Glowworm BBU 54/4 Miami 4 Release note

Hepworth Heating Ltd.,
Nottingham Road, Belper, Derbyshire. DE56 1JT
General/Sales enquiries:
Tel: [phone] Fax: [phone]
One Contact Local Service
Customer Services:
Tel: [phone]
Fax: [phone]
This is a Cat I2H Appliance
9701
BBU 54/4
Installation & Servicing Instructions
2000225024C.07.02
To beleftwiththeuser
G.C. No. 44 - 047 - 05
For Use Only With Specially Designed Firefronts

2
2000225024C
General Data 1 3
Types of Installation 2 7
Flue and Ventilation 3 8
Installation 4 10
Electrical Wiring 5 14
Commissioning 6 17
Fire Installation 7 20
Servicing 8 21
Fault Finding 9 25
Replacement of Parts 10 27
Spare Parts 11 30
CONTENTS DESCRIPTION SECTION PAGE No.
INSTALLATION
INSTRUCTIONS
SERVICING
INSTRUCTIONS
TESTING AND CERTIFICATION
It is important that no alteration is made to the boiler without permission, in writing, from Hepworth Heating Ltd.
Any alteration that is not approved by Hepworth Heating Ltd., could invalidate the B.S.I. Certification, the boiler warranty and could
also infringe the current issue of the Statutory Requirements, see Section 1.1.
CE Mark
The boiler meets the requirements of Statutory Instrument, No. 3083 The Boiler (Efficiency) Regulations, and therefore is deemed
tomeettherequirementsofDirective92/42EEContheefficiencyrequirementsfornewhotwaterboilersfiredwithliquidorgaseous
fuels.
Type test for purposes for Regulation 5 certified by: Notified body 0086.
Product/production certified by: Notified by 0086.
1. Directive 90/396/EEC on the approximation of the Laws of the Member States relating to appliances burning gaseous fuels.
2. Directive 73/23/EEC on the harmonization of the Laws of the Member States relating to electrical equipment designed for use
within certain voltage limits.
3. Directive 89/336/EEC on the approximation of the Laws of the Member States relating to electromagnetic compatibility.
INFORMATION FOR THE INSTALLER AND SERVICE ENGINEER.
Under Section 6 of The Health and Safety at Work Act 1974, we are required to provide information on substances hazardous to
health.
The adhesives and sealants used in this appliance are cured and give no known hazard in this state.
Insulation Pads
These can cause irritation to skin, eyes and the respiratory tract.
If you have a history of skin complaint you may be susceptible to irritation. High dust levels are usual only if the material is broken.
Normalhandlingshouldnotcausediscomfort,butfollownormalgoodhygieneandwashyourhands before eating, drinking or going
to the lavatory.
If you do suffer irritation to the eyes or severe irritation to the skin seek medical attention.
SPARE PARTS
REMEMBER, when replacing a part on this appliance, use only spare parts that you can be assured conform to the safety and
performancespecificationthatwerequire. DonotusereconditionedorcopypartsthathavenotbeenclearlyauthorisedbyHepworth
Heating Ltd.
MANUAL HANDLING GUIDANCE
During the appliance installation and the replacement of the heat exchanger it will be necessary to employ caution and assistance
whilst lifting as the appliance or component exceeds the recommended weight for a one man lift.
In certain situations it may be required to use a mechanical handling aid.
Take care to avoid trip hazards, slippery or wet surfaces.
Important Information

32000225024C
ReferencesintheseinstructionstoBritishStandards,Statutory
RegulationsandRequirementsapplyonlytotheUnitedKingdom.
For Ireland the rules in force must be used.
Theseinstructionsconsistoftwoparts,InstallationandServicing
Instructions for the Back Boiler Unit and the Guarantee
RegistrationCard. User,InstallationandServicingInstructions
for the specified fire are supplied with the firefront.
The boiler is for use only with a specially designed Glow-worm
Gas firefront, see table 1.
This boiler is NOT suitable for fitting to precast flues.
The boiler is delivered in one pack which contains all the parts
necessary for the installation.
ifinstallingthebackboilerunitandthefirefrontatthesametime
please read both sets of instructions before starting.
IMPORTANT NOTICE
This boiler is for use only on G20 gas.
The back boiler unit is fitted with a flue blockage safety device
whichwillshut it down if there is alackof oxygen resulting from
a build up of combustion products. The flame on the pilot light
will become unstable and lift up off the sensing device, this will
deactivatethegasvalveviathep.c.b.,cuttingoffthegassupply.
If the back boiler unit shuts down frequently for no apparent
reason the first things to check are the chimney and air inlets
into the room. Any problems found must be put right, by a
competentperson,anda fulloperationaltestcarriedout before
the fire is used again.
The flue blockage safety device incorporates the electrode,
pilot assemblies and sampling tube assembly in conjunction
with P.C.B.
The flue blockage safety device MUST NOT be adjusted or
disconnected. It must be serviced strictly in accordance
with the instructions in this book. Any unauthorised
interference could result in the device failing to operate,
creatingapotentiallydangeroussituation.Ifreplacing,use
only the correct and approved parts.
Wherever possible, all materials, appliances and components
to be used shall comply with the requirements of applicable
British Standards.
Where no British Standard exists, materials and equipment
should be fit for their purpose and of suitable quality and
workmanship.
Sheet Metal Parts
WARNING. When installing or servicing this back boiler care
should be taken when handling the edges of sheet metal parts
to avoid any possibility of personal injury.
Refer to Manual Handling Operations, 1992 Regulations.
1.1 Statutory Requirements
The installation of this back boiler unit must be carried out by a
competent person in accordance with the current issue and
relevant requirements of:
Manufacturer’s instructions, supplied.
TheGasSafety(InstallationandUse)Regulations,TheBuilding
Regulations, The Building Standards (Scotland) Regulations,
applicableinScotland,LocalGasUndertaking,Bye-lawsofthe
Local Water Company, The Health and Safety at Work Act,
Control of Substances Hazardous to Health, The Electricity at
Work Regulations and any applicable local regulations.
1 General
Detailedrecommendationsarecontainedinthecurrentissueof
the following British Standard codes of practice,
BS1251, BS5440 Part 1 and 2, BS5449, BS5546, BS5871,
BS6798, BS6891, BS7593, BS7671.
Manufacturer’snotesmustnotbe taken asoverridingstatutory
obligations.
1.2 Data
Seediagram1.1, RangeRatingtablefor friefrontsandTable1.
Gas connection Rc1/2(1/2inBSPT)
Water connection Rc1
Electrical supply 230V~50Hz fused 3A
Weight, about 38kg (83.6lb)
Water content 2.18Litres (0.48gall)
Injector 3.35mm
Dimensions, except as noted, shown on diagrams are in
millimetres.
Data Label: On the base of the boiler next to the electrical
control box.
The Seasonal Efficiency Domestic Boilers UK (SEDBUK) for
LFE and radiant firesis 78.8%, for Inset fires it is 79.5%.
ThevalueisusedintheUKGovernment’sStandardAssessment
Procedure (SAP) for energy rating of dwellings. The test data
from which it has been calculated have been certified by B.S.I.
1.3 Gas Supply
The gas installation must be in accordance with the current
issue of BS6891.
The supply from the governed gas meter must be of adequate
size to provide a steady inlet working pressure of 20mbar (8in
wg) at the boiler.
Do not use pipe of a smaller diameter than Rc1/2(1/2BSP) inlet
or 15mm, see diagram 1.1 for position of gas connection.
The gas meter must be capable of passing natural gas at the
following rate: 85ft3/h (2.4m3/h).
This rate is in addition to all other natural gas appliances
supplied from the same meter.
It is recommended that the gas supply enters the builder’s
opening on the right hand side.
If the gas supply enters from the left hand side it will be
necessarytorouteandinsulatethepipebehindthecombustion
chamber before final fixing.
Oncompletiontestthe gasinstallationforsoundnessusing the
pressure drop method and suitable leak detection fluid, purge
in accordance with the above standard.
1.4 Electrical Supply
WARNING. This boiler must be earthed.
All system components shall be of an approved type and shall
be connected in accordance with the current issue of BS7671
and any applicable local regulations.
Connection of the boiler and system controls to the mains
supply should be through a common isolator , a double pole
isolating switch, fused 3A, should be used, having a minimum
contact separation of 3mm in both poles.
Alternatively, a fused 3A 3pin plug and unswitched shuttered
socket both to the current issue of BS1363 may be used.
Wiring to the boiler must be PVC (85oC) insulated type to the
current issue of BS6500 Table 9, not less than 0.75mm2(24/
0.20mm)..

