Glowworm Economy Plus 41 319 04 Release note

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Tobeleftwiththeuser
Installation & Servicing Instructions
This is a Cat I2H Appliance BS6332
BS5258
Balanced Flue Boilers With Honeywell Control
G.C. No. 41 319 04
G.C. No. 41 319 62
60B
75B
2
2404
One Contact Total Service
Hepworth Heating Ltd.,
Nottingham Road, Belper, Derbyshire. DE56 1JT
General/Sales enquiries :
Tel: [phone] Fax: [phone]

Customer Services:
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1 General
C
L
OVERALL DIMENSIONS
Given in millimetres Diagram 1.1
338 300
225
FLOW
WATER
CONNECTIONS
WATER
CONNECTIONS
GAS
CONNECTION 98
446 98
43 154
340
414
11
490
600
56 110
GAS
CONNECTION
FLUE
2401
RETURN
The instructions consist of two parts Installation and
Servicing Instructions and Instructons for Use which
includes the Guarantee Registration Card.
The instructions are an integral part of the appliance and
must, comply with the current issue of the Gas Safety
(Installation and Use) Regulations, be handed to the user
on completeion of the installation.
1 General Notes and Information.
This boiler is suitable for fully pumped systems only.
Important Notice
The boiler is for use on natural gas as distributed in the
United Kingdom (G20) and cannot be used on any other
gas.
Sheet Metal Parts
WARNING. When installing or servicing the boiler care
should be taken when handling sheet metal parts to avoid
any possibility of personal injury.
Wherever possible, all materials, appliances and
components to be used shall comply with the
requirements of applicable British Standards.
Where no British Standards exists, materials and
equipment should be fit for their purpose and of suitable
quality and workmanship.

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1 General
1.1 Statutory Requirements
This boiler must be installed by a competent person in
accordance with the requirements of the current issue of:
The Gas Safety (Installation and Use) Regulations,
The Building Regulations, The Building Standards
(Scotland) Regulations, (applicable in Scotland), Local
Water Company Bye-laws, Control of Substances
Hazardous to Health, The Electricity at Work
Regulations and any applicable local regulations.
Detailed recommendations are contained in the current
issue of the following British Standards and Codes of
Practice:
BS6798, BS5440 Parts 1 and 2, BS6891, BS5546 Part 1,
BS5449, BS7074 Part 1 and 2, BS7478, BS7593,
BS7671.
1.2 Data
Weight 60B - 32kg (71lb)
75B - 33.2kg (73.1lb)
Electrical supply - 240V~50Hz fused 3A
Water content 60B - 0.71Litre (0.16gal)
75B - 0.75Litre (0.17gal)
Gas connection - Rc 1/2
Water connection- 28mm copper flow at right
Data label- Bottom right, inner case.
Injector 60B - Bray 30-1700
75B - Bray 30-2200
1.3 Range Rating
This boiler is range rated and may be adjusted to suit
individual system requirements.
Table 1 gives the ratings and settings.
1.4 B.S.I. Certification
This boiler is certificated to the current issue of BS6332
Part 1, invoking the current issue of BS5258 Part 1 for
performance and safety. It is, therefore, 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 of the
boiler, the warranty and could also infringe the current
issue of the Statutory Requirements.
CE Mark
The CE Mark on this appliance shows compliance with:
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.

