in diagram 10.7 and that electrical connections are made as shown in diagrams 9.6 or 9.7.
  • Page 78 11 Spare Parts 11.1 Part Identification 11.2 Ordering The key number on the diagram and the list will help to identify When ordering any spare parts please quote the number and the part. description from the list together with the model name and serial number.
  • Page 79 11 Spare Parts Diagram 11.1 221962A...
  • Page 80 Because of our constant endeavour for improvement, details may vary slightly from those shown in these instructions. 221962A...
  • Page 81 221520F.04.01 Instructions for Use Installation and Servicing To b e l e f t w i t h t h e u s e r 50FF G.C. No. 41 047 14 Fanned Flue Boiler (SIT) BS 6332 BS 5258 This is a Cat II Appliance 2H3P Reference in these instructions to British Standards and Statutory...
  • Page 82 Important Information Testing and Certification This boiler is tested and certificated for safety and performance. It is therefore important that no alteration is made to the boiler, without permission, in writing, from Hepworth Heating Ltd. Any alteration not approved by Hepworth Heating Ltd., could invalidate the certification, boiler warranty and may also infringe the current issue of the Statutory Requirements, see Section 1.4.
  • Page 83 Instructions for Use Introduction To obtain service, please call your installer or Heatcall (Glow- worm’s own Service Organisation) using the telephone number WARNING. It is important that the case (not the controls tray) given on the controls tray. is not disturbed or removed other than for servicing by a Please be advised that the ‘Benchmark’...
  • Page 84 Instructions for Use Cleaning To Light the Boiler WARNING. This appliance contains metal parts (components) WARNING. Sealed Systems and care should be taken when handling and cleaning, with A sealed water system must be filled and pressurised by a particular regard to edges. competent person.

  • Page 85: General Data

    1 General Data WATER CONNECTIONS 22mm COPPER PIPE GAS CONNECTIONS in. BSPT) All dimensions are given in millimetres (except as noted) SIDE ELEVATION FRONT ELEVATION Diagram 1.1 Important Notice This boiler is for use only on natural gas (G20), but may be Detailed recommendations are contained in the current issue of converted for use on L.P.G.
  • Page 86 1 General Data 1.5 Gas Supply 1.6 Electrical Supply The gas installation shall be in accordance with the current WARNING. This boiler must be earthed. issue of BS6891. All system components shall be of an approved type and shall The supply from the governed meter must be of adequate size be connected in accordance with the current issue of BS7671 to provide a steady inlet working pressure of 20mbar (8in wg) at and any applicable local regulations.
  • Page 87 1 General Data 1.12 Boiler Clearances Refer to diagram 1.2. This boiler must be positioned so that at least the minimum operational and servicing clearances are provided. Additional clearances may be required for installation. 500mm If fixtures are positioned next to the boiler they should be made removable for access to pipework.
  • Page 88 2 Flue and Ventilation Note: Detailed recommendations for flues are given in the current issue of BS5440 Part 1. 2.1 Terminal Position The minimum acceptable siting dimensions for the terminal from obstructions, other terminals and ventilation openings are shown in diagram 2.1. The terminal must be exposed to the external air, the position allowing free passage of air across it at all times.

  • Page 89: Water Systems

    3 Water Systems The installation of the boiler must comply with the requirements of the current issue of BS6798. 1000 3.1 Frost Protection If the position of the boiler is such that it may be vulnerable to freezing it should be protected as specified in the current issue of BS5422.
  • Page 90 3 Water Systems OPEN VENTED FULLY PUMPED WATER SYSTEM FLOW RECOMMENDED RELATIONSHIP BETWEEN PUMP COLD FEED AND VENT RETURN 22mm 22mm VENT (MIN.) PIPE 450mm MIN. HEIGHT 15mm (MINIMUM) COLD FEED FEED AND EXPANSION CISTERN 1150mm MIN. PUMP 22mm VENT & 15mm COLD FEED TO BE FITTED IN ACCORDANCE There must always WITH BS 5449...
  • Page 91 3 Water Systems 3.12 Expansion Vessel 3.13 Pressure Gauge A diaphragm type expansion vessel, conforming to the current A pressure gauge with a set pointer and covering at least the issue of BS4814 (see also BS7074 Part 1 and 2) must be range of 0 to 4bar (0 to 60lb/in ) shall be permanently fitted to connected at a point close to the inlet side of the circulating...
  • Page 92 3 Water Systems 3.16 Filling a Sealed Water System 0051M METHOD 1 COMBINED Provision for filling the system at low level must be made. Three CHECK VALVE HEATING methods are shown in diagram 3.6. There must be no permanent TEMPORARY AND VACUUM SYSTEM connection to the mains water supply, even through a non-...

  • Page 93: Flue And Appliance Preparation

    4 Flue and Appliance Preparation 4.1 Unpacking Open the carton, check the items supplied against the boiler pack contents list on the flap and diagram 4.1. 4.2 Flue Position and Length Determine flue application, length and terminal position before starting. Refer to diagram 4.2 or 4.3.
  • Page 94 4 Flue and Appliance Preparation 4.3 Flue Preparation All flue assemblies are designed for internal installation (optional wall liner is required), given that there is sufficient clearances opposite to the flue for the installation of the flue. 115mm If there is insufficient clearance the flue can be installed from MINIMUM outside.
  • Page 95 4 Flue and Appliance Preparation 4.6 Wall Mounting Bracket Reposition the template, making sure of dimensional alignment with the flue hole. Mark the boiler fixing points and mounting bracket position, see diagram 4.5. Drill holes and plug, to suit No.12x2in wood screws, fit the screws allowing sufficient clearance, about 5mm, to accept the swing brackets, see diagram 4.5.
  • Page 96 4 Flue and Appliance Preparation 4.9 Air Duct/Terminal and Flue Duct Assembly Locate the flue duct into the air duct/terminal, see diagram 4.10. Take the flue manifold from the loose items pack together with the sealant. Place the sealant onto the flue manifold. Fully locate the flue manifold in to the air duct/terminal and flue duct assembly as shown in diagram 4.10, make sure the correct alignment of the “Top”s.
  • Page 97 4 Flue and Appliance Preparation 4.12 Flue Assembly - Installation If the boiler is not to be fitted for some time cover the hole in the wall. On limited access installations push the flue assembly into the hole such that it is within the wall and does not stick out into the room, see diagram 4.12.

  • Page 98: Boiler Installation

    5 Boiler Installation 5.1 Boiler Preparation With the boiler still in the bottom tray, slide the controls cover CONTROLS upward and remove it as shown in diagram 5.1. COVER Remove the front cover by undoing the wing nut, nut and washer, lift the front cover off, see diagram 5.1.
  • Page 99 5 Boiler Installation 5.3 Water Circulation System The mains cable outer insulation must not be cut back external to the cable clamp. Complete the water connections to the boiler. Make sure the cable is suitably secured. Fill, vent and flush the system. When making connections, make sure that the earth conductor Check for any water leaks and put right.
  • Page 100 5 Boiler Installation SCREW SIDE REAR RIGHT 2.5mm dia.drill JUBILEE CLIP DUCT EXTENSION LEFT RIGHT REAR VERTICAL SIDE LEFT DUCT EXTENSION Cutting 'MARK' lengths. Lefthand flue does not require cutting. FLUE ELBOW Diagram 5.6 GASKET BLANKING (REAR FLUE OUTLET ILLUSTRATED) PLATE NUT (3) FLUE...
  • Page 101 5 Boiler Installation 5.10 External Controls Make sure that the supply cable and all external cables are SECURING secured and away from hot surfaces. SCREWS (2) GRAVITY DOMESTIC HOT WATER AND PUMPED CENTRAL HEATING, SEE DIAGRAM 5.9. FULLY PUMPED OPEN VENTED OR SEALED WATER SYSTEMS, SEE DIAGRAM 5.10.

  • Page 102: Commissioning

    6 Commissioning Please ensure the “Benchmark” logbook is completed and left with the user. 6.1 All Systems Commissioning should be carried out by a competent person in accordance with the current issue of BS6798. Make sure that the system has been thoroughly flushed out with cold water without the pump in place.
  • Page 103 6 Commissioning Turn the control thermostat knob to “O” and isolate the boiler from the electrical supply. Fit the combustion chamber front. Reconnect the ignition lead to the PCB. SECURING Stick the self adhesive arrow indicator to the data label, against SCREW (4) the rating that the boiler is going to be set to, for future reference.
  • Page 104 6 Commissioning Turn the control thermostat knob fully anticlockwise to “Off”. Remove the pressure gauge from the test point and refit screw, SEAL making sure a gas tight seal is made. SIDE When the control thermostat is turned to the “Off” position, by SEAL hand, wait at least 30 seconds before turning “On”...

  • Page 105: Instructions To User

    7 Instructions to the User Instruct and demonstrate the safe and efficient operation of the Section 35, which imposes a duty of care on all persons who let boiler, heating system and domestic hot water system. out any property containing a gas appliance. Advise the user, that to ensure the continued efficient and safe It is the Law that servicing is carried out by a competent person.
  • Page 106 8 Servicing Remove the main burner from the main injector at the rear. Raise the burner up and forward, easing the pilot pipe down, to clear, take care not to damage the combustion chamber insulation or the pilot burner assembly. Use a vacuum cleaner or suitable stiff brush to clean the burner thoroughly, making sure that all the burner ports are clear and unobstructed.

  • Page 107: Fault Finding

    9 Fault Finding 9.1 Electrical 9.2 Electrical Supply Failure Important. On completion of the Service/Fault Finding task Failure of the electrical supply will cause the burner to go out. which has required the breaking and remaking of the electrical Operation will normally resume on the restoration of the electrical connections the earth continuity, polarity, short circuit and supply.
  • Page 108 9 Fault Finding Before detailed checking of electrical components ensure that remote controls are calling for heat. Check the gas supply is free of obstructions and purged of air. Check the overheat cutoff has not operated, for fully pumped systems only. Isolate the electrical supply and physically check ALL cables, connections and the printed circuit board fuse.
  • Page 109 9 Fault Finding Pump Overrun Operation For Fully Pumped System Only The PCB has a timed pump overrun facility. The pump should run for several minutes after remote controls have stopped calling for heat. Before using the fault finding chart ensure all wiring is correct and in good condition, the pump is not faulty and check the PCB fuse F2 Does the pump run when SL is applied ? Faulty PCB.
  • Page 110 9 Fault Finding bk BLACK or ORANGE bk BLACK or ORANGE br BROWN w WHITE br BROWN w WHITE BLUE BLUE PURPLE y YELLOW PURLPLE YELLOW Red Link must be fitted between SL and 9. RED LINK LINK SPARK ELECTRODE PUMP SPARK ELECTRODE...
  • Page 111 9 Fault Finding KEY: GRAVITY DOMESTIC - BLUE HOT WATER AND bk - BLACK PUMPED CENTRAL - BROWN HEATING g/y - GREEN/YELLOW - ORANGE - PURPLE - RED MULTI-FUNCTIONAL - YELLOW CONTROL - WHITE ELECTRODE PRESSURE SWITCH CHASSIS CHASSIS EARTH EARTH SEQUENCE Yellow link fitted to bridge out the...
  • Page 112 9 Fault Finding KEY: FULLY PUMPED - BLUE OPEN VENTED bk - BLACK OR SEALED - BROWN WATER SYSTEM g/y - GREEN/YELLOW - ORANGE - PURPLE - RED MULTI-FUNCTIONAL - YELLOW CONTROL - WHITE ELECTRODE PRESSURE Remove red link between SWITCH 9 and SL when fitting a time control etc (If no switch is fitted,...