4
2000225024C
1 General
OVERALL DIMENSIONS
9702
Diagram 1.1
D
A
B
E
F
G
HJ
K
WATER
CONNECTIONS
RC1
SIDE ELEVATION FRONT ELEVATION
DIMENSION A B C D E F G H J K L M N
BBU 54/4 338 244 124 97 545 348 390 195 195 38 146 175 173
GAS CONNECTION
RC (1/2in BSPT)
C
L
N
M
BOILER
DRAIN
POINT
INJECTOR
MARKING
14.84
50,650
RANGE RATING TABLE
Minimum
Miami 4
Heartbeat 4
Contour 4
Firelite 4
13.19
45,000
10.0
4.02
HEAT kW
INPUT
(NETT) Btu/h
HEAT kW
OUTPUT Btu/h
COLD mbar
BURNER
PRESSURE in.w.g
205773
Medium
Miami 4
Heartbeat 4
Contour 4
Firelite 4
Maximum
Miami 4
Heartbeat 4
Contour 4
Firelite 4
Minimum
Dovedale 4
Chatsworth 4
Medium
Dovedale 4
Chatsworth 4
Maximum
Dovedale 4
Chatsworth 4
16.13
55,050
14.51
49,500
11.8
4.74
17.42
59,450
15.83
54,000
13.7
5.50
12.99
44,330
11.72
40,000
7.6
3.05
14.28
48,740
12.97
44,250
9.2
3.69
15.49
52,840
14.21
48,500
10.8
4.34

52000225024C
1.5 Site Requirements
Refer to diagram 1.1 for dimensions appropriate to the back
boiler.
For all types of installation a standard builder’s front opening is
required, see diagram 1.2.
IMPORTANT NOTES :
ThedepthofthefireopeningMUSTconformtothedimensions
given in diagram 1.2.
Any larger front opening will need to be reduced, with non-
combustible material to conform to this requirement.
It is important that the opening is cleared of debris and mortar
etc.
The void behind the the front opening should be sufficient to
allow for the water connections fittings.
It is recommended that the access hole for pipework into the
fireplace or builders opening is either at the left hand or right
hand side of the chimney breast. if access is required at both
sides then it may be necessary to prepare some of the
connections before fitting the back boiler into the builders
opening.
The prepared base for the back boiler must be level.
Refer to diagram 1.3 for dimensions of the fire fixing wall face
which MUST be true.
1.6 Water System - Open Vented
Thisboilercanbeusedonanunrestrictedopenventedsystem
with the water supply taken from a feed and expansion cistern,
having a head between 1m (3ft 3in) minimum and 27m (90ft)
maximum.
Diagrammaticlayoutsofsystemsareshownindiagram1.4and
1.5.
1 General
6302
PREPARED
BASE
B
A
C
Diagram 1.3
C
L
5506
Minimum flat area and fixture or
surround protection clearance
PREPARED BASE
Y
X
FIRE TYPE
(BBU)
DIMENSIONS
FOR MINIMUM
FLAT AREA
(NO FIXTURES)
DIMENSIONS
FOR FIXTURE
OR SURROUND
PROTECTION
CLEARANCE
MIAMI 4 625 686 775 986
FIRELITE4 633 620 783 920
CONTOUR 4 638 617 788 917
B/BEAUTY 4 655 657 805 957
HEARTBEAT 4 643 632 793 932
CHATS/DOV 4
STD. FRAME 630 547 780 690
WIDE FRAME 652 590 800 690
XYXY
Table 1 GC Number
Firelite 4 37-047-13
Contour 4 37-047-14
Miami 4 Teak 37-047-15
Miami 4 Mahogany 37-047-20
Heartbeat 4 37-047-16
BlackBeauty 4 37-047-17
Chatsworth 4 37-047-18
Dovedale 4 37-047-19
Diagram 1.2
AB C
Miami 4 350 406-580 560-590
Firelite 4/ Contour 4 350 406-480 560-590
Heartbeat 4/
BlackBeauty 4 350 406-480 560-590
Chatsworth 4/
Dovedale 4 350 406-460 560-590
BUILDERS FRONT OPENING