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1 General
RANGE RATING
NOMINAL
HEAT
OUTPUT
BURNER
SETTING
RANGE RATING
NOMINAL
HEAT
OUTPUT
BURNER
SETTING
PRESSURE
kW
Btu/h
kW
Btu/h
m bar
ECONOMY PLUS 60B Table 1
-18.47 22.00
-63,000 75,000
16.1214.66 17.59
55,00050,000 60,000
11.69.3 13.4
4.63.7 5.4
Max.Min. Med.
in. w.g.
kW
Btu/h
kW
Btu/h
m bar
ECONOMY PLUS 75B Table 1
-22.13 27.50
-75,500 93,800
19.817.60 22.00
67,50060,000 75,000
11.89.4 14.5
4.73.8 5.8
Max.Min. Med.
in. w.g.
1.5 Gas Supply
The gas installation shall be in accordance with the
current issue of BS6891.
The supply from the governed meter must be of
adequate size to provide a steady inlet working pressure
of 20mbar (8in wg) at the boiler.
On completion test the gas installation for soundness
using the pressure drop method and suitable leak
detection fluid, purge in accordance with the above
standard.
1.6 Electrical Supply
WARNING. This boiler must be earthed.
All system components shall be of the approved type
and wiring shall comply with and be connected in
accordance with the requirements of the current issue of
BS7671 and any applicable local regulations.
Connection of the boiler and system controls to the
mains supply must be through a common isolator and
must be fused 3A maximum. This method of connection
should be, preferably, by a fused double pole isolating
switch, provided it has a minimum contact separation of
3mm on both poles. This should be readily accessible
and preferably adjacent to the appliance. It should
supply the appliance only and be easily identifiable as so
doing.
Alternatively an unswitched shuttered socket outlet and
3A fused 3 pin plug both to the current issue of BS1363
may be used provided that they are not used in a room
containing a bath or shower.
Wiring to the boiler must be PVC insulated type to the
current issue of BS6500 Table 16, not less than
0.75mm2(24/0.20mm).
1.7 Contents of Packaging
The boiler is delivered in one pack.
The other pack contains the balanced flue terminal
assembly and accessories.
Refer to Section 2.3 to check that the flue terminal
assembly supplied is suitable.
1.8 Water System
The boiler may be fitted to an open vented or sealed
system, refer to Section 3 for details.
PRESSURE
B
AA
C
MINIUMUM CLEARANCES Diagram 1.2
AL.H and R.H. side of casing 5
BTop of casing 75
CBottom of casing 150
D Front of boiler
(from a permanent surface) 305
Balanced
Flue
Model
Minimum Clearances
from Walls, Ceiling, Floor,
Cupboard, Worktops,
Inflammable Material etc.
2399
NOMINAL
HEAT
INPUT
NOMINAL
INPUT
HEAT

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1 General
Diagram 2.1
MINIUMUM SITING DIMENSIONS FOR BALANCED FLUE TERMINALS
POSITION MINIMUM
SPACING
ADirectly below an openable window,
air or any other ventilation opening 300mm
BBelow gutter, drain/soil pipe 300mm
CBelow eaves 300mm
DBelow a balcony or car port 600mm
EFrom vertical drain pipes and soil pipes 75mm
FFrom internal or external corners 600mm
GAbove adjacent ground or balcony level 300mm
HFrom a surface facing the terminal 600mm
I Facing terminals 600mm
JFrom opening (door/window) in car
port into dwelling 600mm
KVertical from a terminal 1500mm
1.9 Draining Tap
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.
The boiler is fitted with a drain tap for draining down the
heat exchanger.
Draining taps shall be to the current issue of BS2879.
1.10 Safety Valve
A safety valve need not be fitted to an open vented
system.
1.11 Location
This boiler is not suitable for outdoor location.
The boiler may be installed in any room, although
particular attention is drawn to the requirements of the
current issue of BS7671 with respect to the installation
of a boiler in a room containing a bath or shower.
Any electrical switch or boiler control using mains
electricity should be so fitted that it cannot be touched by
a person using the bath or shower. The electrical
provisions of the Building Standards (Scotland)
Regulations are applicable to such installations in
Scotland.
The boiler must be mounted on a flat wall which is
sufficiently robust to take its weight.
1.12 Boiler Location
Refer to diagram 1.2.
The boiler must be positioned so that at least the
minimum operational and servicing clearances are
provided.
Additional clearances may be required for installation.
If fixtures are positioned next to the boiler they should
be made removable for access to pipework.
Sufficient clearance must be left in front of the boiler for
servicing.
2.1 Terminal Position
The minimum acceptable spacings from the terminal to
obstructions and ventilation openings are shown in
diagram 2.1.
Where the terminal is fitted within 850mm (34in) below
plastic guttering or within 450mm (18in) of painted
eaves or painted gutters an aluminium shield 750mm
(2ft6in) long should be fitted to the underside and
immediately beneath the guttering/eaves.
2.2 Protecting the Terminal
A terminal guard is required if persons could come into
contact with the terminal or the terminal could be subject
to damage.
2 Flue and Ventilation
1112
Under Car Port etc.
H,I
JD
F
K
A
A
FGEA
GG
B,C B,C
FF
K
K
K
C
LL
G
G
1112
If a terminal guard is required, it must be positioned to
provide a minimum of 50mm clearance from any part of
the terminal and be central over the terminal.
Guards are available from,
Tower Flue Components Ltd.,
Morley Road,
Tonbridge,
Kent, TN9 1RA.
quoting their reference “F”black,