  • Page 113: Replacement Parts

    10 Replacement of Parts Note. Replacement of parts must only be carried out by a CONTROL competent person. THERMOSTAT SHAKEPROOF Before replacing any parts isolate the boiler from the electrical WASHERS AND supply and turn the gas supply off at the gas service cock, SCREWS indicator slot to be vertical.
  • Page 114 10 Replacement of Parts ELECTRICAL PLUGS PHIAL RETAINING BOILER BRACKET THERMOSTAT SECURING ELECTRICAL SCREW CONNECTION NO.3 "YELLOW" OVERHEAT CABLE CUTOFF DEVICE PHIAL CHASSIS CONTROL EARTH THERMOSTAT CONNECTION PHIAL SUPPORT SECURING EARTH POST (4) SCREW (2) CONNECTION IGNITION SPLIT MAIN LEAD TERMINAL STRIP PLASTIC...
  • Page 115 10 Replacement of Parts 10.8 Solenoid - diagram 10.3 Remove the electrical plug from the multifunctional control. Remove the securing screw and then the solenoid Assembly. 10.9 Main Burner Remove the main burner as Section 8.3. RESTRICTOR 10.10 Main Injector EXTENDED Remove the main burner as Section 8.3.
  • Page 116 10 Replacement of Parts 10.11 Insulation - diagram 10.5 Combustion Chamber Front Remove the retaining screw then the insulation. Sides Slide the insulation out. Rear With the side insulation removed the rear insulation can be removed and replaced. 10.12 Viewing Window - diagram 10.6 Remove the old self adhesive aluminium foil gasket and the old mica window.
  • Page 117 10 Replacement of Parts 10.13 Air Pressure Switch - diagram 10.7 Release the control box as Section 5.6. MICA WINDOW Remove the air pressure tubes and electrical connections from the PCB, release the screws and remove the switch. When fitting the replacement make sure that the plastic tubes are fitted as shown in diagram 10.7 and that electrical connections are made as shown in diagrams 9.6 or 9.7.
  • Page 118 11 Spare Parts 11.1 Part Identification 11.2 Ordering The key number on the diagram and the list will help to identify When ordering any spare parts please quote the number and the part. description from the list together with the model name and serial number.
  • Page 119 11 Spare Parts Diagram 11.1 221520F...
  • Page 120 Because of our constant endeavour for improvement, details may vary slightly from those shown in these instructions. 221520F...
  • Page 121 221963B.04.02 Instructions for Use Installation and Servicing To b e l e f t w i t h t h e u s e r 50FF G.C. No. 41 047 55 Fanned Flue Boiler BS 6332 BS 5258 This is a Cat II Appliance 2H3P Reference in these instructions to British Standards and Statutory...
  • Page 122 Important Information TESTING AND CERTIFICATION This boiler is tested and certificated for safety and performance. It is therefore important that no alteration is made to the boiler, without permission, in writing, from Hepworth Heating Ltd. Any alteration not approved by Hepworth Heating Ltd., could invalidate the certification, boiler warranty and may also infringe the current issue of the Statutory Requirements, see Section 1.4.
  • Page 123 Instructions for Use Introduction To obtain service, please call your installer or Heatcall (Glow- worm’s own Service Organisation) using the telephone number WARNING. It is important that the case (not the controls tray) given on the controls tray. is not disturbed or removed other than for servicing by a Please be advised that the ‘Benchmark’...
  • Page 124 Instructions for Use Cleaning To Light the Boiler WARNING. This appliance contains metal parts (components) WARNING. Sealed Systems and care should be taken when handling and cleaning, with A sealed water system must be filled and pressurised by a particular regard to edges. competent person.

  • Page 125: General Data

    1 General Data ; ; ; ; ; ; ; ; WATER CONNECTIONS 22mm COPPER PIPE GAS CONNECTIONS in. BSPT) All dimensions are given in millimetres (except as noted) SIDE ELEVATION FRONT ELEVATION Diagram 1.1 Important Notice This boiler is for use only on G20 gas, but may be converted for use on G31 gas (Propane L.P.G.) with an available conversion DATA TABLE 1.
  • Page 126 1 General Data 1.8 Water System 1.2 Data This boiler may be fitted to an open vented or a sealed water See Table 1 and diagram 1.1 system. All dimensions are given in millimetres (except as noted). 1.9 Drain 1.3 Range Rating System This boiler is range rated and may be adjusted to suit individual A drain tap must be provided at the lowest points of the system...
  • Page 127 1 General Data 1.12 Boiler Clearances Refer to diagram 1.3. This boiler must be positioned so that at least the minimum operational and servicing clearances are provided. Additional clearances may be required for installation. 500mm If fixtures are positioned next to the boiler they should be made removable for access to pipework.
  • Page 128 2 Flue and Ventilation Note: Detailed recommendations for flues are given in the current issue of BS5440 Part 1. 2.1 Terminal Position The minimum acceptable siting dimensions for the terminal from obstructions, other terminals and ventilation openings are shown in diagram 2.1. The terminal must be exposed to the external air, the position allowing free passage of air across it at all times.

  • Page 129: Water Systems

    3 Water Systems The installation of the boiler must comply with the requirements of the current issue of BS6798. 1000 3.1 Frost Protection If the position of the boiler is such that it may be vulnerable to freezing it should be protected as specified in the current issue of BS5422.
  • Page 130 3 Water Systems OPEN VENTED FULLY PUMPED WATER SYSTEM FLOW RECOMMENDED RELATIONSHIP BETWEEN PUMP COLD FEED AND VENT RETURN 22mm 22mm VENT (MIN.) PIPE 450mm MIN. HEIGHT 15mm (MINIMUM) COLD FEED FEED AND EXPANSION CISTERN 1150mm MIN. PUMP 22mm VENT & 15mm COLD FEED TO BE FITTED IN ACCORDANCE There must always WITH BS 5449...
  • Page 131 3 Water Systems 3.12 Expansion Vessel 3.13 Pressure Gauge A diaphragm type expansion vessel, conforming to the current A pressure gauge with a set pointer and covering at least the issue of BS4814 (see also BS7074 Part 1 and 2) must be range of 0 to 4bar (0 to 60lb/in ) shall be permanently fitted to connected at a point close to the inlet side of the circulating...
  • Page 132 3 Water Systems 3.16 Filling a Sealed Water System 0051M METHOD 1 COMBINED Provision for filling the system at low level must be made. Three CHECK VALVE HEATING methods are shown in diagram 3.6. There must be no permanent TEMPORARY AND VACUUM SYSTEM connection to the mains water supply, even through a non-...

  • Page 133: Flue And Appliance Preparation

    4 Flue and Appliance Preparation 4.1 Unpacking Open the carton, check the items supplied against the boiler pack contents list on the flap and diagram 4.1. 4.2 Flue Position and Length Determine flue application, length and terminal position before starting. Refer to diagram 4.2 or 4.3.
  • Page 134 4 Flue and Appliance Preparation 4.3 Flue Preparation All flue assemblies are designed for internal installation (optional wall liner is required), given that there is sufficient clearances opposite to the flue for the installation of the flue. 115mm If there is insufficient clearance the flue can be installed from MINIMUM outside.
  • Page 135 4 Flue and Appliance Preparation 4.6 Wall Mounting Bracket Reposition the template, making sure of dimensional alignment with the flue hole. Mark the boiler fixing points and mounting bracket position, see diagram 4.5. Drill holes and plug, to suit No.12x2in wood screws, fit the screws allowing sufficient clearance, about 5mm, to accept the swing brackets, see diagram 4.5.
  • Page 136 4 Flue and Appliance Preparation 4.9 Air Duct/Terminal and Flue Duct Assembly Locate the flue duct into the air duct/terminal, see diagram 4.10. Take the flue manifold from the loose items pack together with the sealant. Place the sealant onto the flue manifold. Fully locate the flue manifold in to the air duct/terminal and flue duct assembly as shown in diagram 4.10, make sure the correct alignment of the “Top”s.
  • Page 137 4 Flue and Appliance Preparation 4.12 Flue Assembly - Installation If the boiler is not to be fitted for some time cover the hole in the wall. On limited access installations push the flue assembly into the hole such that it is within the wall and does not stick out into the room, see diagram 4.12.

  • Page 138: Boiler Installation

    5 Boiler Installation 5.1 Boiler Preparation With the boiler still in the bottom tray, slide the controls cover CONTROLS upward and remove it as shown in diagram 5.1. COVER Remove the front cover by undoing the wing nut, nut and washer, lift the front cover off, see diagram 5.1.
  • Page 139 5 Boiler Installation 5.3 Water Circulation System The mains cable outer insulation must not be cut back external to the cable clamp. Complete the water connections to the boiler. Make sure the cable is suitably secured. Fill, vent and flush the system. When making connections, make sure that the earth conductor Check for any water leaks and put right.
  • Page 140 5 Boiler Installation SCREW SIDE REAR RIGHT 2.5mm dia.drill JUBILEE CLIP DUCT EXTENSION LEFT RIGHT REAR VERTICAL SIDE LEFT DUCT EXTENSION Cutting 'MARK' lengths. Lefthand flue does not require cutting. FLUE ELBOW Diagram 5.6 GASKET BLANKING (REAR FLUE OUTLET ILLUSTRATED) PLATE NUT (3) FLUE...
  • Page 141 5 Boiler Installation 5.10 External Controls Make sure that the supply cable and all external cables are SECURING secured and away from hot surfaces. SCREWS (2) GRAVITY DOMESTIC HOT WATER AND PUMPED CENTRAL HEATING, SEE DIAGRAM 5.9. FULLY PUMPED OPEN VENTED OR SEALED WATER SYSTEMS, SEE DIAGRAM 5.10.

  • Page 142: Commissioning

    6 Commissioning Please ensure the “Benchmark” logbook is completed and left with the user. 6.1 All Systems Commissioning should be carried out by a competent person in accordance with the current issue of BS6798. Make sure that the system has been thoroughly flushed out with cold water without the pump in place.
  • Page 143 6 Commissioning Turn the control thermostat knob to “O” and isolate the boiler from the electrical supply. Fit the combustion chamber front. Reconnect the ignition lead to the PCB. SECURING Stick the self adhesive arrow indicator to the data label, against SCREW (4) the rating that the boiler is going to be set to, for future reference.
  • Page 144 6 Commissioning Turn the control thermostat knob fully anticlockwise to “Off”. Remove the pressure gauge from the test point and refit screw, SEAL making sure a gas tight seal is made. SIDE When the control thermostat is turned to the “Off” position, by SEAL hand, wait at least 30 seconds before turning “On”...

  • Page 145: Servicing

    7 Instructions to the User Instruct and demonstrate the safe and efficient operation of the Section 35, which imposes a duty of care on all persons who let boiler, heating system and domestic hot water system. out any property containing a gas appliance. Advise the user, that to ensure the continued efficient and safe It is the Law that servicing is carried out by a competent person.
  • Page 146 8 Servicing Remove the main burner from the main injector at the rear. Raise the burner up and forward, easing the pilot pipe down, to clear, take care not to damage the combustion chamber insulation or the pilot burner assembly. Use a vacuum cleaner or suitable stiff brush to clean the burner thoroughly, making sure that all the burner ports are clear and unobstructed.