6
2000225024C
C
L
BOILER
FLOW
PUMP
TO HEATING
CIRCUIT
INDIRECT
CYLINDER
1 METRE MIN
27 METRE MAX
RETURN
150mm
1 General
Diagram 1.5
9625
FULLY PUMPED SYSTEM
(DIAGRAMMATIC)
Diagram 1.4
PUMPED HEATING & GRAVITY DOMESTIC HOT
WATER (DIAGRAMMATIC)
9624
HEATING
SYSTEM
PUMP
28mm
1m MIN.
27m MAX.
INDIRECT
CYLINDER
15mm COLD FEED
22mm VENT
1.7 Hot Water Cylinder
The back boiler is suitable for open vented systems using an
indirectcylinder. Thecylindermustbefittedtothemanufacturer’s
recommendations and the system must conform to the
requirements of the current issue of BS5449.
It is recommended that the cylinder be fitted with some form of
temperature control.
1.8 Frost Protection
If the position of the boiler is such that it may be vulnerable to
freezingitshouldbeprotectedasspecifiedinthecurrentissue
of BS5422.
It is also recommended that a frost thermostat is fitted.
1.9 Draining Tap
System
A draining tap must be provided at the lowest point of the
system which will allow the entire system, the boiler and hot
water cylinder to be drained.
Draining taps shall be to the current issue of BS2879.
Boiler
A draining point is fitted at the bottom of the side of the heat
exchanger where the water connections are located, see
diagram 1.1.
When draining is required cover the controls to avoid water
damage.
1.10 Safety Valve
A safety valve need not be fitted to an open vented system.
1.11 Boiler Location
ThisbackboilerunitMUSTNOTbeinstalledinaprivategarage
or in a room containing a bath or shower or a room used or
intended to be used as sleeping accommodation.
1.12 Sealed Water System
Akitandinstructions,partnumber2000463000,isavailableto
enable the back boiler to be used on a sealed water system.
Pleasegivetheserialnumberofthebackboilerwhenordering
the kit.
1.13 Inhibitor
Attentionisdrawntothecurrent issue BS5499 andBS7593on
the use of inhibitors in central heating systems.
If an inhibitor is to be used, contact a mnufacturer for their
recommendations as to the best product to use.
If using in an existing system take special care to drain the
entiresystem,includingtheradiators,thenthoroughlycleaning
out before fitting the boiler whether or not adding an inhibitor.
The COLD FEED PIPE may be connected to flow
pipe, adjacent to the open vent pipe as shown.
(THERE MUST ALWAYS BE A COLD WATER
PATH TO THE RETURN CONNECTION OF THE
BOILER)
22mm
22mm

72000225024C
Diagram 2.1
Diagram 2.2
2Types of Installation
2.1 With Non-combustible Hearth
For minimum dimensions of a hearth, see diagram 2.1.
Thebackboilermustbe installedlevelwiththehearthor above
it, see diagram 2.1.
Carpet or similar floor covering must not be placed on the
hearth.
2.2 Combustible Hearth
Ifthe hearth is existing and made of a combustible material the
back boiler must be installed to the dimensions in diagram 2.3.
2.3 With Surround
The combined thickness of the surround and lintel must be
checked, to make sure that the back boiler can be positioned
within the opening to allow easy connection of the flue into the
back boiler flue socket, see diagram 2.2.
For fireplaces where the wall is not plastered and not covered
byBS1251itisimportantthatsuchinstallationscomplywiththe
current issue of The Building Regulations.
Anycombustiblematerial,forexample,blownvinylwallcovering,
on the fire front fixing face area must be removed to a height of
625mm and 268.5mm each side of the centre line. These
dimensionswillallowthestandardframe,iffitted,tooverlapthe
remaining wall covering by 5mm.
This area, to the depth removed should then be rendered with
a sand/cement mixture.
2.4 Without Surround or Hearth
If there is to be any combustible material beneath the fire front,
forexample,carpet,thenthebaseofthebuilder’sopeningmust
not be less than 75mm above the floor covering as shown in
diagram 2.3.
Thebuilder’sopening,withlintelmusthaveminimumdimensions
as shown in diagrams 1.2 and 2.3.
Theinformationregardingthefirefrontopeningmustbefollowed
together with the last three paragraphs of section 2.3.
5423
6196
PREPARED
BOILER
BASE
HEARTH
300mm
710mm
50mm MIN
FIRE WALL FACE
165mm
MAX
PREPARED BASE
TOPS OF HEARTH
MUST NOT BE
ABOVE PREPARED
BASE
13mm MIN
NON-COMBUSTIBLE
MATERIAL
50mm
MIN
350mm MIN FIRE FIXING
WALL FACE
*NOTE
This dimension can
be increased up to
190mm if builder’s
opening depth is at
least 375mm deep
*165mm
MAX
FLUE
PIPE
350mm
MIN
Diagram 2.3
1590
FIRE FIXING
WALL FACE
PREPARED BASE
TOP OF CARPET,
FLOOR COVERING
OR COMBUSTIBLE
HEARTH
N.B. *Minimum dimension.
This dimension refers to
minimum clearance after
carpet or any floor covering
has been fitted.
*75mm
350mm
MIN
COMBUSTIBLE HEARTH/ WALL
MOUNTED INSTALLATIONS

