Glow-worm Energysaver 70 Instructions For Use Installation And Servicing

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Installation and Servicing

Energysaver

Cat I

G.C. No.

41 319 92

High Efficiency Boiler

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.

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

T o b e l e f t w i t h t h e u s e r

Cat II

2H3P

G.C. No.

41 319 84

PAS010

Guarantee Registration

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

to offer our customers' a Comprehensive First Year Guarantee.

return as soon as possible.

Service number 01773 828100.

FOR 1ST YEAR GUARANTEE PROTECTION

CALL 0208 247 9857

Customer Services:

Tel: (01773) 828100

Fax: (01773) 828070

Hepworth Heating Ltd.,

Nottingham Road, Belper, Derbyshire. DE56 1JT

General/Sales enquiries:

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

221837B.11.00

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Page 1: Instructions For Use
Guarantee Registration Thank you for installing a new Glow-worm appliance in your home. Glow-worm appliances' are manufactured to the very highest standard so we are pleased to offer our customers' a Comprehensive First Year Guarantee. In the center pages are to be found your Guarantee Registration Card, which we recommend you complete and return as soon as possible.
Page 2: Important Information
Important Information TESTING AND CERTIFICATION CERAMIC FIBRE/INSULATION PADS, GLASSYARN. This boiler is tested and certificated for safety and performance. It is therefore important that no alteration is made to the boiler, These can cause irritation to skin, eyes and the respiratory tract. without permission, in writing, from Hepworth Heating Ltd.
Page 3 Instructions for Use HIGH/LOW CONTROL KNOB GREEN CONTROL LIGHT THERMOSTAT FOR HIGH KNOB FLAME GREEN LIGHT FOR LOW FLAME ORANGE DEMAND LIGHT Diagram 1 Introduction Maintenance/Servicing Please read these instructions and follow them for the safe and To ensure the continued efficient and safe operation of the economical use of your boiler.
Page 4 Instructions for Use Boiler Clearances If fixtures are positioned close to the boiler, space must be left as shown in diagram 3. Enough space must also be left in front of the boiler to allow for servicing. Boilers Installed in a Compartment or Cupboard If the boiler is installed in a cupboard or compartment do not obstruct any ventilation openings.
Page 5 Instructions for Use Overheat Safety Cutoff To Turn the Boiler Off If the cutoff operates on any other occasion than an electrical For short periods, turn thermostat control knob anti-clockwise failure, press the reset button as stated in “Electrical Supply until “O”...
Page 6 1 General FLUE TERMINAL DETAIL Ensure flue slopes 2 ˚ down towards the boiler i.e. 35mm fall per metre of flue length (2 ˚ CONDENSATE DRAIN WATER CONNECTIONS 28mm COPPER GAS CONNECTION DRAIN CONNECTION CAPPED OFF Diagram 1.1 Important Notice Substances Hazardous to Health, The Electricity at Work Regulations and any applicable local regulations.
Page 7 It is, therefore, recommended that any external condensate TABLE 2. Energysaver 70 drain pipe is insulated to prevent it freezing up. RANGE RATING Alternatively, a larger diameter pipe can be used and insulated.
Page 8: Water System
Design Minimum of high efficiency (“condensing”) boilers. Flow Rate Flow Rate If an existing system is to be reused take special care to drain Energysaver 70 26.8L/min 19.6L/m the entire system, including the radiators, then thoroughly Energysaver 80 30.5L/min 22.5L/m cleaning out before fitting the boiler whether or not adding an inhibitor.
Page 9 2 Water System 2.8 Domestic Hot Water System - Unvented Open (vented) ststem. Recommended Where a storage system will not have a vent to atmosphere the rellationship between installation must comply with the Building Regulations and local 450mm pump,cold feed and vent. Water Company bylaws, see also the current issue of BS5546 MIN.
Page 10 2 Water Sytem 2.11 Expansion Vessel 0051M METHOD 1 COMBINED A diaphragm type expansion vessel, conforming to the current CHECK VALVE HEATING issue of BS4814 (see also BS7074 Part 1 and 2) must be TEMPORARY AND VACUUM SYSTEM connected at a point close to the inlet side of the circulating HOSE BREAKER pump, see the diagrammatic layout, diagram 2.4 unless laid...
Page 11: Boiler Location
A compartment used to enclose the boiler must be designed Diagram 3.1 and constructed specifically for this purpose. The doorway opening should be of sufficient size to allow for TABLE 4 easy removal of the boiler. ENERGYSAVER 70 high level low level Ventilation from 32.6 32.6...
Page 12 4 Flue NOTE: The flue must be installed in accordance with the current issue of BS5440 Part 1. Important. The flue must be installed with a fall of: 35mm per metre (2 ) TOWARDS the boiler, see diagram 4.1. It is of no advantage to exceed the angle of 2 , indeed sealing of the fan to the flue elbow may become more difficult as the angle is increased.