  • Page 147: Fault Finding

    9 Fault Finding 9.1 Electrical 9.2 Electrical Supply Failure Important. On completion of the Service/Fault Finding task Failure of the electrical supply will cause the burner to go out. which has required the breaking and remaking of the electrical Operation will normally resume on the restoration of the electrical connections the earth continuity, polarity, short circuit and supply.
  • Page 148 9 Fault Finding Before detailed checking of electrical components ensure that remote controls are calling for heat. Check the gas supply is free of obstructions and purged of air. Check the overheat cutoff has not operated, for fully pumped systems only. Isolate the electrical supply and physically check ALL cables, connections and the printed circuit board fuse.
  • Page 149 9 Fault Finding Pump Overrun Operation For Fully Pumped System Only The PCB has a timed pump overrun facility. The pump should run for several minutes after remote controls have stopped calling for heat. Before using the fault finding chart ensure all wiring is correct and in good condition, the pump is not faulty and check the PCB fuse F2 Does the pump run when SL is applied ? Faulty PCB.
  • Page 150 9 Fault Finding bk BLACK or ORANGE bk BLACK or ORANGE br BROWN w WHITE br BROWN w WHITE BLUE BLUE PURPLE y YELLOW PURLPLE YELLOW Red Link must be fitted between SL and 9. RED LINK LINK SPARK ELECTRODE PUMP SPARK ELECTRODE...
  • Page 151 9 Fault Finding KEY: GRAVITY DOMESTIC - BLUE HOT WATER AND bk - BLACK PUMPED CENTRAL - BROWN HEATING g/y - GREEN/YELLOW - ORANGE - PURPLE - RED MULTI-FUNCTIONAL - YELLOW CONTROL - WHITE ELECTRODE PRESSURE SWITCH CHASSIS CHASSIS EARTH EARTH SEQUENCE Yellow link fitted to bridge out the...
  • Page 152 9 Fault Finding KEY: FULLY PUMPED - BLUE OPEN VENTED bk - BLACK OR SEALED - BROWN WATER SYSTEM g/y - GREEN/YELLOW - ORANGE - PURPLE - RED MULTI-FUNCTIONAL - YELLOW CONTROL - WHITE ELECTRODE PRESSURE Remove red link between SWITCH 9 and SL when fitting a time control etc (If no switch is fitted,...
  • Page 153 10 Replacement of Parts Note. Replacement of parts must only be carried out by a CONTROL competent person. THERMOSTAT SHAKEPROOF Before replacing any parts isolate the boiler from the electrical WASHERS AND supply and turn the gas supply off at the gas service cock, SCREWS indicator slot to be vertical.
  • Page 154 10 Replacement of Parts ELECTRICAL PLUGS PHIAL RETAINING BOILER BRACKET THERMOSTAT SECURING ELECTRICAL SCREW CONNECTION NO.3 "YELLOW" OVERHEAT CABLE CUTOFF DEVICE PHIAL CHASSIS CONTROL EARTH THERMOSTAT CONNECTION PHIAL SUPPORT SECURING EARTH POST (4) SCREW (2) CONNECTION IGNITION SPLIT MAIN LEAD TERMINAL STRIP PLASTIC...
  • Page 155 10 Replacement of Parts 10.8 Solenoid - diagram 10.3 Remove the electrical plug from the multifunctional control. Remove the securing screw and then the solenoid Assembly. 10.9 Main Burner Remove the main burner as Section 8.3. RESTRICTOR 10.10 Main Injector EXTENDED Remove the main burner as Section 8.3.
  • Page 156 10 Replacement of Parts 10.11 Insulation - diagram 10.5 Combustion Chamber Front Remove the retaining screw then the insulation. Sides Slide the insulation out. Rear With the side insulation removed the rear insulation can be removed and replaced. 10.12 Viewing Window - diagram 10.6 Remove the old self adhesive aluminium foil gasket and the old mica window.
  • Page 157 10 Replacement of Parts 10.13 Air Pressure Switch - diagram 10.7 Release the control box as Section 5.6. MICA WINDOW Remove the air pressure tubes and electrical connections from the PCB, release the screws and remove the switch. When fitting the replacement make sure that the plastic tubes are fitted as shown in diagram 10.7 and that electrical connections are made as shown in diagrams 9.6 or 9.7.
  • Page 158 11 Spare Parts 11.1 Part Identification 11.2 Ordering The key number on the diagram and the list will help to identify When ordering any spare parts please quote the number and the part. description from the list together with the model name and serial number.
  • Page 159 11 Spare Parts Diagram 11.1 221963B...
  • Page 160 Because of our constant endeavour for improvement, details may vary slightly from those shown in these instructions. 221963B...
  • Page 161 221521F.04.01 Instructions for Use Installation and Servicing To b e l e f t w i t h t h e u s e r 60FF G.C. No. 41 047 15 Fanned Flue Boiler (SIT) BS 6332 BS 5258 This is a Cat II Appliance 2H3P Reference in these instructions to British Standards and Statutory...
  • Page 162 Important Information Testing and Certification This boiler is tested and certificated for safety and performance. It is therefore important that no alteration is made to the boiler, without permission, in writing, from Hepworth Heating Ltd. Any alteration not approved by Hepworth Heating Ltd., could invalidate the certification, boiler warranty and may also infringe the current issue of the Statutory Requirements, see Section 1.4.
  • Page 163 Instructions for Use Introduction To obtain service, please call your installer or Heatcall (Glow- worm’s own Service Organisation) using the telephone number WARNING. It is important that the case (not the controls tray) given on the controls tray. is not disturbed or removed other than for servicing by a Please be advised that the ‘Benchmark’...
  • Page 164 Instructions for Use Cleaning To Light the Boiler WARNING. This appliance contains metal parts (components) WARNING. Sealed Systems and care should be taken when handling and cleaning, with A sealed water system must be filled and pressurised by a particular regard to edges. competent person.
  • Page 165 1 General Data WATER CONNECTIONS 22mm COPPER PIPE GAS CONNECTIONS in. BSPT) All dimensions are given in millimetres (except as noted) SIDE ELEVATION FRONT ELEVATION Diagram 1.1 Detailed recommendations are contained in the current issue of Important Notice the following British Standards and Codes of Practice:- This boiler is for use only on natural gas (G20), but may be BS4814, BS6798, BS5440 Part 1 and 2, BS5546 Part 1, BS5449, converted for use on L.P.G.
  • Page 166 1 General Data 1.5 Gas Supply 1.6 Electrical Supply The gas installation shall be in accordance with the current WARNING. This boiler must be earthed. issue of BS6891. All system components shall be of an approved type and shall The supply from the governed meter must be of adequate size be connected in accordance with the current issue of BS7671 to provide a steady inlet working pressure of 20mbar (8in wg) at and any applicable local regulations.
  • Page 167 1 General Data 1.12 Boiler Clearances Refer to diagram 1.2. This boiler must be positioned so that at least the minimum operational and servicing clearances are provided. Additional clearances may be required for installation. 500mm If fixtures are positioned next to the boiler they should be made removable for access to pipework.
  • Page 168 2 Flue and Ventilation Note: Detailed recommendations for flues are given in the current issue of BS5440 Part 1. 2.1 Terminal Position The minimum acceptable siting dimensions for the terminal from obstructions, other terminals and ventilation openings are shown in diagram 2.1. The terminal must be exposed to the external air, the position allowing free passage of air across it at all times.

  • Page 169: Water Systems

    3 Water Systems The installation of the boiler must comply with the requirements of the current issue of BS6798. 1000 3.1 Frost Protection If the position of the boiler is such that it may be vulnerable to freezing it should be protected as specified in the current issue of BS5422.
  • Page 170 3 Water Systems OPEN VENTED FULLY PUMPED WATER SYSTEM FLOW RECOMMENDED RELATIONSHIP BETWEEN PUMP COLD FEED AND VENT RETURN 22mm 22mm VENT (MIN.) PIPE 450mm MIN. HEIGHT 15mm (MINIMUM) COLD FEED FEED AND EXPANSION CISTERN 1150mm MIN. PUMP 22mm VENT & 15mm COLD FEED TO BE FITTED IN ACCORDANCE There must always WITH BS 5449...
  • Page 171 3 Water Systems 3.12 Expansion Vessel 3.13 Pressure Gauge A diaphragm type expansion vessel, conforming to the current A pressure gauge with a set pointer and covering at least the issue of BS4814 (see also BS7074 Part 1 and 2) must be range of 0 to 4bar (0 to 60lb/in ) shall be permanently fitted to connected at a point close to the inlet side of the circulating...
  • Page 172 3 Water Systems 3.16 Filling a Sealed Water System 0051M METHOD 1 COMBINED Provision for filling the system at low level must be made. Three CHECK VALVE HEATING methods are shown in diagram 3.6. There must be no permanent TEMPORARY AND VACUUM SYSTEM connection to the mains water supply, even through a non-...

  • Page 173: Flue And Appliance Preparation

    4 Flue and Appliance Preparation 4.1 Unpacking Open the carton, check the items supplied against the boiler pack contents list on the flap and diagram 4.1. 4.2 Flue Position and Length Determine flue application, length and terminal position before starting. Refer to diagram 4.2 or 4.3.
  • Page 174 4 Flue and Appliance Preparation 4.3 Flue Preparation All flue assemblies are designed for internal installation (optional wall liner is required), given that there is sufficient clearances opposite to the flue for the installation of the flue. 115mm If there is insufficient clearance the flue can be installed from MINIMUM outside.
  • Page 175 4 Flue and Appliance Preparation 4.5 Flue Hole Cutting Having marked out the flue centre cut a hole for the flue using, preferably, a 115mm minimum core drill. 4.6 Wall Mounting Bracket Reposition the template, making sure of dimensional alignment with the flue hole.
  • Page 176 4 Flue and Appliance Preparation 4.8 Air Duct/Terminal Mark the duct length, see diagram 4.8 for rear flue and diagram 4.9 for side flue, then cut square and remove any burrs. 4.9 Air Duct/Terminal and Flue Duct Assembly Locate the flue duct into the air duct/terminal, see diagram 4.10. Take the flue manifold from the loose items pack together with the sealant.
  • Page 177 4 Flue and Appliance Preparation 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 4.11 for position of self adhesive seal.

  • Page 178: Boiler Installation

    5 Boiler Installation 5.1 Boiler Preparation With the boiler still in the bottom tray, slide the controls cover CONTROLS upward and remove it as shown in diagram 5.1. COVER Remove the front cover by undoing the wing nut, nut and washer, lift the front cover off, see diagram 5.1.
  • Page 179 5 Boiler Installation 5.3 Water Circulation System The mains cable outer insulation must not be cut back external to the cable clamp. Complete the water connections to the boiler. Make sure the cable is suitably secured. Fill, vent and flush the system. When making connections, make sure that the earth conductor Check for any water leaks and put right.
  • Page 180 5 Boiler Installation SCREW SIDE REAR RIGHT 2.5mm dia.drill JUBILEE CLIP DUCT EXTENSION LEFT RIGHT REAR VERTICAL SIDE LEFT DUCT EXTENSION Cutting 'MARK' lengths. Lefthand flue does not require cutting. FLUE ELBOW Diagram 5.6 GASKET BLANKING (REAR FLUE OUTLET ILLUSTRATED) PLATE NUT (3) FLUE...
  • Page 181 5 Boiler Installation 5.10 External Controls Make sure that the supply cable and all external cables are SECURING secured and away from hot surfaces. SCREWS (2) GRAVITY DOMESTIC HOT WATER AND PUMPED CENTRAL HEATING, SEE DIAGRAM 5.9. FULLY PUMPED OPEN VENTED OR SEALED WATER SYSTEMS, SEE DIAGRAM 5.10.

  • Page 182: Commissioning

    6 Commissioning Please ensure the “Benchmark” logbook is completed and left with the user. 6.1 All Systems Commissioning should be carried out by a competent person in accordance with the current issue of BS6798. Make sure that the system has been thoroughly flushed out with cold water without the pump in place.
  • Page 183 6 Commissioning Turn the control thermostat knob to “O” and isolate the boiler from the electrical supply. Fit the combustion chamber front. Reconnect the ignition lead to the PCB. SECURING Stick the self adhesive arrow indicator to the data label, against SCREW (4) the rating that the boiler is going to be set to, for future reference.
  • Page 184 6 Commissioning Turn the control thermostat knob fully anticlockwise to “Off”. Remove the pressure gauge from the test point and refit screw, SEAL making sure a gas tight seal is made. When the control thermostat is turned to the “Off” position, by SIDE hand, wait at least 30 seconds before turning “On”...