8
2000225024C
BACK
BOILER
UNIT
3 Flue andVentilation
Diagram 3.1
3.1 General
The general recommendations of the current issue of BS5440
Part 1 should be followed.
In all cases the flue should be lined, preferably with a flexible
liner.
It is essential that the flue has an equivalent height of at least
2.5m(8.2ft)measuredfromtheflueconnectionontheappliance.
The first 600mm, at least, above the draught diverter must be
vertical.
Wheretheinstallationisnewitisessentialtomakesurethatthe
annular space between the boiler flue liner and the chimney is
sealed at the base and at the top of the chimney, as shown in
diagram 3.2.
The flue socket is designed to take flue pipe to BS567. If flue
pipe conforming to a different standard is used a suitable
adaptermustbefittedandsecuredtothefluesocket. Aflexible
flue liner may be used, with connection to the back boiler flue
socket, see diagram 3.1
The existing flue may not be completely sound. Therefore, to
preventthepossibilityofleakagetoan adjacent flue, additional
sealing MUST be carried out between the base of the chimney
and the flue liner.
Theendoftheflue liner at the chimney top must be adequately
sealed and clamped, using proprietary fittings suitable for the
flue liner used, see diagram 3.2.
The flue should, preferably, end above ridge height but at the
least above the eaves of a pitched roof. Use a certificated
terminal.
If the flue is to pass through or near any combustible material it
should be installed in accordance with the current issue of
BS5440 Part 1. If in doubt seek advice from the local gas
undertaking or Hepworth Heating Ltd.
3.2 Existing Chimney
An existing brick chimney must be thoroughly swept and all
debris cleared away before lining.
Remove any damper or register plate. Alternatively it may be
locked in the open position,
Aflexiblefluelinerispreferredbutarigidlinermaybeused,with
connection to the back boiler flue socket made with a short
vertical piece of flexible liner, see diagram 3.1.
Anyairsupplythatentersthebuilder’sopeningotherthanbythe
front opening, that is underdraught openings and the like must
be completely sealed off.
Thesealingplatealsopreventsdebrisfallingandgivestheflue
better insulation, reducing the possibility of condensation, see
diagram 3.2.
Check the flue system efficiency before installing the back
boiler.
1593
APPROVED
SEAL
FLEXIBLE
LINER
BACK BOILER
RIGID
FLUE
LINER
Diagram 3.2
6197
SEALING AND
CLAMPING
PLATE
AIR
SPACE
150mm (6in) plug of Mineral Wool or similar
600mm
SEALING
PLATE

92000225024C
3 Flue andVentilation
3.3 New Chimney
A newly built chimney can be lined with a moisture resistant
lining, such as salt glazed pipe, of an appropriate diameter as
specified in the Building Regulations
In the case of a salt glazed lined flue, it is recommended that a
short vertical length of flue pipe, preferably flexible metallic be
used. Fix and seal it to the back boiler flue socket, make good
withapprovedpackingandpargewithfirecement,seediagram
3.1.
If a flue and false chimney breast are to be constructed all
openingsforpipeworktoupperfloorsetc.,mustbesealed. The
onlyopeningforthebackboilermustbeatthefront,beingofthe
dimensions as shown in diagram 1.2.
If a specially built compartment is constructed for the back
boiler, it must conform to the requirements of the current issue
of BS5440 Part 1 and BS5871.
The flue should, preferably, end above ridge height but at least
above the eaves of a pitched roof. Use a certificated terminal.
3.4 Ventilation - Back Boiler and Fire
The room in which the back boiler unit is installed must have
adequate air inlets to ensure correct operation as specified in
the current issue of BS5440 Part 2.
Ventilation requirement, see vent size table.
Thisventilationareatakes intoaccountthetotalrequirement of
the back boiler unit and fire.
Theventilationopeningsmay bedirecttotheoutside air orwith
an internal room or space (such as a hall) which itself has a
permanent air vent of the same effective area. The permanent
air vent should be in a position which will cause the least
nuisance to occupants, due to draughts.
This vent MUST NOT be placed in the builder’s opening.
If the appliance is to be installed in a room already containing
another fuel burning unit, the air supply required for this other
unit MUST be added to the figure above.
Any air vent taken through a cavity wall must be ducted.
3.5 Extract Fans
Ifanextractfanisfittedinthepremises,thereisapossibilitythat
if adequate air inlet openings are not provided spillage of the
products of combustion could occur.
When openings are fitted in accordance with the
recommendationsofthecurrentissueofBS5440Part2,extract
fans should not cause spillage.
Where such a fan installation is found, a clearance of products
testmustbeconductedasdescribedinthefirefrontInstallation
Instructions, Section 4.5.
This test must be carried out with the back boiler fitted with its
fire front.
See also Section 6.3 of these instructions.
Note: Refer again to Section 1.6 and diagram 1.2 and make
sure that there is sufficient depth for the back boiler unit.
VENT SIZESTABLE
54/4
Dovedale 4 77cm2/ 12in2
Chatsworth 4
Miami 4
Firelite 4
Contour 4 80cm2/ 13in2
B/Beauty 4
Heartbeat 4