Page 13 4 Flue 4.1 Terminal Position The minimum acceptable spacings from the terminal to obstructions and ventilation openings are as shown in diagram 4.4. The boiler must be installed so that the terminal is exposed to the external air. It is important that the position of the terminal allows the free passage of air across it at all times.
Page 14 5 Preparation 5.1 Unpacking - refer diagram 5.1 BOILER Open carton top, remove top fitting, wall template, loose items LOOSE ITEMS MOUNTING pack and boiler mounting bracket. Remove carton wrap and PACK BRACKET packing pieces. No.10 x Lift off white outer case front. Remove protective packing piece. SELF TAPPER Remove the cover of the inner case, see diagram 5.3.
Page 15 5 Preparation 5.4 Wall Mounting Bracket 5.2 Rear and Side Flue Application Reposition the template, making sure of dimensional alignment Having selected the location and flue application, with due with the flue centre lines. regard to the terminal position. Mark the boiler securing screws and mounting plate position, Take the template from the boiler pack and temporarily position see diagram 5.5.
Page 16 5 Preparation 5.5 Boiler Preparation BOILER TOP TEMPLATE FIXING POINTS Lift the boiler into position above the boiler mounting bracket, lowering the boiler into position at the same time locating the key hole slots of the boiler on to the securing screws, when located secure the screws, see diagram 5.5.
Page 17: Flue Installation
7 Flue Installation 7.1 Rear Flue Mark and cut the air duct terminal assembly, see diagram 7.3 and the flue duct, diagram 7.4 to the lengths required, cutting square and removing any burrs. Refer to diagram 7.5, mark through the holes in the flue elbow assembly and drill the duct as shown, making sure of the correct FAN BRACKET alignment of the “Top”.
Page 18 7 Flue Installation 7.4 External Flue Installation Locate the air duct/terminal assembly into the flue elbow 2.8mm assembly as shown in diagram 7.5, making sure of correct terminal alignment of the “TOP”. DRILL SIZE Mark the position of the air duct terminal assembly securing holes and drill two 2.8mm diameter holes through the air duct/ AIR DUCT/TERMINAL terminal assembly.
Page 19 7 Flue Installation 7.5 Flue Elbow FLUE Remove transit bracket and label, see diagram 7.1. DUCT Fit the flue elbow gasket, from the fittings pack, to the casing top. The two fan bracket securing screws should be loosened, but not removed, before slackening the three fan securing screws. SEALANT After locating the flue elbow into the outlet of the fan, secure the flue elbow onto the top panel with the four M4x14 screws...
Page 20: Gas Connection
7 Flue Installation STD FLUE TERMINAL = 63 FOAM SEAL STD FLUE TERMINAL = 61 FLUE "Q" minus 25mm TERMINAL FLUE DUCT "Q" SEAL (joint to be at top) Diagram 7.11 Diagram 7.10 8 Gas Connection Make the gas connection to the gas service cock, see diagram 8.1. SOLENOID SUPPORT BRACKET MULTI-FUNCTIONAL...
Page 21: Electrical Connection
9 Electrical Connection NOTE: Any external controls must only be connected to terminals 1 and SL. after removing red link. WARNING: This boiler must be earthed. Thread the cable(s) through the large cable clamp in the side of Remove the screws as diagram 9.1. the control box.
Page 22: Sealed Systems
10 Commissioning Please ensure the “Benchmark” logbook is completed and left The centre, plastic posidrive screw controls the “Low” burner with the user. pressure. The centre, plastic posidrive screw must be held in position 10.1 Preliminaries - All Systems whilst adjusting the main (high) burner pressure, brass nut. Commissioning should be carried out by a competent person in After adjustment the low pressure must be checked, by turning accordance with current issue of BS6798.
Page 23: User Information
10 Commissioning 10.7 Operational Checks 10.5 Heating System Adjust the control thermostat and any system controls to their Check that all remote controls are calling for heat. required settings and set “high/low” switch to “high”. Allow the system to reach maximum temperature and examine Do not attempt to adjust the thermostat calibration screw.
Page 24 12 Servicing NOTES: SECURING SCREW(2) To ensure the continued efficient and safe operation of the boiler it is recommended that it is checked and serviced at regular intervals. The frequency of servicing will depend upon the particular installation and usage, but in general once a year AIR BAFFLE should be enough.
Page 25 12 Servicing 12.3 Injector Remove the injector by releasing the three screws at the injector manifold burner box, the two screws at the inner case base sealing plate, see diagram 12.7, and the four screws at the multifunctional valve, see diagram 8.1. Make sure that the “O”...