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2 Flue and Ventilation
AIR VENT AREA TABLE FOR
COMPARTMENT INSTALLATIONS
TABLE 2 AIR VENT AREAS
POSITION AIR FROM AIR DIRECT
OF ROOM OR FROM
AIR VENTS INTERNAL OUTSIDE
SPACE
HIGH VENT 200cm2100cm2
LOW VENT 200cm2100cm2
3 Water Systems
PRESSURE LOSS OF BOILER Diagram 3.1
2.3 Wall Thickness
Check the thickness of the wall.
The standard flue set supplied is suitable for wall
thickness 238mm to 330mm. For other wall thickness, a
short flue kit No.443239 for 76mm to 238mm and a long
flue kit No. 443240 for 324 to 580mm are available.
2.4 Boilers in a Compartment
Where the installation of the boiler will be in an unusual
location, special procedures are necessary, the current
issue of BS6798 gives detailed guidance on this aspect.
A compartment used to enclose the boiler must be
designed and constructed specifically for this purpose.
An existing cupboard or compartment modified for the
purpose may be used.
Details of essential features of cupboard design are given
in the current issue of BS6798.
The doorway opening should be of sufficient size to
allow for easy removal of the boiler.
Where the boiler is fitted in a cupboard or compartment,
permanent high and low level ventilation must be
provided. The minimum ventilation areas required are
given in Table 2.
2.5 Timber Frame Buildings
If the boiler is to be installed in a timber frame building
it should be fitted in accordance with the British Gas
publication “Guide for Gas Installation in Timber
Framed Housing” reference “DM2”. If in doubt, seek
advice from the local gas undertaking or Hepworth
Heating Ltd.
Notes
Pump
The pump should be fitted in the flow pipework from the
boiler with valves each side, integral if possible, it
should produce at least 2.5m (8ft) head, a temperature
difference across the boiler of 11oC (20oF). Flow rate
through the boiler of 23Litres/min (5.1gal/min).
See diagram 3.1 for pressure loss across the boiler.
High resistance microbore systems may require a higher
duty pump.
Bypass
A bypass must be fitted, see diagram 3.2.
The flow rate through the boiler must not be allowed to
fall below 18Litres/min (3.9gal/min) whilst the burner is
alight.
3.1 Water System - Open Vented Systems
For an open, vented, system the boiler must be supplied
from an unrestricted water supply taken from a feed and
expansion tank, situated at a maximum height of
27.5metres (90ft) above the boiler.
The cold feed supply must be 15mm minimum size.
It is important that the relative positions of the pump,
cold feed and open vent are as shown in diagram 3.2.
Flow rate (gallons/minute)
Water pressure loss (mm head of water)
60B
75B
Water pressure loss (inches head of water)
Flow rate (litres/minute)
01
1500
1250
1000
750
500
250
60
50
40
30
20
10
00
23456
0123456
2428