10
2000225024C
4 Installation
4.1 Preparation
Removedraughtdiverterbody,draughtdiverter,fluewaybaffles
and fittings pack from carton.
Check contents of fittings pack against packed list.
Remove back boiler body from carton.
Remove the combustion chamber extension by loosening the
two securing screws and lift off, see diagram 4.1.
Putthecombustionchamberextensiontoonesideuntilrequired,
see note below.
Take care not to damage the user control during installation,
see diagram 4.3.
Removecontrol/burnerassemblyfrombackboilerbyremoving
the four combustion chamber screws and the gas manifold
securing screw. Slide the control/burner assembly forwards to
remove, see diagram 4.10.
Note: If the back boiler is to be installed with a Chatsworth/
Dovedalefirefront,discardthedraughtdiverterandcombustion
chamber extension, use the draught diverter supplied with the
fire front, see User, Installation and Servicing instructions
supplied with the fire front, see diagram 4.1.
4.2 Water Connections
IT IS EXTREMELY IMPORTANT THAT NO SERVICE PIPES
ARE ROUTED IN FRONT OF THE BOILER. If the builder’s
opening was previously used for solid fuel all pipework within
shouldbeprotected withPVCtapeor equal. Pipeworkpassing
throughwallsoftheopeningshouldbesleevedandmadegood.
4.3 Pumped Heating with Gravity Domestic
Hot Water
All pipework must comply with the current issue of BS5546.
The domestic hot water flow and return pipes must be 28mm.
Refer to diagram 1.4 for a diagrammatic layout.
For systems with gravity domestic hot water and pumped
heating circuits, pipe crossover maybe required. This type of
installation maybe simplified by the use of a Street elbow.
For installation of Street elbow, see diagram 4.2.
Pipes should then be bent accordingly.
If it is necessary to route pipework from both sides of the
builder’sopening,itisrecommendedthattheheatexchangeris
positioned on the combustion chamber so that the gravity
circuits exit on the same side as the boiler connections.
If the heat exchanger connections are opposite hand to that
required,theheatexchangercanbeturnedasfollows,carefully
tiltthebackboilerfirstonitsback,thentiltagainsothattheback
boiler is now upside down.
Remove the four screws securing the combustion chamber to
heat exchanger, see diagram 4.1, replace the combustion
chamber seal, from fittings pack, turn combustion chamber in
respect to heat exchanger and refit with the four screws.
Carefully upright the appliance by tilting as above.
4.4 Pumped Heating and Hot Water
Refer to diagram 1.5 for a diagrammatic layout.
If the heat exchanger connections are opposite hand to that
required, turn in the same manner as described in Section 4.3
paragraph 5.
4.5 Circulating Pump
Isolating valves, integral if possible, must be fitted each side of
the circulating pump. Diagram 4.1
HEAT
EXCHANGER
SECURING
SCREWS
(4)
COMBUSTION
CHAMBER
9384
COMBUSTION
CHAMBER
EXTENSION
SECURING
SCREWS
DRAUGHT
DIVERTER
10281
OUTSET
DRAUGHT
DIVERTER
BODY
INSET
DRAUGHT
DIVERTER
BODY
DRAUGHT
DIVERTER

11 2000225024C
4 Installation
4.6 Chatsworth 4, Dovedale 4 Only
IMPORTANT: With the control/burner assembly removed, fit
the blanking plate, supplied with the fire front, to the rear of the
combustionchamberandsecurewithanumber6screwprovided,
see diagram 4.11.
Pleasenote that the hole for the securing screw in the blanking
plate is offset to avoid incorrect fitting.
4.7 Positioning the Back Boiler
IMPORTANT.WithregardstotheManualHandlingOperations,
1992 Regulations, the following lift operation exceeds the
recommended weight for a one man lift.
Carefully lift the back boiler by the heat exchanger casting and
place centrally in the builders opening.
The installation centre line is indicated on the base by a notch
on the front of the plate and the fire fixing wall face positioning
line by the front corner edges of the base, see diagram 4.3.
Diagram 4.2
NOTCH
BASE
FIXING
WALL
FACE
HEAT
EXCHANGER
CASTING
9386
10mm
10mm
Diagram 4.3
9583
FIXING
HOLES
FIRE
FIXING
WALL
FACE
TOP VIEW INSIDE
BUILDERS OPENING
FIXING
HOLES
Diagram 4.2
11622
11623
STREET
ELBOW
STREET
ELBOW

12
2000225024C
4 Installation
Chatsworth 4 and Dovedale 4 only
The back boiler must be positioned so that a line across the
opening of the wall face coincides with the fire fixing wall face
positioning line, see diagram 4.3.
Pleasenote:ThisistheonlypermittedpositionfortheChatsworth
4 and Dovedale 4.
Use a straight edge across the wall face to make sure that the
back boiler is square to it.
Firelite 4, Contour 4, Miami 4, Heartbeat 4 and
Black Beauty 4 only
The back boiler may be positioned so that a line across the
opening of the wall face coincides with the fire fixing wall face
positioningline. Providingthewallissquarethepositioningline
can either be set back or set forward up to 10mm from the wall
face, see diagram 4.3.
continued -
Checkthatthebackboilerislevel.Ifpackingisrequiredtoadjust
thelevelofthebackboiler,usemetalshimsandpackunderthe
full width of the base.
Markthroughthethreefixingholesonthefloorprotectionplate,
seediagram4.4. Removethebackboilerunit. Drillthreeholes
using a masonry drill bit to accept appropriate plugs.
4.8 Positioning the Back Boiler - continued
Fitthefluewaybaffles,fromfittingspack,intoflueways,ensuring
that they are positioned centrally in the flueways, see diagram
4.5.
IMPORTANT: Do not fit the flueway baffles if a Chatsworth
4ora Dovedale 4isto be installedwitha BBU 54/4,discard
flueway baffles.
NOTE: The front flueway does not have a baffle. If the heat
exchanger has been turned the baffles must still be fitted into
the back and middle flue ways only.
Fit the draught diverter body onto the heat exchanger with the
two securing screws supplied in the fittings pack, see diagram
4.6.
Takethefluesensingtube,packedwiththeboiler,andfittubing
nutintobrassfitting,locatedatsideofthedraughtdiverterbody,
Diagram 4.4
9389
BAFFLES (centre in
flueway)
HEAT
EXCHANGER
Diagram 4.5
9388
DRAUGHT
DIVERTER
BODY
SECURING SCREWS (2)
NOTE: PLACE BAFFLES IN REAR AND
CENTRE FLUE WAYS
Firelite 4, Contour 4, Miami 4, Heartbeat 4
and Black Beauty 4 only
andtighten,makingsurethesensingtubeiscorrectlypositioned,
see diagram 4.7.
Where a flexible flue liner is being used, fully fit the No.8x3/8in
selftappingscrewprovidedinto the rear of the flue socket as in
diagram 4.8.
Reposition the back boiler unit into the builders opening then
secure with fixing screws.
Refit control/burner assembly leaving the combustion top left
hand securing screw off, see diagram 4.7.
Push fit the silicone tube which is fitted to the flue blockage
safety device, on to the sensing tube, see diagram 4.7.
Fit the sensing tube securing bracket in position, see diagram
4.6,firstremovingthetoplefthandcombustionchamberscrew,
seediagram4.6. Locatethebottomofthebracketbypositioning
the hole in the base of the bracket so that it engages onto the
frontlefthandnibintheboilerbase plate. Secure the top of the
brackettothecombustionchamberwiththecombustionchamber
securing screw replaced in its original position, see diagram
4.7.
IMPORTANT: Check that the sensing tube is positioned
flatagainstthecombustionchambersidewhenthesensing
tube bracket securing screw is tightened up and that the
siliconetubeisnottrappedagainstthecombustionchamber
side. Checkalsothattherearenokinksinthesiliconetube.
NOTE: At this point it may be more convenient to fit the water
connections.
Connect the system pipework to the back boiler unit/pre-
plumbed pipework.
Ifaflexiblefluelinerisbeingused,positionthelinerintotheflue
socket. Using two No.8x1/2in self tapping screws, coloured
black, from the fittings pack, screw through the two remaining
holes in the flue socket to centralise and secure the flue liner,
see diagram 4.8. Seal with a suitable fire clay cement.
Connect gas supply to gas service cock. Leave gas service
cockandgasfiresupplycockinthe“OFF”position,seediagram
4.9 and 6.2.