  • Page 185: Servicing

    7 Instructions to the User Instruct and demonstrate the safe and efficient operation of the Section 35, which imposes a duty of care on all persons who let boiler, heating system and domestic hot water system. out any property containing a gas appliance. Advise the user, that to ensure the continued efficient and safe It is the Law that servicing is carried out by a competent person.
  • Page 186 8 Servicing Remove the main burner from the main injector at the rear. Raise the burner up and forward, easing the pilot pipe down, to clear, take care not to damage the combustion chamber insulation or the pilot burner assembly. Use a vacuum cleaner or suitable stiff brush to clean the burner thoroughly, making sure that all the burner ports are clear and unobstructed.
  • Page 187 9 Fault Finding 9.1 Electrical 9.2 Electrical Supply Failure Important. On completion of the Service/Fault Finding task Failure of the electrical supply will cause the burner to go out. which has required the breaking and remaking of the electrical Operation will normally resume on the restoration of the electrical connections the earth continuity, polarity, short circuit and supply.
  • Page 188 9 Fault Finding Before detailed checking of electrical components ensure that remote controls are calling for heat. Check the gas supply is free of obstructions and purged of air. Check the overheat cutoff has not operated, for fully pumped systems only. Isolate the electrical supply and physically check ALL cables, connections and the printed circuit board fuse.
  • Page 189 9 Fault Finding Pump Overrun Operation For Fully Pumped System Only The PCB has a timed pump overrun facility. The pump should run for several minutes after remote controls have stopped calling for heat. Before using the fault finding chart ensure all wiring is correct and in good condition, the pump is not faulty and check the PCB fuse F2 Does the pump run when SL is applied ? Faulty PCB.
  • Page 190 9 Fault Finding bk BLACK or ORANGE bk BLACK or ORANGE br BROWN w WHITE br BROWN w WHITE BLUE BLUE PURPLE y YELLOW PURLPLE YELLOW Red Link must be fitted between SL and 9. RED LINK LINK SPARK ELECTRODE PUMP SPARK ELECTRODE...
  • Page 191 9 Fault Finding KEY: GRAVITY DOMESTIC - BLUE HOT WATER AND bk - BLACK PUMPED CENTRAL - BROWN HEATING g/y - GREEN/YELLOW - ORANGE - PURPLE - RED MULTI-FUNCTIONAL - YELLOW CONTROL - WHITE ELECTRODE PRESSURE SWITCH CHASSIS CHASSIS EARTH EARTH SEQUENCE Yellow link fitted to bridge out the...
  • Page 192 9 Fault Finding KEY: FULLY PUMPED - BLUE OPEN VENTED bk - BLACK OR SEALED - BROWN WATER SYSTEM g/y - GREEN/YELLOW - ORANGE - PURPLE - RED MULTI-FUNCTIONAL - YELLOW CONTROL - WHITE ELECTRODE PRESSURE Remove red link between SWITCH 9 and SL when fitting a time control etc (If no switch is fitted,...
  • Page 193 10 Replacement of Parts Note. Replacement of parts must only be carried out by a CONTROL competent person. THERMOSTAT SHAKEPROOF Before replacing any parts isolate the boiler from the electrical WASHERS AND supply and turn the gas supply off at the gas service cock, SCREWS indicator slot to be vertical.
  • Page 194 10 Replacement of Parts ELECTRICAL PLUGS PHIAL RETAINING BOILER BRACKET THERMOSTAT SECURING ELECTRICAL SCREW CONNECTION NO.3 "YELLOW" OVERHEAT CABLE CUTOFF DEVICE PHIAL CHASSIS CONTROL EARTH THERMOSTAT CONNECTION PHIAL SUPPORT SECURING EARTH POST (4) SCREW (2) CONNECTION IGNITION SPLIT MAIN LEAD TERMINAL STRIP PLASTIC...
  • Page 195 10 Replacement of Parts 10.8 Solenoid - diagram 10.3 Remove the electrical plug from the multifunctional control. Remove the securing screw and then the solenoid Assembly. 10.9 Main Burner Remove the main burner as Section 8.3. RESTRICTOR 10.10 Main Injector EXTENDED Remove the main burner as Section 8.3.
  • Page 196 10 Replacement of Parts 10.11 Insulation - diagram 10.5 Combustion Chamber Front Remove the retaining screw then the insulation. Sides Slide the insulation out. Rear With the side insulation removed the rear insulation can be removed and replaced. 10.12 Viewing Window - diagram 10.6 Remove the old self adhesive aluminium foil gasket and the old mica window.
  • Page 197 10 Replacement of Parts 10.13 Air Pressure Switch - diagram 10.7 Release the control box as Section 5.6. MICA WINDOW Remove the air pressure tubes and electrical connections from the PCB, release the screws and remove the switch. When fitting the replacement make sure that the plastic tubes are fitted as shown in diagram 10.7 and that electrical connections are made as shown in diagrams 9.6 or 9.7.
  • Page 198 11 Spare Parts 11.1 Part Identification 11.2 Ordering The key number on the diagram and the list will help to identify When ordering any spare parts please quote the number and the part. description from the list together with the model name and serial number.
  • Page 199 11 Spare Parts Diagram 11.1 221521F...
  • Page 200 Because of our constant endeavour for improvement, details may vary slightly from those shown in these instructions. 221521F...
  • Page 201 221964C.03.03 Instructions for Use Installation and Servicing To b e l e f t w i t h t h e u s e r 60FF G.C. No. 41 047 56 Fanned Flue Boiler BS 6332 BS 5258 This is a Cat I Appliance Reference in these instructions to British Standards and Statutory Regulations/Requirements apply only to the United Kingdom.
  • Page 202 Important Information TESTING AND CERTIFICATION This boiler is tested and certificated for safety and performance. It is therefore important that no alteration is made to the boiler, without permission, in writing, from Hepworth Heating Ltd. Any alteration not approved by Hepworth Heating Ltd., could invalidate the certification, boiler warranty and may also infringe the current issue of the Statutory Requirements, see Section 1.4.
  • Page 203 Instructions for Use Introduction All CORGI Registered Installers carry a CORGI ID card, and have a registration number. Both should be recorded in your WARNING. It is important that the case (not the controls tray) boiler Logbook. You can check your installer is CORGI registered is not disturbed or removed other than for servicing by a by calling CORGI direct on :- 01256 372300.
  • Page 204 Instructions for Use Boiler Electrical Supply To Light the Boiler WARNING. This boiler must be earthed. WARNING. Sealed Systems The boiler must only be connected to a 230V~50Hz supply A sealed water system must be filled and pressurised by a protected by a 3A fuse.
  • Page 205 1 General Data ; ; ; ; ; ; ; ; WATER CONNECTIONS 22mm COPPER PIPE GAS CONNECTIONS in. BSPT) All dimensions are given in millimetres (except as noted) SIDE ELEVATION FRONT ELEVATION Important Notice Diagram 1.1 This boiler is for use only on natural gas (G20) only. DATA TABLE 1.
  • Page 206 1 General Data 1.9 Drain 1.3 Range Rating System This boiler is range rated and may be adjusted to suit individual system requirements. A drain tap must be provided at the lowest points of the system which will allow the entire system, boiler and hot water cylinder See diagram 1.2 for the ratings and settings.
  • Page 207 1 General Data 1.12 Boiler Clearances Refer to diagram 1.3. This boiler must be positioned so that at least the minimum operational and servicing clearances are provided. Additional clearances may be required for installation. 500mm If fixtures are positioned next to the boiler they should be made removable for access to pipework.
  • Page 208 2 Flue and Ventilation Note: Detailed recommendations for flues are given in the current issue of BS5440 Part 1. 2.1 Terminal Position The minimum acceptable siting dimensions for the terminal from obstructions, other terminals and ventilation openings are shown in diagram 2.1. The terminal must be exposed to the external air, the position allowing free passage of air across it at all times.

  • Page 209: Water Systems

    3 Water Systems The installation of the boiler must comply with the requirements of the current issue of BS6798. 1000 3.1 Frost Protection If the position of the boiler is such that it may be vulnerable to freezing it should be protected as specified in the current issue of BS5422.
  • Page 210 3 Water Systems OPEN VENTED FULLY PUMPED WATER SYSTEM FLOW RECOMMENDED RELATIONSHIP BETWEEN PUMP COLD FEED AND VENT RETURN 22mm 22mm VENT (MIN.) PIPE 450mm MIN. HEIGHT 15mm (MINIMUM) COLD FEED FEED AND EXPANSION CISTERN 1150mm MIN. PUMP 22mm VENT & 15mm COLD FEED TO BE FITTED IN ACCORDANCE There must always WITH BS 5449...
  • Page 211 3 Water Systems 3.12 Expansion Vessel 3.13 Pressure Gauge A diaphragm type expansion vessel, conforming to the current A pressure gauge with a set pointer and covering at least the issue of BS4814 (see also BS7074 Part 1 and 2) must be range of 0 to 4bar (0 to 60lb/in ) shall be permanently fitted to connected at a point close to the inlet side of the circulating...
  • Page 212 3 Water Systems 3.16 Filling a Sealed Water System 0051M METHOD 1 COMBINED Provision for filling the system at low level must be made. Three CHECK VALVE HEATING methods are shown in diagram 3.6. There must be no permanent TEMPORARY AND VACUUM SYSTEM connection to the mains water supply, even through a non-...

  • Page 213: Flue And Appliance Preparation

    4 Flue and Appliance Preparation 4.1 Unpacking Open the carton, check the items supplied against the boiler pack contents list on the flap and diagram 4.1. 4.2 Flue Position and Length Determine flue application, length and terminal position before starting. Refer to diagram 4.2 or 4.3.
  • Page 214 4 Flue and Appliance Preparation 4.3 Flue Preparation All flue assemblies are designed for internal installation (optional wall liner is required), given that there is sufficient clearances opposite to the flue for the installation of the flue. 115mm If there is insufficient clearance the flue can be installed from MINIMUM outside.
  • Page 215 4 Flue and Appliance Preparation 4.5 Flue Hole Cutting Having marked out the flue centre cut a hole for the flue using, preferably, a 115mm minimum core drill. 4.6 Wall Mounting Bracket Reposition the template, making sure of dimensional alignment with the flue hole.
  • Page 216 4 Flue and Appliance Preparation 4.8 Air Duct/Terminal Mark the duct length, see diagram 4.8 for rear flue and diagram 4.9 for side flue, then cut square and remove any burrs. 4.9 Air Duct/Terminal and Flue Duct Assembly Locate the flue duct into the air duct/terminal, see diagram 4.10. Take the flue manifold from the loose items pack together with the sealant.
  • Page 217 4 Flue and Appliance Preparation 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 4.11 for position of self adhesive seal.

  • Page 218: Boiler Installation

    5 Boiler Installation 5.1 Boiler Preparation With the boiler still in the bottom tray, slide the controls cover CONTROLS upward and remove it as shown in diagram 5.1. COVER Remove the front cover by undoing the wing nut, nut and washer, lift the front cover off, see diagram 5.1.
  • Page 219 5 Boiler Installation 5.3 Water Circulation System The mains cable outer insulation must not be cut back external to the cable clamp. Complete the water connections to the boiler. Make sure the cable is suitably secured. Fill, vent and flush the system. When making connections, make sure that the earth conductor Check for any water leaks and put right.
  • Page 220 5 Boiler Installation SCREW SIDE REAR RIGHT 2.5mm dia.drill JUBILEE CLIP DUCT EXTENSION LEFT RIGHT REAR VERTICAL SIDE LEFT DUCT EXTENSION Cutting 'MARK' lengths. Lefthand flue does not require cutting. FLUE ELBOW Diagram 5.6 GASKET BLANKING (REAR FLUE OUTLET ILLUSTRATED) PLATE NUT (3) FLUE...
  • Page 221 5 Boiler Installation 5.10 External Controls Make sure that the supply cable and all external cables are SECURING secured and away from hot surfaces. SCREWS (2) GRAVITY DOMESTIC HOT WATER AND PUMPED CENTRAL HEATING, SEE DIAGRAM 5.9. FULLY PUMPED OPEN VENTED OR SEALED WATER SYSTEMS, SEE DIAGRAM 5.10.

  • Page 222: Commissioning

    6 Commissioning Please ensure the “Benchmark” logbook is completed and left with the user. 6.1 All Systems Commissioning should be carried out by a competent person in accordance with the current issue of BS6798. Make sure that the system has been thoroughly flushed out with cold water without the pump in place.
  • Page 223 6 Commissioning Turn the control thermostat knob to “O” and isolate the boiler from the electrical supply. Fit the combustion chamber front. Reconnect the ignition lead to the PCB. SECURING Stick the self adhesive arrow indicator to the data label, against SCREW (4) the rating that the boiler is going to be set to, for future reference.
  • Page 224 6 Commissioning Turn the control thermostat knob fully anticlockwise to “Off”. Remove the pressure gauge from the test point and refit screw, SEAL making sure a gas tight seal is made. When the control thermostat is turned to the “Off” position, by SIDE hand, wait at least 30 seconds before turning “On”...

  • Page 225: Servicing

    7 Instructions to the User Instruct and demonstrate the safe and efficient operation of the Section 35, which imposes a duty of care on all persons who let boiler, heating system and domestic hot water system. out any property containing a gas appliance. Advise the user, that to ensure the continued efficient and safe It is the Law that servicing is carried out by a competent person.
  • Page 226 8 Servicing Remove the main burner from the main injector at the rear. Raise the burner up and forward, easing the pilot pipe down, to clear, take care not to damage the combustion chamber insulation or the pilot burner assembly. Use a vacuum cleaner or suitable stiff brush to clean the burner thoroughly, making sure that all the burner ports are clear and unobstructed.