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3 Water Systems
3.2 Cylinder
SINGLE FEED (SELF PRIMING) CYLINDERS ARE
NOT RECOMMENDED.
The hot water cylinder must be a double feed, fully
indirect, type.
3.3 Inhibitor
Attention is drawn to the current issue of BS5449 and
BS7593 on the use of inhibitors in central heating
systems.
If an inhibitor is to be used, contact a manufacturer for
their recommendations for the best product to use.
When fitting the boiler in an existing system take special
care to drain the entire system including the radiators,
then thoroughly cleaning out before fitting the boiler
whether or not adding an inhibitor.
Sealed Water Systems
The installation should comply with the requirements of
the current issue of BS4814, BS5449, BS6759, BS6798
and BS7074 Part 1 and 2.
See diagram 3.3. for a suggested layout.
3 LITRES (0.66 gals)
MAKE-UP BOTTLE
(if required)
NON-RETURN
VALVE
AUTO
AIR
VENT
FLOW
22mm (min)
BYPASS
WITH
LOCKSHIELD
VALVE
RETURN
DRAIN
COCK BOILER
SAFETY
VALVE
( Make-up
alternatives) EXPANSION
VESSEL
PRESSURE
GAUGE
CIRCULATING
PUMP
FILLING POINT
AIR
RELEASE
POINT
HEATING CIRCUIT
Diagram 3.3
SEALED WATER SYSTEM
DIAGRAMMATIC LAYOUT
Open (vented) system.
Recommended
relationship between
pump, cold feed and
vent.
22 mm (MIN) VENT
FEED AND
EXPANSION
CISTERN
15mm (MINIMUM)
COLD FEED
22mm (MINIMUM)
BY-PASS WITH
LOCKSHIELD VALVE
450mm
MIN.
HEIGHT
1150mm
MIN.
BOILER
PUMP
150mm
MAX
FLOW
RET.
RET.
CYLINDER
FLOW
HEATING
0011M
OPEN (VENTED) WATER SYSTEM
Recommended relationship between
pump, cold feed and vent
0854
0750
Diagram 3.2

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METHOD 1
METHOD 2
METHOD 3
SUPPLY STOP
VALVE
SUPPLY
PIPE
HOSE
UNIONS SERVICING
VALVE
TEMPORARY
HOSE
HEATING
SYSTEM
HEATING
SYSTEM
TEMPORARY
HOSE
HOSE
UNIONS SERVICING
VALVE
SUPPLY
PIPE
SUPPLY STOP
VALVE
DOUBLE CHECK
VALVE ASSEMBLY
HEATING
SYSTEM
SERVICING
VALVE
SUPPLY
STOP VALVE
SUPPLY
PIPE
HOSE
UNIONS DOUBLE CHECK
VALVE ASSEMBLY
OVERFLOW
CISTERN
COMBINED
CHECK VALVE
AND VACUUM
BREAKER
PRESSURE
REDUCING
VALVE
3 Water Systems
Diagram 3.4
FILLING SEALED
WATER SYSTEMS
3.4 Safety Valve
A safety valve must be fitted in a sealed water system.
It shall be preset, nonadjustable with a lift pressure of
3bar, incorporating seating of a resilient material, a test
device and a connection for drain.
The drain from the safety valve must be routed clear of
any electrical fittings and positioned so that any
discharge can be seen.
3.5 Expansion Vessel
A diaphragm type expansion vessel, conforming to the
current issue of BS4814, see also BS7074 Part 1 and 2,
must be connected at a point close to the inlet side of the
circulating pump, see diagram 3.3 or as laid down by the
manufacturer.
The expansion vessel volume depends on the total water
system volume and the initial system design pressure.
For any system an accurate calculation of the vessel size
is given in the current issue of BS7074 Part 1.
Example. For an initial system design pressure of
0.7bar, the minimum total vessel volume required id
0.063xTotal System volume.
Note. A higher initial design pressure requires a larger
volume expansion vessel.
Guidance on vessel sizing is also given in the current
issue of BS5449 and BS7074 Part 1.
The charge pressure must not be less than the static head
of the system, that is, the height of the highest point of
the system above the expansion vessel.
The water content of the boiler is given in Data Table 1.
3.6 Pressure Gauge
A pressure gauge with a set pointer and covering at least
the range 0 to 4bar (0 to 60lb/in2) shall be permanently
fitted to the system in a position where it can be seen
when carrying out the filling operation.
3.7 Cylinder
SINGLE FEED INDIRECT CYLINDERS ARE NOT
SUITABLE.
The hot water cylinder must be of the indirect coil type.
It must be suitable for working at a gauge pressure of
0.35bar above the safety valve setting.
3.8 Water Make Up
Provision must be made for replacing water lost from the
system. A make up vessel mounted above the highest
point of the system and connected through a non-return
valve to the system on the return side of either the hot
water cylinder or heating system.
Alternatively, provision for make up can be made by
using a filling loop.
3.9 Filling Sealed Water Systems
Provision for filling the system at low level must be
made. Three methods of filling are shown in
diagram 3.4. There must be no permanent connection to
the mains supply, even through a non-return valve.
3132