13 2000225024C
Diagram 4.7
9393
Diagram 4.8
9387
GAS SERVICE
COCK (OFF)
No. 8 3/8 in.
SCREWS
REAR
SOCKET
FRONT
No. 8 1/2 in.
SCREWS
Fully fit No. 8 3/8 in.
screw into rear of
socket. Centralise
flexible flue liner
using the two
No. 8 1/2 in.
screws provided.
(Left hand water connection shown)
4 Installation
Diagram 4.9
9584
COMBUSTION
CHAMBER SCREW (4) GAS
MANIFOLD
SCREW
Diagram 4.6
10260
SILICONE
TUBE
TUBING NUT
SENSING
TUBE
Diagram 4.10
BLANKING
PLATE
SECURING
SCREW
COMBUSTION
CHAMBER
10112
LOCATING
NIB
SENSING TUBE
SECURING
BRACKET
SECURING
SCREW
SENSING
TUBE
FLUE
BLOCKAGE
SAFETY
DEVICE

14
2000225024C
5.1 General
WARNING. This boiler must be earthed.
ISOLATE THE ELECTRICAL SUPPLY BEFORE DOING ANY
WIRING
Alloftheelectricalinstallationmustbecorrectlyearthedandbe
in accordance with the current issue of BS7671 and be carried
out by a competent person.
The boiler electrical supply is 230V~ 50Hz, fused at 3A. A
double pole isolating switch, having a minimum contact
separation of 3mm in both poles should be used.
Theboilerdoesnotrequire a permanentlive. Externalcontrols
are connected to the live 'L' terminal in the 3 way plug, as an
example see diagram 5.1.
Supplycableshouldbe(85oC)PVCinsulatedtypetothecurrent
issueofBS6500Table16,notlessthan0.75mm2(24/0.20mm).
NOTE:Thesupply totheboilerandanyremotecontrol mustbe
through the same isolating switch or plug and socket.
Itispreferabletohavetheboilerelectricalsupplycableentering
thebuilder’sopeningattheleft,seediagram5.2.Keepthecable
well clear of hot surfaces.
If right hand access is required and the boiler electrical supply
cablehastoberouteddowntherighthandsideofthecombustion
chamber keep the cable well clear of hot surfaces. The cable
mustalsoberoutedinfrontofthegascontrolvalve,seediagram
5.3.
Note:Ifthefirefronttobefittedtothebackboilerunitis,aFirelite
4,Contour4,Miami4,Heartbeat4,orBlackBeauty4,themains
cable, if it is routed from the right, will have to be secured in a
retaining clip on the combustion chamber extension. Fitting
instructionsforthecombustionchamber extension aregivenin
theUse,InstallationandServicinginstructions oftheabove fire
fronts.
NOTE: The boiler electrical supply cable must not be
routed along the back of the appliance.
The cable must be kept well clear of hot surfaces.
When fitting the back boiler unit do not trap the cable.
5.2 Control Thermistor Phial
Route the cable well clear of any part of the back boiler which
becomes hot. Push the phial into the pocket and secure with
retainingwire,fromfittingspack, see diagram5.4. Againmake
sure that the cable is not touching the casing.
5.3 Boiler Control Box
Taking care that the POWER IS OFF, wire the incoming mains
cable to the mains plug supplied in the fittings pack. Do not
connect the mains supply plug to the control box socket, see
diagram 5.5.
5.4 Boiler User Control lead fitting,
Chatsworth 4 and Dovedale 4 only.
Beforethefirefrontispositionedtheboilerusercontrolwillneed
to be fitted to the control box.
Remove the control box lid securing screws, see diagram 5.5.
Remove the control box lid taking care not to damage the
insulation.
Remove the boiler user control and its long connecting lead
from the control box, see diagrams 5.8 and 10.4.
Remove the long connecting lead and bracket from boiler user
control, first unscrewing cable grip to remove support bracket
and then unplug lead. Discard support bracket and long lead,
see diagram 5.6.
5 ElectricalWiring
Diagram 5.3
9636
ELECTRICAL
SUPPLY
CABLE
Diagram 5.1
6452
Froststat Pipestat
RoomstatProgrammer
Pump
L
N
E
L
N
E
Double
Pole
Switchspur
3 Way
Plug at
Appliance
(Right hand shown)
Diagram 5.2
11615
ELECTRICAL
SUPPLY CABLE
(Left hand shown)