  • Page 227: Fault Finding

    9 Fault Finding 9.1 Electrical 9.2 Electrical Supply Failure Important. On completion of the Service/Fault Finding task Failure of the electrical supply will cause the burner to go out. which has required the breaking and remaking of the electrical Operation will normally resume on the restoration of the electrical connections the earth continuity, polarity, short circuit and supply.
  • Page 228 9 Fault Finding Before detailed checking of electrical components ensure that remote controls are calling for heat. Check the gas supply is free of obstructions and purged of air. Check the overheat cutoff has not operated, for fully pumped systems only. Isolate the electrical supply and physically check ALL cables, connections and the printed circuit board fuse.
  • Page 229 9 Fault Finding Pump Overrun Operation For Fully Pumped System Only The PCB has a timed pump overrun facility. The pump should run for several minutes after remote controls have stopped calling for heat. Before using the fault finding chart ensure all wiring is correct and in good condition, the pump is not faulty and check the PCB fuse F2 Does the pump run when SL is applied ? Faulty PCB.
  • Page 230 9 Fault Finding bk BLACK or ORANGE bk BLACK or ORANGE br BROWN w WHITE br BROWN w WHITE BLUE BLUE PURPLE y YELLOW PURLPLE YELLOW Red Link must be fitted between SL and 9. RED LINK LINK SPARK ELECTRODE PUMP SPARK ELECTRODE...
  • Page 231 9 Fault Finding KEY: GRAVITY DOMESTIC - BLUE HOT WATER AND bk - BLACK PUMPED CENTRAL - BROWN HEATING g/y - GREEN/YELLOW - ORANGE - PURPLE - RED MULTI-FUNCTIONAL - YELLOW CONTROL - WHITE ELECTRODE PRESSURE SWITCH CHASSIS CHASSIS EARTH EARTH G.D.H.W.
  • Page 232 9 Fault Finding KEY: FULLY PUMPED - BLUE OPEN VENTED bk - BLACK OR SEALED - BROWN WATER SYSTEM g/y - GREEN/YELLOW - ORANGE - PURPLE - RED MULTI-FUNCTIONAL - YELLOW CONTROL - WHITE ELECTRODE PRESSURE Remove red link between SWITCH 9 and SL when fitting a time control etc (If no switch is fitted,...
  • Page 233 10 Replacement of Parts Note. Replacement of parts must only be carried out by a CONTROL competent person. THERMOSTAT SHAKEPROOF Before replacing any parts isolate the boiler from the electrical WASHERS AND supply and turn the gas supply off at the gas service cock, SCREWS indicator slot to be vertical.
  • Page 234 10 Replacement of Parts ELECTRICAL PLUGS PHIAL RETAINING BOILER BRACKET THERMOSTAT SECURING ELECTRICAL SCREW CONNECTION NO.3 "YELLOW" OVERHEAT CABLE CUTOFF DEVICE PHIAL CHASSIS CONTROL EARTH THERMOSTAT CONNECTION PHIAL SUPPORT SECURING EARTH POST (4) SCREW (2) CONNECTION IGNITION SPLIT MAIN LEAD TERMINAL STRIP PLASTIC...
  • Page 235 10 Replacement of Parts 10.8 Solenoid - diagram 10.3 Remove the electrical plug from the multifunctional control. Remove the securing screw and then the solenoid Assembly. 10.9 Main Burner Remove the main burner as Section 8.3. RESTRICTOR 10.10 Main Injector EXTENDED Remove the main burner as Section 8.3.
  • Page 236 10 Replacement of Parts 10.11 Insulation - diagram 10.5 Combustion Chamber Front Remove the retaining screw then the insulation. Sides Slide the insulation out. Rear With the side insulation removed the rear insulation can be removed and replaced. 10.12 Viewing Window - diagram 10.6 Remove the old self adhesive aluminium foil gasket and the old mica window.
  • Page 237 10 Replacement of Parts 10.13 Air Pressure Switch - diagram 10.7 Release the control box as Section 5.6. MICA WINDOW Remove the air pressure tubes and electrical connections from the PCB, release the screws and remove the switch. When fitting the replacement make sure that the plastic tubes are fitted as shown in diagram 10.7 and that electrical connections are made as shown in diagrams 9.6 or 9.7.
  • Page 238 11 Spare Parts 11.1 Part Identification 11.2 Ordering The key number on the diagram and the list will help to identify When ordering any spare parts please quote the number and the part. description from the list together with the model name and serial number.
  • Page 239 11 Spare Parts Diagram 11.1 221964C...
  • Page 240 Because of our constant endeavour for improvement, details may vary slightly from those shown in these instructions. 221964C...
  • Page 241 221965B.04.02 Instructions for Use Installation and Servicing To b e l e f t w i t h t h e u s e r 70FF 80FF G.C. No. 41-047-57 G.C. No.41-047-58 Cat I Cat II 2H3P Fanned Flue Boiler BS 6332 BS 5258 Reference in these instructions to British Standards and Statutory...
  • Page 242 Important Information Testing and Certification This boiler is tested and certificated for safety and performance. It is therefore important that no alteration is made to the boiler, without permission, in writing, from Hepworth Heating Ltd. Any alteration not approved by Hepworth Heating Ltd., could invalidate the certification, boiler warranty and may also infringe the current issue of the Statutory Requirements, see Section 1.4.
  • Page 243 Instructions for Use To obtain service, please call your installer or Heatcall (Glow- Introduction worm’s own Service Organisation) using the telephone number WARNING. It is important that the case (not the controls tray) given on the controls tray. is not disturbed or removed other than for servicing by a Please be advised that the ‘Benchmark’...
  • Page 244 Instructions for Use To Light the Boiler Cleaning WARNING. Sealed Systems WARNING. This appliance contains metal parts (components) and care should be taken when handling and cleaning, with A sealed water system must be filled and pressurised by a particular regard to edges. competent person.
  • Page 245 1 General Data ; ; ; ; ; ; WATER CONNECTIONS 22mm COPPER PIPE GAS CONNECTIONS in. BSPT) SIDE ELEVATION FRONT ELEVATION MODEL 70FF/80FF Diagram 1.1 Detailed recommendations are contained in the current issue of Important Notice the following British Standards and Codes of Practice:- This boiler is for use only on G20 gas, but the 80FF may be BS4814, BS6798, BS5440 Part 1 and 2, BS5546 Part 1, converted for use on G31 gas (Propane L.P.G.) with an available...
  • Page 246 1 General Data DATA TABLE 1. MODEL 70FF/80FF TOTAL DRY WEIGHT 51 kg (112 lb) (Including Terminal) LIFT 45.3 kg (100lb) WEIGHT WATER 3.35 litre (0.74 gallon) CONTENT CONNECTION ELECTRICITY RATING Internal fuse F1 & F2 (F1A) 2x22mm copper pipes from WATER top of case CONNECTION...
  • Page 247 1 General Data 1.7 Contents of Packaging The boiler is delivered in one pack, refer to Section 4.1 for contents. 1.8 Water System This boiler may be fitted to an open vented or a sealed water system. 500mm 1.9 Drain System Additional clearances may be required for installation...
  • Page 248 2 Flue and Ventilation 2.1 Terminal Position The minimum acceptable siting dimensions for the terminal from obstructions, other terminals and ventilation openings are shown in diagram 2.1. 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.

  • Page 249: Water Systems

    3 Water Systems 3.1 Frost Protection If the position of the boiler is such that it may be vulnerable to 80FF freezing it should be protected as specified in the current issue 1000 of BS5422. It is recommended that a frost protection thermostat 70FF be fitted.
  • Page 250 3 Water Systems OPEN VENTED FULLY PUMPED WATER SYSTEM FLOW RECOMMENDED RELATIONSHIP BETWEEN PUMP COLD FEED AND VENT RETURN 28mm 22mm VENT (MIN.) PIPE 450mm MIN. HEIGHT 15mm (MINIMUM) COLD FEED FEED AND EXPANSION 22 X 28 CISTERN UNION 1150mm CONNECTION MIN.
  • Page 251 3 Water Systems 3 LITRES (0.66 gals) MAKE-UP BOTTLE RELEASE (if required) POINT AUTO VENT NON-RETURN VALVE FILLING POINT IF REQUIRED 22mm (min) BY-PASS WITH LOCKSHIELD VALVE FLOW CIRCULATING SAFETY PUMP VALVE PRESSURE GAUGE RETURN DRAIN COCK (Make-up BOILER alternatives) EXPANSION VESSEL Diagram 3.4...

  • Page 252: Flue And Appliance Preparation

    4 Flue and Appliance Preparation 4.1 Unpacking 4.3 Flue Preparation Open the carton, check the items supplied against the boiler All flue assemblies are designed for internal installation (optional pack contents list on the flap, see diagram 4.1. wall liner is required), given that there is sufficient clearances opposite to the flue for the installation of the flue.
  • Page 253 4 Flue and Appliance Preparation For a wall thickness up to 300mm, provided that there is sufficient space and the optional wall liner kit is used the flue can be fully installed from the inside. For a wall thickness of over 300mm the external flue hole will 115mm need to be made good from the outside.
  • Page 254 4 Flue and Appliance Preparation Drill holes and plug, to suit No.12x2in woodscrews, fit the screws allowing sufficient clearance, about 5mm, to accept the swing brackets, see diagram 4.5. Secure the mounting bracket to the wall with No.12x2in woodscrews and plugs, see diagram 4.5. 4.7 Flue Duct Mark the duct to the length required, this length allows for expansion, see diagram 4.6 for rear flue and diagram 4.7 for...
  • Page 255 4 Flue and Appliance Preparation 4.10 Rear Fitting Fit the self adhesive foam seal provided in the flue pack around the air duct/terminal at the position shown in diagram 4.13. 4.11 Side Fitting Fit the self adhesive foam seal around the air duct/terminal such that, when installed, the seal will be within the wall, see diagram 4.14.
  • Page 256 4 Flue and Appliance Preparation 4.12 Flue Assembly - Installation If the boiler is not to be fitted for some time cover the hole in the wall. On limited access installations push the flue assembly into and through the hole such that it is within the wall and does not stick out into the room, see diagram 4.12.

  • Page 257: Boiler Installation

    5 Boiler Installation 5 Boiler Preparation With the boiler still in the bottom tray, slide the controls tray CONTROLS upwards and remove it as shown in diagram 5.1. COVER Remove the front cover by undoing (and keeping) the screw and wing nuts and lifting the front cover off, see diagram 5.1.
  • Page 258 5 Boiler Installation 5.3 Water Circulation System ELECTRICAL AIR PRESSURE TUBES CONNECTIONS Complete the water connections to the boiler. CLEAR RED Fill, vent and flush the system. Check for any water leaks and put right. 5.4 Safety Valve Discharge Fit a suitable discharge pipe to the safety valve and route it to outside the building so that any discharge can be seen but will not cause injury to persons, damage to property or any electrical installation.
  • Page 259 5 Boiler Installation SCREW SIDE REAR RIGHT 2.5mm dia.drill JUBILEE CLIP DUCT EXTENSION LEFT RIGHT REAR VERTICAL SIDE LEFT DUCT EXTENSION Cutting 'MARK' lengths. Lefthand flue does not require cutting. FLUE ELBOW Diagram 5.6 5.7 Electrical Connection (REAR FLUE OUTLET ILLUSTRATED) WARNING.
  • Page 260 5 Boiler Installation Make sure that the supply cable and all external cables are secured and away from hot surfaces. FIXING SCREWS 5.10 Testing 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.

  • Page 261: Commissioning

    6 Commissioning Please ensure the “Benchmark” logbook is completed and left with the user. OVERHEAT 6.1 All Systems SAFETY CUT-OFF Commissioning should be carried out by a competent person in accordance with the current issue of BS6798. Make sure that the system has been thoroughly flushed out with cold water without the pump in place.
  • Page 262 6 Commissioning Fit the combustion chamber front. Reconnect the ignition lead to the PCB. Stick the self adhesive arrow indicator to the data label, against the rating that the boiler is going to be set to, for future reference. SECURING The arrow is in the loose items pack.
  • Page 263 6 Commissioning Turn the control thermostat knob fully anticlockwise to “O”. Remove the pressure gauge from the test point and refit screw, SEAL making sure a gas tight seal is made. SIDE When the control thermostat is turned to the “Off” position, by SEAL hand, wait at least 30 seconds before turning “On”...

  • Page 264: Servicing

    7 Instructions to the User Instruct and demonstrate the safe and efficient operation of the It is the Law that servicing is carried out by a competent person. boiler, heating system and domestic hot water system. Advise the user of the precautions necessary to prevent damage Advise the user, that to ensure the continued efficient and safe to the system and building in the event of the heating system operation of the boiler it is recommended that it is checked and...
  • Page 265 8 Servicing Remove the main burner from the main injector at the rear. Raise the burner up and forwards, easing the pilot pipe down, to clear, take care not to damage the combustion chamber insulation or the pilot p[pipe. Use a vacuum cleaner or suitable stiff brush to clean the burner thoroughly, making sure that all the burner ports are clear and unobstructed.

  • Page 266: Fault Finding

    9 Fault Finding 9.1 Electrical 9.2 Electrical Supply Failure Important. On completion of the Service/Fault Finding task Failure of the electrical supply will cause the burner to go out. which has required the breaking and remaking of the electrical Operation will normally resume on restoration of the electrical connections the earth continuity, polarity, short circuit and supply.
  • Page 267 9 Fault Finding Before detailed checking of electrical components ensure that remote controls are calling for heat. Check the gas supply is free of obstructions and purged of air. Check the overheat cutoff has not operated. For fully pumped systems only. Isolate the electrical supply and physically check ALL cables, connections and the printed circuit board fuse.
  • Page 268 9 Fault Finding Pump Overrun Operation For Fully Pumped System Only The PCB has a timed pump overrun facility. The pump should run for several minutes after remote controls have stopped calling for heat. Before using the fault finding chart ensure all wiring is correct and in good condition, the pump is not faulty and check the PCB fuse F2 Does the pump run when SL is applied ? Faulty PCB.
  • Page 269 9 Fault Finding bk BLACK or ORANGE br BROWN w WHITE BLUE PURLPLE YELLOW LINK PUMP SPARK ELECTRODE O/H CUTOFF FUSE F1 & F2 (F1A) CONTROL STAT (N/O) PRESSURE SWITCH (N/C) PILOT SOLENOID MAIN SOLENOID Remove red link between 9 and SL when fitting a time control etc (if no switch is fitted, link will make the circulation pump run constantly) AIR PRESSURE SWITCH CONNECTIONS...
  • Page 270 9 Fault Finding KEY: FULLY PUMPED OPEN - BLUE VENTED OR SEALED bk - BLACK WATER SYSTEM - BROWN g/y - GREEN/YELLOW - ORANGE - RED MULTI-FUNCTIONAL - YELLOW CONTROL - WHITE - PURPLE PRESSURE SWITCH ELECTRODE PLUG CHASSIS CHASSIS EARTH EARTH Remove red link between 9 and SL when fitting a time control etc (If no switch is fitted, link...
  • Page 271 10 Replacement of Parts 10 Replacement of Parts CONTROL THERMOSTAT Note. Replacement of parts must only be carried out by a SHAKEPROOF competent person. WASHERS AND Before replacing any parts isolate the boiler from the electrical SCREWS supply and turn the gas supply off at the gas service cock, indicator slot should be vertical.
  • Page 272 10 Replacement of Parts BOILER PHIAL THERMOSTAT ELECTRICAL PLUGS POCKET ELECTRICAL SPLIT CONNECTION NO.3"YELLOW" THERMOSTAT CABLE PUMP OVERHEAT OVERRUN CUTOFF PHIAL ELECTRICAL CONNECTION OVERHEAT "WHITE" CUTOFF PHIAL CABLE DEVICE POCKET PHIAL CHASSIS EARTH CONNECTION SUPPORT IGNITION POST (4) LEAD SPLIT RETAINING CLIP MAIN...
  • Page 273 10 Replacement of Parts 10.7 Multifunctional Control - diagram 10.3 Disconnect the pilot supply by unscrewing the tubing nut at the multifunctional control, take care as there is a restrictor on the pilot pipe. RESTRICTOR Disconnect the electrical plug. Support the multifunctional control, remove the four extended screws from the flanged connections at the left and right hand PILOT PIPE side.
  • Page 274 10 Replacement of Parts MICA WINDOW RETAINING SCREW OPENING (INSIDE FACE OF THE BOILER FRONT COVER) FRONT INSULATION PEEL OFF SELF ADHESIVE BACKING ALUMINIUM FOIL PAPER GASKET Diagram 10.5 CLEAR AIR PRESSURE SWITCH TUBES SECURING SCREWS SIDE INSULATION REAR INSULATION PRESSURE SWITCH Diagram 10.4...