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4 Flue and Appliance Preparation
BOILER FIXING DIMENSIONS Diagram 4.1
4.1 Positioning
Place the template, provided, square on the wall in the
required position and mark location of the balanced flue
hole, see diagram 4.1.
Cut the hole in the wall to accept the wall liner, see
diagram 4.1.
Make good any plasterwork at this stage. When dry,
select the liner with the turned flange at one end “C”, see
diagram 4.2. Push it into the cavity until the flange is
flush to the internal wall. Fit the second half of the liner
“B” from inside so that it is flush with the outside
brickwork. Mark the two liner positions and remove
from hole. Align the marks on the liners and tape
together with the tape provided.
The extension “B” is not required when the wall
thickness is equal to the length of duct.
Reposition the template on the wall in line with the wall
opening, or see diagram 4.1.
Mark the positions for the three fixing screws.
Drill and plug the fixing holes, suitable for No.10x50mm
woodscrews and plugs.
TERMINAL and AIR DUCT Diagram 4.2
A - TERMINAL ASSEMBLY
B - AIR DUCT EXTENSION
C - AIR DUCT
D - SELF ADHESIVE SEAL
E - HOLE FOR CORD / STRING 15 mm
APPROX
E
B
C
AD
0855
0858

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5.1 External Access Procedure
From inside the room fit the already prepared air duct
assembly.
Attach the self adhesive seal “D” to the terminal wall
plate, see diagram 4.2.
Place the terminal against the outside wall with the inner
flange of the wall plate located inside the air duct
assembly. Support the terminal in any suitable way.
Working from the inside, bend the two perforated straps
around the hexagon nuts provided at about 15mm from
the brackets on the air duct assembly, see diagram 4.2.
Secure the two straps with the screws and nuts, the screw
head passing first through the large part of the keyhole in
the bracket, then sliding into the smaller recessed
portion.
Tighten the screws to tension the straps securing the
terminal in position, do not overtighten. Cut off any
excess strap length.
5.2 Internal Access Procedure
If required the terminal can be installed from inside the
premises.
Fit the already prepared air duct assembly into the hole
in the wall.
Attach the self adhesive seal “D” to the terminal wall
plate “A”, see diagram 4.2.
Attach a length of strong cord or similar, to the terminal
through the small hole “E” provided in the top centre
baffle, see diagram 4.2. Attach a suitable weight to the
free end of the cord.
Pass the terminal through the duct assembly, using the
straps to manoeuvre the terminal into position.
NOTE, the terminal “Top” is indicated and the inside
flange of the wall plate is located inside the air duct
assembly. The weight will support the terminal in
position.
Bend the two perforated straps around the hexagon nuts
provided, see diagram 4.2.
Secure the two straps with the screws and nuts, the
screws head passing first through the large part of the
keyhole in the bracket, then sliding into the smaller
recessed portion.
Tighten the screws to tension the straps securing the
terminal in position, but do not overtighten. Cut off
excess strap length and remove cord.
5 Installation
LUG
INNER
CASE OUTER
CASE
OUTER CASE
SECURING
SCREW
OUTER
CASE INNER
CASE
LUG
INNER CASE
SECURING
SCREWS (TOP)
INNER and OUTER CASING Diagram 5.1
INNER CASE
SECURING
SCREWS
(BOTTOM)
SECURING
SCREW
CASING SIDE STRIP
WING NUT
AND SPRING
WASHER (2) HOOK
BOLT (2)
FLUE
HOOD
SECURING
ANGLE
APPLIANCE PREPARATION Diagram 5.2
2389
2407