15 2000225024C
Diagram 5.4
Diagram 5.5
9394
9395
CONTROL
THERMISTOR
PHIAL
POCKET
MAINS
SUPPLY
PLUG
CONTROL BOX
SOCKET
CONTROL
BOX
Plug the short connecting lead (supplied in the fire front fittings
pack) into the boiler user control
Slidetheboilerusercontrolintopositiononthecontrolboxfront,
making sure that it fits into the groove in the control box, and
connect the lead plug on to P.C.B., see diagrams 5.8 and10.4.
Refit the control box lid ensuring the boiler user control fits into
the slot in the lid, see diagram 5.7.
Refit the control box securing screws.
5.5 Testing - Electrical
Checks to ensure electrical safety must be carried out by a
competent person.
After installation of the system, preliminary electrical system
checks as below should be carried out,
1. Test insulation resistance to earth of mains cable.
2. Test the earth continuity and short circuit of all cables.
3. Test the polarity of the mains.
4.Withthemainssupplyoff.Plugthemainssupplyplugintothe
control box socket, see diagram 5.5.
5.6 Overheat Cut-off Device
(sealed systems only)
A kit No. 2000463000 is available with Fitting Instructions.
5 ElectricalWiring
L
E
NSECURING
SCREWS
(4)
Diagram 5.6
9634
CONNECTING
LEAD
CABLE
GRIP
SECURING
SCREW
SUPPORT
BRACKET
INSERT
RETAINING WIRE
AND SECURE
Diagram 5.7
9395
MAINS SUPPLY
PLUG
CONTROL BOX
SOCKET
CONTROL
BOX
L
E
N
SECURING
SCREWS
(4)
BOILER USER
CONTROL

16
2000225024C
5 ElectricalWiring
Diagram 5.8
9490
MAINS IN
BOILER
USER
CONTROL
THERMISTOR
EARTH
POST
GAS VALVE
FLUE BLOCKAGE
SAFETY DEVICE
AND PILOT
b
br
g/y
g/y
g/y
b
br
bk
rbwhbk
y g
bk wh
bk bk
or
KEY
Black bk
Blue b
Brown br
Green g
Yellow y
Green/Yellow g/y
White wh
Orange or
OVERHEAT CUT-OFF
SAFETY DEVICE
(SEALED SYSTEM ONLY)
b
br

17 2000225024C
6 Commissioning
6.1 Commissioning the Back Boiler
Before commissioning the back boiler, the whole of the system
should be thoroughly flushed out with cold water with the
circulation pump removed. Replace the pump, fill the system
andexamineforwatersoundness.Ventairfromthesystemand
pump.
The back boiler unit is fitted with a flue blockage safety device,
whichwill shut it down if there is a lack of oxygen. The principle
by which this operates is that when there is a depletion of
oxygen resulting from a build up of combustion products, the
flame on the pilot light will become unstable and lift up off the
sensing device, this will deactivate the gas valve via the p.c.b.,
cutting off the gas supply.
If the back boiler unit shuts down frequently for no apparent
reason the first things to be checked are the chimney and air
inlets into the room. Any problems found must be put right, by
a competent person, and a full operational test carried out
before the back boiler unit is used again.
Theflueblockagesafetydeviceincorporatestheelectrode and
pilot assembly.
The flue blockage safety device MUST NOT be adjusted or
disconnected. It must be serviced strictly in accordance
with the instructions in this book. Any unauthorised
interference could result in the device failing to operate,
creating a potentially dangerous situation. If replacing,
use only the correct and approved parts.
CAUTION: The following work should be carried out by a
competent person.
Identify the back boiler controls by reference to diagram 6.1.
Open all windows and put out any naked lights, cigarettes etc.
Testthegassupplyforsoundness.Purgeairinaccordancewith
the current issue of BS6891.
Checkthattheelectricalsupplytothebackboilerisswitchedoff.
Setthecontrolthermistorknob“A”to“O”position,seediagram
6.1.
NOTE:Firelite4, Contour4,Miami 4,Heartbeat4 andBlack
Beauty 4 only.
Take care when handling the boiler user control so that the
extension lead is not strained.
continued -
Make sure the thermistor phial is fitted correctly, see diagram
5.4.
Loosen the back boiler burner pressure test screw “B” and
connect a suitable pressure gauge.
Turngas service cock “C” tothe “On” position making surethat
the fire front service cock “D” is in the “Off” position, restrictor
fully screwed in, see diagram 6.2.
Diagram 6.1
9396
CONTROL
BOX
CONTROL
THERMISTOR
KNOB “A”
PRESSURE TEST
POINT “B”
GAS
CONTROL
VALVE
GAS SERVICE
COCK “C”
ADJUSTER “G”
ELECTRICAL
PLUG
BOILER
USER
CONTROL