  • Page 275: Spare Parts

    10 Spare Parts 11.1 Part Identification The key number on the diagram and the list will help to identify the part. 11.2 Ordering When ordering any spare parts please quote the number and description from the list together with the model name and serial number.
  • Page 276 11 Spare Parts Diagram 11.1 Because of our constant endeavour for improvement, details may vary slightly from those shown in these instructions. 221965B...
  • Page 277 221420F.12.00 Instructions for Use Installation and Servicing To b e l e f t w i t h t h e u s e r 70FF 80FF G.C. No. 41 319 86 G.C. No.41 319 60 Cat I Cat II 2H3P Fanned Flue Boiler BS 6332...
  • Page 278 Important Information Testing and Certification This boiler is tested and certificated for safety and performance. It is therefore important that no alteration is made to the boiler, without permission, in writing, from Hepworth Heating Ltd. Any alteration not approved by Hepworth Heating Ltd., could invalidate the certification, boiler warranty and may also infringe the current issue of the Statutory Requirements, see Section 1.4.
  • Page 279 Instructions for Use To obtain service, please call your installer or Heatcall (Glow- Introduction worm’s own Service Organisation) using the telephone number WARNING. It is important that the case (not the controls tray) given on the controls tray. is not disturbed or removed other than for servicing by a Please be advised that the ‘Benchmark’...
  • Page 280 Instructions for Use To Light the Boiler Cleaning WARNING. Sealed Systems WARNING. This appliance contains metal parts (components) and care should be taken when handling and cleaning, with A sealed water system must be filled and pressurised by a particular regard to edges. competent person.
  • Page 281 1 General Data WATER CONNECTIONS 22mm COPPER PIPE GAS CONNECTIONS in. BSPT) SIDE ELEVATION FRONT ELEVATION MODEL 70FF/80FF Diagram 1.1 1.1 Statutory Requirements Important Notice The installation of the boiler must be carried out by a competent This boiler is for use only on G20 gas, but the 80FF may be person in accordance with the relevant requirements of the converted for use on G31 gas (Propane L.P.G.) with an available conversion kit.
  • Page 282 1 General Data TABLE 2. 70FF DATA TABLE 1. RANGE RATING Min. Medium Max. MODEL 70FF/80FF NOMINAL 22.39 24.03 25.64 TOTAL DRY HEAT WEIGHT 51 kg (112 lb) INPUT(GROSS)Btu/h 76,400 82,000 87,500 (Including Terminal) NOMINAL 17.58 19.05 20.52 HEAT LIFT 45.3 kg (100lb) OUTPUT Btu/h...
  • Page 283 1 General Data 1.9 Drain System A drain tap must be provided at the lowest points of the system which will allow the entire system, boiler and hot water cylinder be drained. 500mm Draining taps should be to the current issue of BS2879. Boiler A draining point is fitted at the bottom right hand side of the heat Additional clearances may be...
  • Page 284 2 Flue and Ventilation Note. Detailed recommendations for flue are given in the current issue of BS5440 Part 1. 2.1 Terminal Position The minimum acceptable siting dimensions for the terminal from obstructions, other terminals and ventilation openings are shown in diagram 2.1. The terminal must be exposed to the external air, the position allowing free passage of air across it at all times.
  • Page 285 3 Water Systems The installation of the boiler must comply with the requirements of the current issue of BS6798. 80FF 1000 3.1 Frost Protection 70FF If the position of the boiler is such that it may be vulnerable to freezing it should be protected as specified in the current issue of BS5422.
  • Page 286 3 Water Systems OPEN VENTED FULLY PUMPED WATER SYSTEM FLOW RECOMMENDED RELATIONSHIP BETWEEN PUMP COLD FEED AND VENT RETURN 28mm 22mm VENT (MIN.) PIPE 450mm MIN. HEIGHT 15mm (MINIMUM) COLD FEED FEED AND EXPANSION 22 X 28 CISTERN UNION 1150mm CONNECTION MIN.
  • Page 287 3 Water Systems 3 LITRES (0.66 gals) MAKE-UP BOTTLE RELEASE (if required) POINT AUTO VENT NON-RETURN VALVE FILLING POINT IF REQUIRED 22mm (min) BY-PASS WITH LOCKSHIELD VALVE FLOW CIRCULATING SAFETY PUMP VALVE PRESSURE GAUGE RETURN DRAIN COCK (Make-up BOILER alternatives) EXPANSION VESSEL Diagram 3.4...
  • Page 288 4 Flue and Appliance Preparation 4.1 Unpacking 4.3 Flue Preparation Open the carton, check the items supplied against the boiler All flue assemblies are designed for internal installation (optional pack contents list on the flap, see diagram 4.1. wall liner is required), given that there is sufficient clearances opposite to the flue for the installation of the flue.
  • Page 289 4 Flue and Appliance Preparation For a wall thickness up to 300mm, provided that there is sufficient space and the optional wall liner kit is used the flue can be fully installed from the inside. For a wall thickness of over 300mm the external flue hole will 115mm need to be made good from the outside.
  • Page 290 4 Flue and Appliance Preparation Drill holes and plug, to suit No.12x2in woodscrews, fit the screws allowing sufficient clearance, about 5mm, to accept the swing brackets, see diagram 4.5. Secure the mounting bracket to the wall with No.12x2in woodscrews and plugs, see diagram 4.5. 4.7 Flue Duct Mark the duct to the length required, this length allows for expansion, see diagram 4.6 for rear flue and diagram 4.7 for...
  • Page 291 4 Flue and Appliance Preparation 4.10 Rear Fitting Fit the self adhesive foam seal provided in the flue pack around the air duct/terminal at the position shown in diagram 4.13. 4.11 Side Fitting Fit the self adhesive foam seal around the air duct/terminal such that, when installed, the seal will be within the wall, see diagram 4.14.
  • Page 292 4 Flue and Appliance Preparation 4.12 Flue Assembly - Installation If the boiler is not to be fitted for some time cover the hole in the wall. On limited access installations push the flue assembly into and through the hole such that it is within the wall and does not stick out into the room, see diagram 4.12.
  • Page 293 5 Boiler Installation 5 Boiler Preparation With the boiler still in the bottom tray, slide the controls tray CONTROLS upwards and remove it as shown in diagram 5.1. COVER Remove the front cover by undoing (and keeping) the screw and wing nuts and lifting the front cover off, see diagram 5.1.
  • Page 294 5 Boiler Installation 5.3 Water Circulation System ELECTRICAL AIR PRESSURE TUBES CONNECTIONS Complete the water connections to the boiler. CLEAR RED Fill, vent and flush the system. Check for any water leaks and put right. 5.4 Safety Valve Discharge Fit a suitable discharge pipe to the safety valve and route it to outside the building so that any discharge can be seen but will not cause injury to persons, damage to property or any electrical installation.
  • Page 295 5 Boiler Installation SCREW SIDE REAR RIGHT 2.5mm dia.drill JUBILEE CLIP DUCT EXTENSION LEFT RIGHT REAR VERTICAL SIDE LEFT DUCT EXTENSION Cutting 'MARK' lengths. Lefthand flue does not require cutting. FLUE ELBOW Diagram 5.6 5.7 Electrical Connection WARNING. This boiler must be earthed. (REAR FLUE OUTLET ILLUSTRATED) Take care not to damage any internal wiring and capillaries.
  • Page 296 5 Boiler Installation Make sure that the supply cable and all external cables are secured and away from hot surfaces. FIXING SCREWS 5.10 Testing 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.
  • Page 297 6 Commissioning Please ensure the “Benchmark” logbook is completed and left with the user. OVERHEAT 6.1 All Systems SAFETY CUT-OFF Commissioning should be carried out by a competent person in accordance with the current issue of BS6798. Make sure that the system has been thoroughly flushed out with cold water without the pump in place.
  • Page 298 6 Commissioning Fit the combustion chamber front. Reconnect the ignition lead to the PCB. Stick the self adhesive arrow indicator to the data label, against the rating that the boiler is going to be set to, for future reference. SECURING The arrow is in the loose items pack.
  • Page 299 6 Commissioning Turn the control thermostat knob fully anticlockwise to “O”. Remove the pressure gauge from the test point and refit screw, SEAL making sure a gas tight seal is made. SIDE When the control thermostat is turned to the “Off” position, by SEAL hand, wait at least 30 seconds before turning “On”...
  • Page 300 7 Instructions to the User Instruct and demonstrate the safe and efficient operation of the It is the Law that servicing is carried out by a competent person. boiler, heating system and domestic hot water system. Advise the user of the precautions necessary to prevent damage Advise the user, that to ensure the continued efficient and safe to the system and building in the event of the heating system operation of the boiler it is recommended that it is checked and...
  • Page 301 8 Servicing Remove the securing screw from the burner support bracket, see diagram 8.4. Remove the main burner from the main injector at the rear. Raise the burner up and forwards, easing the pilot pipe down, to clear, take care not to damage the combustion chamber insulation or the pilot p[pipe.
  • Page 302 9 Fault Finding 9.1 Electrical 9.2 Electrical Supply Failure Important. On completion of the Service/Fault Finding task Failure of the electrical supply will cause the burner to go out. which has required the breaking and remaking of the electrical Operation will normally resume on restoration of the electrical connections the earth continuity, polarity, short circuit and supply.
  • Page 303 9 Fault Finding Before detailed checking of electrical components ensure that remote controls are calling for heat. Check the gas supply is free of obstructions and purged of air. Check the overheat cutoff has not operated. For fully pumped systems only. Isolate the electrical supply and physically check ALL cables, connections and the printed circuit board fuse.
  • Page 304 9 Fault Finding Pump Overrun Operation For Fully Pumped System Only The PCB has a timed pump overrun facility. The pump should run for several minutes after remote controls have stopped calling for heat. Before using the fault finding chart ensure all wiring is correct and in good condition, the pump is not faulty and check the PCB fuse F2 Does the pump run when SL is applied ? Faulty PCB.
  • Page 305 9 Fault Finding bk BLACK or ORANGE br BROWN w WHITE BLUE PURLPLE YELLOW LINK PUMP SPARK ELECTRODE O/H CUTOFF FUSE F1 & F2 (F1A) CONTROL STAT (N/O) PRESSURE SWITCH (N/C) PILOT SOLENOID MAIN SOLENOID Remove red link between 9 and SL when fitting a time control etc (if no switch is fitted, link will make the circulation pump run constantly) AIR PRESSURE SWITCH CONNECTIONS...
  • Page 306 9 Fault Finding KEY: FULLY PUMPED OPEN - BLUE VENTED OR SEALED bk - BLACK WATER SYSTEM - BROWN g/y - GREEN/YELLOW - ORANGE - RED MULTI-FUNCTIONAL - YELLOW CONTROL - WHITE - PURPLE PRESSURE SWITCH ELECTRODE PLUG CHASSIS CHASSIS EARTH EARTH Remove red link between 9 and SL when fitting a time control etc (If no switch is fitted, link...
  • Page 307 10 Replacement of Parts 10 Replacement of Parts CONTROL THERMOSTAT Note. Replacement of parts must only be carried out by a SHAKEPROOF competent person. WASHERS AND Before replacing any parts isolate the boiler from the electrical SCREWS supply and turn the gas supply off at the gas service cock, indicator slot should be vertical.
  • Page 308 10 Replacement of Parts BOILER PHIAL THERMOSTAT ELECTRICAL PLUGS POCKET ELECTRICAL SPLIT CONNECTION NO.3"YELLOW" THERMOSTAT CABLE PUMP OVERHEAT OVERRUN CUTOFF PHIAL ELECTRICAL CONNECTION OVERHEAT "WHITE" CUTOFF PHIAL CABLE DEVICE POCKET PHIAL CHASSIS EARTH CONNECTION SUPPORT IGNITION POST (4) LEAD SPLIT RETAINING CLIP MAIN...
  • Page 309 10 Replacement of Parts 10.7 Multifunctional Control - diagram 10.3 Disconnect the pilot supply by unscrewing the tubing nut at the multifunctional control, take care as there is a restrictor on the pilot pipe. RESTRICTOR Disconnect the electrical plug. Support the multifunctional control, remove the four extended screws from the flanged connections at the left and right hand PILOT PIPE side.
  • Page 310 10 Replacement of Parts MICA WINDOW RETAINING SCREW OPENING (INSIDE FACE OF THE BOILER FRONT COVER) FRONT INSULATION PEEL OFF SELF ADHESIVE BACKING ALUMINIUM FOIL PAPER GASKET Diagram 10.5 CLEAR AIR PRESSURE SWITCH TUBES SECURING SCREWS SIDE INSULATION REAR INSULATION PRESSURE SWITCH Diagram 10.4...
  • Page 311 10 Replacement of Parts 11.1 Part Identification The key number on the diagram and the list will help to identify the part. 11.2 Ordering When ordering any spare parts please quote the number and description from the list together with the model name and serial number.
  • Page 312 11 Spare Parts Diagram 11.1 Because of our constant endeavour for improvement, details may vary slightly from those shown in these instructions. 221420F...
  • Page 313 221966B.04.03 Instructions for Use Installation and Servicing To b e l e f t w i t h t h e u s e r 100FF 120FF G.C. No. 41 047 59 G.C. No. 41 319 75 Fanned Flue Boiler BS 6332 BS 5258 This is a Cat I...
  • Page 314 Important Information Testing and Certification This boiler is tested and certificated for safety and performance. It is therefore important that no alteration is made to the boiler, without permission, in writing, from Hepworth Heating Ltd. Any alteration not approved by Hepworth Heating Ltd., could invalidate the certification, boiler warranty and may also infringe the current issue of the Statutory Requirements, see Section 1.4.
  • Page 315 Important Information CONTENTS DESCRIPTION SECTION PAGE No. Introduction INSTRUCTIONS Lighting the Boiler FOR USE General Data INSTALLATION Flue Terminal INSTRUCTIONS Water Systems Flue and Appliance Preparation Boiler Installation Flue Fixing Electrical Connectors Commissioning Instructions to the User Servicing SERVICING Fault Finding INSTRUCTIONS Replacement of Parts Spare Parts...
  • Page 316 Instructions for Use Maintenance CONTROLS COVER To ensure the continued efficient and safe operation of the boiler it is recommended that it is checked and serviced as necessary at regular intervals. The frequency of servicing will depend upon the particular installation conditions and usage, but in general once a year should be enough.
  • Page 317 Instructions for Use To Light the Boiler WARNING. Sealed Systems A sealed water system must be filled and pressurised by a competent person. Only light the boiler when you are sure that the system has been filled and pressurised. The pressure gauge should show at least 0.7bar, anything less than this figure could indicate a leak and you MUST contact your 500mm installation/servicing company.
  • Page 318 1 General WATER CONNECTIONS 28mm COPPER PIPE GAS CONNECTIONS in. BSPT) SIDE ELEVATION FRONT ELEVATION MODEL 132.5 100FF,120FF 78.5 Diagram 1.1 Important Notice 1.1 Statutory Requirements This boiler is for use only on G20 gas. The installation of the boiler must be carried out by a competent person in accordance with the relevant requirements of the This boiler can be used on an open vented or sealed water current issue of:-...
  • Page 319 1 General TABLE 2. 100FF DATA TABLE 1. Med. Max. RANGE RATING Min. MODEL 100FF 120FF NOMINAL TOTAL DRY 26.44 29.24 32.38 HEAT WEIGHT 71.0 kg 71.0 kg 90,210 99,760 110,485 INPUT(NETT) Btu/h (Including (157 lb) (157 lb) Terminal) NOMINAL 23.45 26.38 29.31...
  • Page 320 1 General 1.8 Water System This boiler may be fitted to an open vented or sealed water system. It is recommended that plastic pipes for primary pipework should not be used for this boiler. PLAN 1.9 Drain VIEW 500mm System A draining tap must be provided at the lowest points of the Additional clearances may be required for installation...
  • Page 321 2 Flue Terminal Note. Detailed recommendations for flues are given in the current issue of BS5440 Part 1. 2.1 Terminal Position The minimum acceptable siting dimensions for the terminal from obstructions, other terminals and ventilation openings are shown in diagram 2.1. The terminal must be exposed to the external air, the position allowing free passage of air across it at all times.