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5.3 Appliance Preparation
Remove the controls cover by pulling if forward and off.
Remove the outer case by undoing the screw at the
bottom and unhooking at the top.
Remove the inner case by undoing the screws at the top
and bottom, see diagram 5.1.
Remove the flue hood by releasing the wing nuts and
remove angle, see diagram 5.2. Lift off flue hood.
Remove the two flue duct screws.
Fit the sponge seal “J” around the spigot at the back of
the boiler, adhesive face to the back of the case, see
diagram 5.3.
Take the side strips from the packaging and hook them
over the top edge of the side panel and secure with a
screw at the bottom.
5.4 Appliance Fixing
Fit the top two screws, allowing them to protrude from
the wall face to accept the keyhole slots on the boiler.
Hook the boiler onto the screws, fit the bottom screw
and tighten all three.
5.5 Standard and Short Flue Only
Push the flue duct “G” into the terminal with the
unflanged end entering the terminal. Make sure that the
lower flange of the duct fits behind the combustion
chamber rear panel. For wall less than 150mm thick cut
the surplus length from the unflanged end of the flue
duct “G”, see diagram 5.3.
Fit the two screws through the flue duct flange and
sealing plates but do not fully tighten.
Replace the flue hood “H”, inserting the rear into the flue
duct. Push on the rear of the hood and tighten the duct
screws. Refit the securing angle, hook bolts, wing nuts
and spring washers firmly but do not overtighten.
Refit the inner case and secure with the screws
previously removed.
5 Installation
STANDARD or SHORT FLUE DUCT Diagram 5.3
G - FLUE
H - FLUE HOOD
J - CASE SEAL
J
FLUE
DUCT
SECURING
SCREW (2)
H (60)
H (60)
G
2775

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5 Installation
5.6 Long Flue Set Only
For long flues the flue duct “G”, extension “L” and
sleeve “K” need to be assembled together to suit the wall
thickness. This assembly is 75mm longer than the air
duct assembly already prepared. A minimum overlap of
40mm is required at each joint. Use the tape provided to
make permanent the assembly of the three flue parts, see
diagram 5.4.
Push the flue duct assembly into the terminal, with the
unflanged end entering the terminal. Make sure that the
lower flange of the duct fits behind the combustion
chamber rear panel.
Fit the two screws through the flue duct flange and
sealing plates, do not overtighten.
Replace the flue hood “H”, inserting the rear into the flue
duct. Push down on the rear of the hood and tighten the
sealing plate screws. Refit the securing angle, tie rods
and wing nuts firmly, do not overtighten.
Refit the inner case and secure it with the screws
previously removed.
LONG FLUE DUCT Diagram 5.4
G - FLUE DUCT
H - FLUE HOOD
L - FLUE DUCT EXTENSION
K - FLUE DUCT SLEEVE
J - CASE SEAL
FLUE
DUCT
SECURING
SCREW(S)
H (60)
H (75)
J
LK
G
2776