18
2000225024C
Diagram 6.2
9608
ADJUSTER “G”
GAS
CONTROL
VALVE
GAS SERVICE COCK “C”
(SHOWN IN THE OFF
POSITION)
GAS FIRE
SUPPLY COCK "D"
CAP
RESTRICTOR
SCREW
WASHER
Technical Sequence of Operation
When an external control calls for heat there is approximately
a 5 second delay. The control board (PCB) energises the 1st
gas valve solenoid, the valve will open and the spark unit will
operate. Withthevalve open, gas is allowed to pass totheflue
blockage safety device that will be ignited by the sparks. This
ignitionattemptwillcontinueuntilthemicro-ampagegenerated
at the sense electrode is sufficient to satisfy the board. At this
point the spark unit is de-energised and the green light on the
boiler user control will light up, see diagram 6.1. The main gas
control valve is energised through the control board and main
burnerlights. Whenthewatertemperaturehasreachedtheset
point the control thermistor instructs the control board to close
the gas valve.
NOTE. If the electrical supply is switched rapidly off and on
without gas present the control will purge for 100 sec. Neither
of the indicators will be lit. The appliance will then operate
correctly.
When the water temperature has reduced to a set point the
control thermistor will instruct the control board to restart
ignition.
Theboilerwillcontinue tocycleinthismanner until theexternal
control stops its demand for heat. At this point external power
is removed and the board switches off.
Check the pilot flame is stable and has a length as shown in
diagram 6.3.
Note:Shouldtheredlightonthebackboilercontrolpanelcome
on,itindicatesthatthepilotlightisnotoperatingcorrectly,orthe
flue blockage safety device has been activated, see diagram
6.1.
When the fault has been corrected, turn the control thermistor
knob "A" fully anti-clockwise so that the pointer is against the
"Reset" position on the back boiler user interface, see diagram
6.1.
Turnthecontrolthermistorknob"A"fullyclockwisetomaximum
onthe back boiler user control. After a delay the unit will restart
theignitionsequence.Thisisindicated by thegreenlightonthe
boiler user interface coming on, see diagram 6.1.
The main burner will light.
Test for gas soundness using a suitable leak detection fluid.
The back boiler is supplied preset to a maximum heat output
setting of 14.21 kW (48500 Btu/h) but may be adjusted to suit
design requirements.
This value is permitted and must not be increased when using
the boiler in combination with a Chatsworth 4 and a Dovedale
4 firefront.
For Firelite 4, Contour 4, Miami 4, Heartbeat 4 or Black Beauty
4 fire front the output may be increased to 15.82 kW
(54000 Btu/h).
If adjustment is required, TEN MINUTES after lighting, turn
adjustmentscrew“G”anti-clockwisetosuitsystemdesignheat
input, see diagram 6.1 and 6.2.
Should any doubt exist, the gas rate should be checked at the
gas meter.
The rate of the back boiler should be within the range:
For Firelite 4, Contour 4, Miami 4, Heartbeat 4, Black Beauty 4
1.88m3/h (65.5ft3/h) to 1.45m3/h (51.15ft3/h)
For Chatsworth 4, Dovedale 4:
1.68m3/h (59.3ft3/h) to 1.27m3/h (44.9ft3/h)
Note, if the gas rate is checked, make sure that all other gas
appliances and pilot lights are turned off.
Turn control thermostat knob "A" anti-clockwise to the "Reset"
position. Removepressuregaugeandreplacetestpointscrew
ensure a gas tight seal is made.
Relight the back boiler by turning control thermostat knob "A"
clockwise to maximum.
Use the self-adhesive arrow from the fittings pack and stick it
against the relevant heat input figure on the Data Label.
LIGHTING: SEQUENCE OF OPERATION
1. Switch on the electrical supply to the boiler
and heating sytsems.
2. Set external controls if fitted, to demand heat.
3.Turn the boiler control thermistor knob
fully clockwise to the maximum setting.
The lighting sequence is automatic as follows:-
4. Approximate 30 second delay.
5. Ignition initiated sparking at electrode
EV1 energised, (Pilot solenoid)
pilot lights.
6. EV2 energised, (Main burner solenoid)
main burner lights.
9555
6 Commissioning

19 2000225024C
6 Commissioning
6.2 Testing the Back Boiler Controls
To test the flame failure, turn the boiler on. After about 3
minutes,turnthegasservicecockoff,thelockoutdeviceshould
nowoperate. Thisis indicated by the red light comingonat the
back boiler control panel.
To restart the boiler, turn on the gas supply at the gas service
cock and turn the control thermostat knob "A" anti-clockwise to
the "Reset" position then clockwise to maximum.
DONOTATTEMPTTORELIGHTUNTILATLEAST3MINUTES
HAVE GONE BY.
Check that the boiler thermostat control and any external
controls operate the back boiler correctly.
NOTE. If the electrical supply is switched rapidly off and on
without gas present the control will purge for 100 sec. Neither
of the indicators will be lit. The appliance will then operate
correctly.
6.3 Clearance of Products
Aclearanceofproducts(spillage)testmustbecarriedoutafter
installation of the back boiler and it's fire.
Beforefittingthefire,checkthattheheatexchangerbafflesare
fitted and seated correctly, see Section 4.9.
Details of the necessary tests to be carried out will be found
under “TEST FOR CLEARANCE OF PRODUCTS” in the Fire
Front Installation Instruction Booklet.
Note: This test must only be carried out after the fire front has
been fitted to the back boiler unit.
6.4 Commissioning the System
Setallcontrolstooperatetheheatingsystem. Adjustcirculating
pump and balance the system to give a temperature drop
acrosstheboilerof11oC(20oF). Attheappropriateflowrate,the
resistance of the back boiler can be found by reference to
diagram 6.4.
There should be no undue noise in the pipework or heat
emitters. There must be NO pumping over of water or entry of
airattheopenventpipeabovethefeedandexpansioncistern. Diagram 6.3
9520
13mm FLAME
DIMENSION
Diagram 6.4
10120
Makesurethe backboilercontrolthermostatknob "A"isturned
clockwise to maximum, which is about 82oC (180oC), against
the setting point, allow the water to reach maximum working
temperature. Examine the system for water soundness.
Turnthecontrolthermostatknob"A"anti-clockwiseto"RESET"
(OFF) and rapidly drain the system whilst still hot, to complete
the flushing process.
Refill the system, vent and check again for water soundness.
Isolate gas at gas service cock ‘C’ and the electrical supply to
the back boiler until the fire front is fitted.

20
2000225024C
7 Fire Installation
Fire Front Installation and Servicing Instructions are packed
with the fire.
7.1 Completion - After Installation of the Fire
Front
Instruct and demonstrate to the user, the efficient and safe
operation of the boiler, heating and hot water system and fire
front.
HandtheInstructions forUsetotheuser,makingsure thatthey
are understood.
Advise the user that to ensure the continued efficient and safe
operation of the appliance it is recommended that it is checked
and serviced as necessary at regular intervals. The frequency
of the servicing will depend upon the particular installation
conditions and usage, but in general once a year should be
enough.
Draw attention, if applicable, to the current issue of the Gas
Safety (Installation and Use) Regulations, Section 35, which
imposes a duty of care on all persons who let out any property
containing a gas appliance.
It is the law that any servicing must be carried out by a
competent person.
Setanyremotecontrolsforthesystemtosettingsrequestedby
the user.
Advisethattheboilerisfittedwith a flue blockagesafetydevice
and refer to the Instructions for Use.
Advise the user of the importance to keep any purpose built
ventilationsystemwherethe applianceisinstalled,clearof any
obstruction that would impede its efficiency.
Reminder, leave these instructions with the user.
Advise the user that the ‘Benchmark’ logbook should be
completed by the installation engineer on completion of
commissioning or servicing.