  • Page 322: Water Systems

    3 Water Systems The installation of the boiler must comply with the requirements of the current issue of BS6798. It is recommended that plastic pipes for primary pipework should not be used for this boiler. 700mm (120FF 3.1 Frost Protection If the position of the boiler is such that it may be vulnerable to 450mm (100FF freezing it should be protected as specified in the current issue...
  • Page 323 3 Water Systems RETURN FLOW OPEN VENTED FULLY PUMPED WATER SYSTEM RECOMMENDED RELATIONSHIP BETWEEN PUMP COLD FEED AND VENT 28mm 22mm VENT PIPE (MIN.) 450mm MIN. FEED AND HEIGHT EXPANSION CISTERN 15mm (MINIMUM) COLD FEED 1150mm MIN. PUMP 22mm VENT & 15mm COLD FEED TO BE FITTED IN ACCORDANCE WITH BS 5449 There must...
  • Page 324 3 Water Systems 3 LITRES (0.66 gals) MAKE-UP BOTTLE RELEASE (if required) POINT AUTO VENT NON-RETURN FILLING POINT VALVE FLOW CIRCULATING PUMP 22mm (min) BY-PASS WITH SAFETY LOCKSHIELD PRESSURE VALVE VALVE GAUGE RETURN DRAIN COCK (Make-up (Make-up alternatives) alternatives) EXPANSION VESSEL BOILER Diagram 3.4...

  • Page 325: Flue And Appliance Preparation

    4 Flue and Appliance Preparation 4.1 Unpacking For a wall thickness up to 300mm, provided that there is sufficient space and the optional wall liner kit is used the flue can Open the carton, check the items supplied against the boiler be fully installed from the inside.
  • Page 326 4 Flue and Appliance Preparation 4.4. Rear and Side Flue Application Take the template from the boiler pack and position it on the wall, making sure that the minimum clearances are maintained, see diagram 1.2. For a rear flue mark the position of the flue as diagram 4.4. 120 mm For a side flue, extend the centre line horizontally left or right to MINIMUM...
  • Page 327 4 Flue and Appliance Preparation 4.7 Flue Length For a rear flue, measure the distance from the outside wall face to the boiler mounting wall. Check that the flue length will be suitable, see diagram 4.2. For a side flue, measure the distance from the outside wall face to the boiler centre line.
  • Page 328 4 Flue and Appliance Preparation FOAM SEAL LONG FLUE TERMINAL STANDARD FLUE TERMINAL 20mm WALL THICKNESS- T MINUS 55mm UP TO 300mm FOAM SEAL BOILER CENTRE LINE Q MINUS 55mm WALL THICKNESS- OVER 300mm Diagram 4.9 Diagram 4.11 FLUE ELBOW SECURING SCREW (2) SEALING TAPE...

  • Page 329: Boiler Installation

    5 Boiler Installation Break the air pressure switch tube connections from the fan, 5.1 Boiler Preparation see diagram 5.3. With the boiler still in the bottom tray, slide the controls cover Remove the fan assembly by removing the screws and sliding upwards and remove it as shown in diagram 5.1.
  • Page 330 5 Boiler Installation 5.3 Water Circulation System Complete the water connections to the boiler. Fill, vent and flush system. Check for any leaks and put right. 5.4 Safety Valve Discharge Fit a suitable discharge pipe to the safety valve and route it outside the building so that any discharge can be seen but will not cause injury to person, damage to property or any electrical installation.
  • Page 331 6 Flue Fixing Note. If external flue fixing is required start at 6.2. 6.1 Flue Fixing - Internal Note : Use of the optional wall liner kit is required. 152 DIA Place the flue assembly into the hole. Check that the flue CORE terminal is correctly positioned and is the distance required from DRILLED...
  • Page 332 7 Electrical Connectors 7.1 Control Box Removal Remove the electrical control box securing screws, see diagram 7.1. Slide the box forwards and release, hook it onto the lip bracket at the front, see diagram 7.1. SECURING SCREWS (2) 7.2 Electrical Connection WARNING.

  • Page 333: Commissioning

    8 Commissioning Please ensure the "Benchmark" logbook is completed and left with the user. 8.1 All Systems Commissioning should be carried out by a competent person in accordance with the current issue of BS6798. Make sure that the system has been thoroughly flushed out with cold water without the pump in place.
  • Page 334 8 Commissioning Fit the combustion chamber front. Reconnect the ignition lead to the PCB. For future reference, stick the self adhesive arrow indicator to the data label, against the rating that the boiler is going to be set to. The arrow is in the loose items pack. 10 to 20mm FLAME LENGTH Loosen the main burner pressure test point screw and connect a suitable pressure gauge, see diagram 8.4.
  • Page 335 8 Commissioning 8.8 Sealed Water System ONLY Turn the control thermostat knob fully anticlockwise to “O”. Remove the pressure gauge from the test point and refit screw, Adjust system to initial design pressure. The set pointer on the making sure a gas tight seal is made. pressure gauge should be set to coincide with the indicating When the control thermostat is turned to “Off”...

  • Page 336: Servicing

    8 Commissioning 8.10 Operational Checks and Completion 8.11 Protection against Freezing Adjust the control thermostat and any system controls to their If the boiler is to be out of use for a period of time during severe required settings. weather conditions we recommended that the whole of the system, including the boiler, be drained off to avoid the risk of Do not attempt to adjust the thermostat calibration screw.
  • Page 337 10 Servicing 10.2 Cleaning Heat Exchanger and Burner Disconnect the air pressure tubes, see diagram 5.3. Remove the blue and red electrical connections from the fan, see diagram 5.3. Remove the fan taking care not to damage the gasket, see diagram 5.3.
  • Page 338 10 Servicing 10.4 Electrode, Pilot Burner and Pilot Injector 10.5 Operational Checks Clean the pilot burner and electrode. After completing a service and before fitting the case, check condition of the case seal and renew if necessary. 100FF Model Only. To remove the electrode release the spring clip, see diagram 10.7.

  • Page 339: Fault Finding

    11 Fault Finding 11.1 Electrical 11.2 Electrical Supply Failure Important. On completion of the Service/Fault Finding task Failure of the electrical supply will cause the burner to go out. which has required the breaking and remaking of the electrical Operation will normally resume on the restoration of the electrical connections, the earth continuity, polarity and short circuit and supply.
  • Page 340 11 Fault Finding Before detailed checking of electrical components ensure that remote controls are calling for heat. Check the gas supply is free of obstructions and purged of air. Check the overheat cutoff has not operated. For fully pumped systems only. Isolate the electrical supply and physically check ALL cables, connections and the printed circuit board fuse.
  • Page 341 11 Fault Finding bk BLACK or ORANGE br BROWN w WHITE BLUE PURPLE YELLOW GREY SPARK ELECTRODE LINK PUMP FUSE TYPE F1 & F2 LINK (F1A) WATER PRESSURE SWITCH Pump overrun Operation for Fully CONTROL Pumped System Only STAT The PCB has a pump overrun facility. The pump should run for several minutes after remote controls have stopped calling for heat.
  • Page 342 11 Fault Finding WATER PRESSURE - YELLOW - BLUE SWITCH - WHITE - BLACK - PURPLE - BROWN - GREY g/y - GREEN/ YELLOW - RED MULTI-FUNCTIONAL CONTROL ELECTRODE PLUG PRESSURE SEQUENCE SWITCH BOARD CHASSIS EARTH CHASSIS EARTH NOTE:- Bridge out Water Pressure Switch between K1 &...
  • Page 343 12 Replacement of Parts Note. Replacement of parts must only be carried out by a CONTROL competent person. THERMOSTAT Before replacing any parts isolate the boiler from the electrical supply and turn the gas supply off at the gas service cock, SHAKEPROOF indicator slot to be vertical.
  • Page 344 12 Replacement of Parts 12.4 Control Board (PCB) - diagram 12.2A 12.7 Multifunctional Control - diagram 10.3 Release the control box, refer to Section 7.1. Disconnect the pilot supply by unscrewing the tubing nut at the multifunctional control. Disconnect the three electrical plugs and ignition lead. 120FF ONLY.
  • Page 345 12 Replacement of Parts 12.9 Main Burner SECURING SCREW Remove the main burner as Section 10.2. 12.10 Main Injector Remove the main burner as Section 10.2. Remove the main injector as Section 10.3. 12.11 Insulation - diagram 12.4 FRONT INSULATION Combustion Chamber Front Remove the retaining screw then the insulation.