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6 Gas and Water Connection
7 Electrical Wiring
7.3 Testing - Electrical
Checks to ensure electrical safety should 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 cables.
2. Test the earth continuity and short circuit of all cables.
3. Test the polarity of the mains.
Connect the gas supply to the Rc1/2gas cock.
The whole of the gas installation, including the meter
should be inspected, tested for soundness and purged in
accordance with the current issue of BS6891.
Connect water to the boiler using the nuts and olives
supplied to BS2871 copper tube.
WARNING. THE BOILER MUST BE EARTHED
AND HAVE A PERMANENT MAINS SUPPLY.
7.1 Electrical Connection
To remove the control box release the two screws at the
front, see diagram, lower the box until it is clear then
push backward to disengage the hinge at the rear, see
diagram 7.1 Take care not to damage the thermostat and
capillaries.
Thread the mains lead through the clamp at the rear of
the control box cover, and connect to the terminal strip.
The mains cable outer insulation must not be cut back
external to the cable clamp.
When making connections, make sure that the earth
conductor is made of greater length than the current
carrying conductors, so that if the cable is strained the
earth conductor would be the last to become
disconnected.
7.2 Pump and External Controls
Connections
The pump must be wired into the boiler control box as
shown in diagram 7.2.
Any external controls must only be wired to interrupt the
red link between terminals 9 and SL.
Take the strain relief grommets from the loose items
pack. Place around the external controls and pump
connection cables respectively. Squeeze the sides of the
grommets when pushing them into the obround holes in
the rear of the control box, see diagram 7.1.
Make sure that the supply cables and all external cables
are secured.
STRAIN
RELIEF
GROMMET
FASTENER
CONTROL BOX Diagram 7.1
EARTH
POST
RETAINING
STRAP
SECURING
SCREWS
TERMINAL
STRIP
2420

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7 Electrical Wiring
WIRING for CONTROL BOX Diagram 7.2
2419
BROWN
BLUE
GRN / YELLOW
BROWN
BLUE
240~50Hz
PERMANENT
MAINS SUPPLY
FUSED AT 3A
L
N
L
N
CIRCULATION
PUMP
CHASSIS
EARTH
POST
GRN/YEL
GAS VALVE
BROWN
BLUE
PURPLE
RED
RED
BROWN 73
98 6
COMBINED THERMOSTAT
AND PUMP OVERUN
BROWN
BLUE
GRN / YELLOW
Remove Red Link
between 9 and SL
when fitting a time
control etc.
(If link is not
removed the
circulation pump
will run constantly.)
SWITCHED
CONTROL
TIME SWITCH
PROGRAMMER ETC.
(if fitted)
NLSL 987
NL987
SL