Page 26: Fault Finding
12 Servicing 12.5 Condensate Drain SECURING SCREW (2) Remove the cap at the base of the condensate drain trap, see diagram 12.8 and carefully flush through, from the condensate SILICONE collecting tray, diagram 12.6, taking care not to allow any water SLEEVING to overflow the tray.
Page 27 13 Fault Finding PUMP OVERRUN OPERATION The control thermostat has a pump overrun facility built into it, when the control thermostat is set at maximum only, the pump overrun will keep the pump running to allow the boiler to cool down after which it will stop, providing the remote controls are NOT calling for heat.
Page 28 13 Fault Finding Before detailed checking of electrical components ensure that remote controls are calling for heat. Check that the gas supply is free of obstructions and purged of air. Check the overheat thermostat and fluehood thermostat have not operated. Isolate the electrical supply and physically check ALL cables, connections and the printed circuit board (PCB) fuse.
Page 29 13 Fault Finding Reconnect supply Is APS neon lit ? Is fan running ? Replace APS Is there 240V at the fan ? Has boiler been operating for 10 Is there 240V Replace ignition seconds yet ? at C ? Switch High/Low Switch Will flue hood to 'low'...
Page 30 13 Fault Finding Does the burner remain alight ? Is the low gas pressure Is condense drain setting correct (see Data blocked, repair. Tables) at the test point Does burner remain on the gas valve ? alight ? Is the low gas pressure setting correct (see data tables)? Adjust as necessary.
Page 31 13 Fault Finding AIR PRESSURE SWITCH HIGH FLAME PLASTIC NEON OVERHEAT DEMAND FLAME NEON NEON HIGH/LOW (FLAME) SWITCH EARTH LAMP INTER- POST CONNECTION P.C.B. LAMP LINK REMOTE PUMP SWITCH SUPPLY MAINS 240VAC 50Hz STAT EARTH POST MULTI-FUNCTIONAL CONTROL MAIN PLUG CONDENSE CUT-OFF CHASSIS...
Page 32 13 Fault Finding RED LINK PUMP DEMAND OVERRUN NEON Stat(2) Stat(4) Lamp(3) Lamp Stat(3) N(3) CONTROL THERMOSTAT PUMP OVERHEAT THERMOSTAT P.C.B.(2) Stat(1) FUSE P.C.B.(1) TYPE F2A PLASTIC OVERHEAT IGNITION P.C.B.(4) CM1(1) CM1(2) P.C.B. AIR PRESSURE SWITCH P.C.B.(3) GV1(1) GV1(3) GV1(2) LOW FLAME NEON Amp Con Lamp N(2)
Page 33: Replacement Of Parts
13 Fault Finding RESET BUTTON RESET BUTTON FLUE HOOD OVERHEAT INSTRUCTION LABEL Diagram 13.5 Diagram 13.4 THERMOSTAT 14 Replacement of Parts Notes: Replacement of parts must be carried out by a competent person. CONDENSATE FLEXIBLE SECURING TUBE SCREW (2) Before replacing any parts isolate the boiler from the electrical supply and turn the gas supply off at the gas service cock, see diagram 8.1.
Page 34 14 Replacement of Parts Control PCB: diagram 14.3 (top) Disconnect the electrical plug on the board. Release from its two support posts and carefully pull the board away noting that the ignition lead is still connected. It may be necessary to hold some of the wires above the PCB clear with an electrical screwdriver on removal or refitting.
Page 35 14 Replacement of Parts CONTROL THERMOSTAT SECURING SCREW (2) RETAINING OVERHEAT CUT OFF PHIAL CONTROL THERMOSTAT ELECTRICAL PHIAL CONNECTION (5) OVERHEAT CUT OFF LOCKNUT Diagram 14.4 HIGH/LOW CONTROLS CONTROL CONTROL FASCIA THERMOSTAT KNOB KNOB SECURING SCREW (3) CONTROLS FASCIA RESET BUTTON PLASTIC OVERHEAT...
Page 36 14 Replacement of Parts 14.7 Multifunctional Control: diagram 8.1. 14.10 Heat Exchanger: diagram 14.8 Disconnect the screws and electrical plugs at the multifunctional Note: To carryout the following operations it will be found more control. convenient if the whole of the heat exchanger and burner are removed as a unit.
Page 37 14 Replacement of Parts Release the flexible tube from the condense drain trap, this is Heat Exchanger: Secondary - diagram 14.9 a push-fit. Disconnect the union connector. Release union connections and the six securing screws, then Remove and fit the flexible hose to the replacement. remove the complete assembly.
Page 38 14 Replacement of Parts 14.14 Insulation - Sides - diagram 14.12 Remove the spark electrode refer to Section 12.4. SIDE INSULATION Remove the insulation by sliding it out. 14.15 Condensate Sensor: diagram 14.13 Refer to the relevant parts of Section 14.2 to remove the screw. The sensing screwis fitted to a push fit cap which can be levered off for easy access.
Page 39: Spare Parts
15 Spare Parts 15 Spare Parts When ordering spare parts, please quote the appliance name and serial number, to be found on the data label, visible when the outer casing is removed. If ordering from Birtish Gas also quote the GC number of the part.
Page 40 15 Spare Parts Diagram 15.1 Because of our constant endeavour for improvement details may vary slightly from those in the instructions. 221837B...

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