  • Page 346: Spare Parts

    12 Replacement of Parts 12.15 Water Pressure Switch - Sealed Water 12.14 Fan - diagram 5.3 System Only Remove the electrical connections and disconnect the air pressure tubes. Release the water pressure and drain, refer to Section 3. Remove the fan assembly securing screws. Disconnect the electrical connections at the microswitch, see diagram 12.7.
  • Page 347 13 Spare Parts Key No Part No Description GC Part No 800442 Multifunctional control 278 021 208040 “O” ring 334 592 205727 Injector - 100FF 278 197 205726 Injector - 120FF 278 196 203432 Pilot burner - 100FF 278 023 203434 Pilot burner - 120FF E00 998...
  • Page 348 Because of our constant endeavour for improvement, details may vary slightly from those shown in these instructions. 221966B...
  • Page 349 221865B.11.00 Instructions for Use Installation and Servicing T o b e l e f t w i t h t h e u s e r 100FF 120FF G.C. No. 41 319 61 G.C. No. 41 319 75 Fanned Flue Boiler BS 6332 BS 5258 This is a Cat I...
  • Page 350 Important Information Testing and Certification This boiler is tested and certificated for safety and performance. It is therefore important that no alteration is made to the boiler, without permission, in writing, from Hepworth Heating Ltd. Any alteration not approved by Hepworth Heating Ltd., could invalidate the certification, boiler warranty and may also infringe the current issue of the Statutory Requirements, see Section 1.4.
  • Page 351 Important Information CONTENTS DESCRIPTION SECTION PAGE No. Introduction INSTRUCTIONS Lighting the Boiler FOR USE General Data INSTALLATION Flue Terminal Water Systems INSTRUCTIONS Flue and Appliance Preparation Boiler Installation Flue Fixing Electrical Connectors Commissioning Instructions to the User Servicing SERVICING Fault Finding INSTRUCTIONS Replacement of Parts Spare Parts...
  • Page 352 Instructions for Use Maintenance CONTROLS COVER To ensure the continued efficient and safe operation of the boiler it is recommended that it is checked and serviced as necessary at regular intervals. The frequency of servicing will depend upon the particular installation conditions and usage, but in general once a year should be enough.
  • Page 353 Instructions for Use To Light the Boiler WARNING. Sealed Systems A sealed water system must be filled and pressurised by a competent person. Only light the boiler when you are sure that the system has been filled and pressurised. The pressure gauge should show at least 0.7bar, anything less than this figure could indicate a leak and you MUST contact your 500mm installation/servicing company.
  • Page 354 1 General WATER CONNECTIONS 28mm COPPER PIPE GAS CONNECTIONS in. BSPT) SIDE ELEVATION FRONT ELEVATION MODEL 132.5 100FF,120FF 78.5 Diagram 1.1 Important Notice 1.1 Statutory Requirements This boiler is for use only on G20 gas. The installation of the boiler must be carried out by a competent person in accordance with the relevant requirements of the This boiler can be used on an open vented or sealed water current issue of:-...
  • Page 355 1 General DATA TABLE 1. TABLE 2. 100FF Med. Max. MODEL 100FF 120FF RANGE RATING Min. NOMINAL TOTAL DRY 29.87 33.25 36.64 HEAT WEIGHT 71.0 kg 71.0 kg 101,900 113,450 125,000 INPUT(GROSS) Btu/h (Including (157 lb) (157 lb) Terminal) NOMINAL 23.45 26.38 29.31...
  • Page 356 1 General 1.8 Water System This boiler may be fitted to an open vented or sealed water system. 1.9 Drain PLAN System VIEW 500mm A draining tap must be provided at the lowest points of the system which will allow the entire system, boiler and hot water cylinder to be drained.
  • Page 357 2 Flue Terminal Note. Detailed recommendations for flues are given in the current issue of BS5440 Part 1. 2.1 Terminal Position The minimum acceptable siting dimensions for the terminal from obstructions, other terminals and ventilation openings are shown in diagram 2.1. The terminal must be exposed to the external air, the position allowing free passage of air across it at all times.
  • Page 358 3 Water Systems The installation of the boiler must comply with the requirements of the current issue of BS6798. 3.1 Frost Protection 700mm (120FF If the position of the boiler is such that it may be vulnerable to freezing it should be protected as specified in the current issue of BS5422.
  • Page 359 3 Water Systems RETURN FLOW OPEN VENTED FULLY PUMPED WATER SYSTEM RECOMMENDED RELATIONSHIP BETWEEN PUMP COLD FEED AND VENT 28mm 22mm VENT PIPE (MIN.) 450mm MIN. FEED AND HEIGHT EXPANSION CISTERN 15mm (MINIMUM) COLD FEED 1150mm MIN. PUMP 22mm VENT & 15mm COLD FEED TO BE FITTED IN ACCORDANCE WITH BS 5449 There must...
  • Page 360 3 Water Systems 3 LITRES (0.66 gals) MAKE-UP BOTTLE RELEASE (if required) POINT AUTO VENT NON-RETURN FILLING POINT VALVE FLOW CIRCULATING PUMP 22mm (min) BY-PASS WITH SAFETY LOCKSHIELD PRESSURE VALVE VALVE GAUGE RETURN DRAIN COCK (Make-up (Make-up alternatives) alternatives) EXPANSION VESSEL BOILER Diagram 3.4...
  • Page 361 4 Flue and Appliance Preparation 4.1 Unpacking For a wall thickness up to 300mm, provided that there is sufficient space and the optional wall liner kit is used the flue can Open the carton, check the items supplied against the boiler be fully installed from the inside.
  • Page 362 4 Flue and Appliance Preparation 4.4. Rear and Side Flue Application Take the template from the boiler pack and position it on the wall, making sure that the minimum clearances are maintained, see diagram 1.2. For a rear flue mark the position of the flue as diagram 4.4. 152 mm For a side flue, extend the centre line horizontally left or right to MINIMUM...
  • Page 363 4 Flue and Appliance Preparation 4.7 Flue Length For a rear flue, measure the distance from the outside wall face to the boiler mounting wall. Check that the flue length will be suitable, see diagram 4.2. For a side flue, measure the distance from the outside wall face to the boiler centre line.
  • Page 364 4 Flue and Appliance Preparation FOAM SEAL LONG FLUE TERMINAL STANDARD FLUE TERMINAL 20mm WALL THICKNESS- T MINUS 55mm UP TO 300mm FOAM SEAL BOILER CENTRE LINE Q MINUS 55mm WALL THICKNESS- OVER 300mm Diagram 4.9 Diagram 4.11 FLUE ELBOW SECURING SCREW (2) SEALING TAPE...
  • Page 365 5 Boiler Installation Break the air pressure switch tube connections from the fan, 5.1 Boiler Preparation see diagram 5.3. With the boiler still in the bottom tray, slide the controls cover Remove the fan assembly by removing the screws and sliding upwards and remove it as shown in diagram 5.1.
  • Page 366 5 Boiler Installation 5.3 Water Circulation System Complete the water connections to the boiler. Fill, vent and flush system. Check for any leaks and put right. 5.4 Safety Valve Discharge Fit a suitable discharge pipe to the safety valve and route it outside the building so that any discharge can be seen but will not cause injury to person, damage to property or any electrical installation.
  • Page 367 6 Flue Fixing Note. If external flue fixing is required start at 6.2. 6.1 Flue Fixing - Internal Note : Use of the optional wall liner kit is required. 152 DIA Place the flue assembly into the hole. Check that the flue CORE terminal is correctly positioned and is the distance required from DRILLED...
  • Page 368 7 Electrical Connectors 7.1 Control Box Removal Remove the electrical control box securing screws, see diagram 7.1. Slide the box forwards and release, hook it onto the lip bracket at the front, see diagram 7.1. SECURING SCREWS (2) 7.2 Electrical Connection WARNING.
  • Page 369 8 Commissioning Please ensure the "Benchmark" logbook is completed and left with the user. 8.1 All Systems Commissioning should be carried out by a competent person in accordance with the current issue of BS6798. Make sure that the system has been thoroughly flushed out with cold water without the pump in place.
  • Page 370 8 Commissioning Fit the combustion chamber front. Reconnect the ignition lead to the PCB. For future reference, stick the self adhesive arrow indicator to the data label, against the rating that the boiler is going to be set to. The arrow is in the loose items pack. 10 to 20mm FLAME LENGTH Loosen the main burner pressure test point screw and connect a suitable pressure gauge, see diagram 8.4.
  • Page 371 8 Commissioning 8.8 Sealed Water System ONLY Turn the control thermostat knob fully anticlockwise to “O”. Remove the pressure gauge from the test point and refit screw, Adjust system to initial design pressure. The set pointer on the making sure a gas tight seal is made. pressure gauge should be set to coincide with the indicating When the control thermostat is turned to “Off”...
  • Page 372 8 Commissioning 8.10 Operational Checks and Completion 8.11 Protection against Freezing Adjust the control thermostat and any system controls to their If the boiler is to be out of use for a period of time during severe required settings. weather conditions we recommended that the whole of the system, including the boiler, be drained off to avoid the risk of Do not attempt to adjust the thermostat calibration screw.
  • Page 373 10 Servicing 10.2 Cleaning Heat Exchanger and Burner Disconnect the air pressure tubes, see diagram 5.3. Remove the blue and red electrical connections from the fan, see diagram 5.3. Remove the fan taking care not to damage the gasket, see diagram 5.3.
  • Page 374 10 Servicing 10.4 Electrode, Pilot Burner and Pilot Injector 10.5 Operational Checks Clean the pilot burner and electrode. After completing a service and before fitting the case, check condition of the case seal and renew if necessary. 100FF Model Only. To remove the electrode release the spring clip, see diagram 10.6.
  • Page 375 11 Fault Finding 11.1 Electrical 11.2 Electrical Supply Failure Important. On completion of the Service/Fault Finding task Failure of the electrical supply will cause the burner to go out. which has required the breaking and remaking of the electrical Operation will normally resume on the restoration of the electrical connections, the earth continuity, polarity and short circuit and supply.
  • Page 376 11 Fault Finding Before detailed checking of electrical components ensure that remote controls are calling for heat. Check the gas supply is free of obstructions and purged of air. Check the overheat cutoff has not operated. For fully pumped systems only. Isolate the electrical supply and physically check ALL cables, connections and the printed circuit board fuse.
  • Page 377 11 Fault Finding bk BLACK or ORANGE br BROWN w WHITE BLUE PURLPLE YELLOW GREY SPARK ELECTRODE LINK PUMP FUSE TYPE F1 & F2 LINK (F1A) WATER PRESSURE SWITCH Pump overrun Operation for Fully CONTROL Pumped System Only STAT The PCB has a pump overrun facility. The pump should run for several minutes after remote controls have stopped calling for heat.
  • Page 378 11 Fault Finding WATER PRESSURE - YELLOW - BLUE SWITCH - WHITE - BLACK - PURPLE - BROWN - GREY g/y - GREEN/ YELLOW - RED MULTI-FUNCTIONAL CONTROL ELECTRODE PLUG PRESSURE SEQUENCE SWITCH BOARD CHASSIS EARTH CHASSIS EARTH NOTE:- Bridge out Water Pressure Switch between K1 &...
  • Page 379 12 Replacement of Parts Note. Replacement of parts must only be carried out by a CONTROL competent person. THERMOSTAT Before replacing any parts isolate the boiler from the electrical supply and turn the gas supply off at the gas service cock, SHAKEPROOF indicator slot to be vertical.
  • Page 380 12 Replacement of Parts 12.4 Control Board (PCB) - diagram 12.2A 12.7 Multifunctional Control - diagram 10.3 Release the control box, refer to Section 7.1. Disconnect the pilot supply by unscrewing the tubing nut at the multifunctional control. Disconnect the three electrical plugs and ignition lead. 120FF ONLY.
  • Page 381 12 Replacement of Parts 12.9 Main Burner SECURING SCREW Remove the main burner as Section 10.2. 12.10 Main Injector Remove the main burner as Section 10.2. Remove the main injector as Section 10.3. 12.11 Insulation - diagram 12.4 FRONT INSULATION Combustion Chamber Front Remove the retaining screw then the insulation.
  • Page 382 12 Replacement of Parts 12.15 Water Pressure Switch - Sealed Water 12.14 Fan - diagram 5.3 System Only Remove the electrical connections and disconnect the air pressure tubes. Release the water pressure and drain, refer to Section 3. Remove the fan assembly securing screws. Disconnect the electrical connections at the microswitch, see diagram 12.7.
  • Page 383 13 Spare Parts Key No Part No Description GC Part No 800442 Multifunctional control 278 021 208040 “O” ring 334 592 205727 Injector - 100FF 278 197 205726 Injector - 120FF 278 196 203432 Pilot burner - 100FF 278 023 203434 Pilot burner - 120FF E00 998...
  • Page 384 Because of our constant endeavour for improvement, details may vary slightly from those shown in these instructions. 221865B...

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