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8 Commissioning
8.1 All Systems
Make sure that the system has been thoroughly flushed
out with cold water without the pump in place.
Refit the pump, fill the system with water, ensuring that
all air is properly vented from the system and pump.
Before operating the boiler check that all external
controls are calling for heat.
8.2 Sealed Water Systems Only
Flush the whole of the system with cold water without
the pump in place. Refit the pump and fill until the
pressure gauge registers 1.5bar (21.5lbf/in2). Clear any
air locks and check for water soundness.
Check the operation of the safety valve, by allowing the
water pressure to rise until the valve opens. The valve
should open within +/- 0.3 bar (+/-4.3lbf/in2) of the 3bar
preset pressure. Where this is not possible conduct a
manual check and test.
Release cold water to initial system design pressure.
The set pointer on the pressure gauge should be set to
coincide with the indicating pointer.
8.3 Initial Lighting and Testing
Refit the outer case, see diagram 5.1.
Identify the controls by reference to diagram 8.1.
Turn boiler thermostat to “O” the Off position.
Remove the gas pressure test point screws “K” and fit a
suitable pressure gauge.
Turn the electrical supply on and check that the pump is
working.
OPEN ALL WINDOWS AND EXTINGUISH ANY
NAKED LIGHTS, PIPES, CIGARETTES etc.
Turn on the main gas supply and purge in accordance
with the current issue of BS6891.
Turn boiler gas service cock “J” to On.
Depress control button “B”, keep pressed in and at the
same time operate the piezo unit button “C” until the
pilot burner lights. After the pilot burner lights keep the
button “B” depressed for about 15 seconds. If the pilot
fails to stay alight a safety device prevents immediate
relighting. Do not attempt to relight until the safety
device has reset. Check the length of the pilot flame, it
should envelop the thermocouple tip as shown in
diagram 10.3. The pilot rate can be adjusted by turning
screw “H” having first removed the gas valve cover by
releasing the screw. Test pilot supply connection for gas
soundness with a suitable leak detection fluid.
BOILER CONTROLS Diagram 8.1
A. BOILER THERMOSTAT H. GAS RATE ADJUSTMENT SCREW
B. GAS CONTROL KNOB H. (UNDER COVER SCREW)
C. IGNITION BUTTON J. GAS SERVICE COCK
G. VIEWING WINDOW K. PRESSURE TEST POINT
L. PILOT BURNER
L. ADJUSTMENT SCREW
J. (SHOWN OFF)
BH
G
L
MODEL AND
SERIAL NUMBER
ACK
2416

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8 Commissioning
Fit the outer case, secure with the screws previously
removed.
Make sure that the pilot is alight and stable, view
through window “G”.
Set the boiler thermostat control knob “A” between “1”
and “5” and check that the burner lights smoothly.
Check the gas connections for gas soundness with a
suitable leak detection fluid.
To set the burner pressure operate the boiler for
10 minutes, remove the gas valve cover, if not already
removed, adjust the the gas pressure by screw “H” until
the required pressure is obtained, see Table 1 for setting
pressures.
Align and attach the self adhesive arrow, from the loose
items pack, in the appropriate space beneath the “MIN”
and “MAX” column on the Data label.
Should any doubt exist about the gas rate this should be
checked at the meter, using a stop watch to time at least
one cubic foot of gas consumption.
Remove the pressure gauge, refit the test point screw and
ensure a gas tight seal is made.
Replace gas valve cover.
8.4 Testing
Check the operation of the flame failure device on the
boiler, by turning the gas service cock off, to make sure
that the gas valve shuts down within 60 seconds,
indicated by a “click” from the valve.
8.5 Flushing
Allow the system to reach maximum working
temperature and examine for water leaks.
The system should then be turned off and drained rapidly
whilst hot.
Refill the system, vent all air and check for water
soundness.
8.6 Adjustment - All Systems
When commissioning the system the boiler should first
be fired with the bypass fully closed on full service, that
is, central heating and domestic hot water. The system
should then be balanced, adjusting the pump and
lockshield valve as necessary. Having achieved a
satisfactory condition operate the boiler with the bypass
valve fully closed on minimum load, normally this will
be central heating only with one radiator operating in the
main living area. The valve should be gradually opened
to achieve a flow rate of 18.0Litre/min (3.9gal/min).
UNDER NO CIRCUMSTANCES SHOULD THIS
VALVE BE LEFT IN THE FULLY CLOSED
POSITION.
Operate the boiler again on full service and check the
balancing, making further adjustments as necessary.
If thermostatic radiator valves are fitted care must be
taken to ensure an adequate flow rate when the valves
close, refer to the current issue of BS7478 for guidance.
Refit the controls cover.
8.7 Sealed Water Systems
Sealed water systems should be adjusted to the initial
design pressure and the set pointer repositioned.
Hand the Instructions for Use to the user for their
retention.
Instruct and demonstrate the safe and efficient operation
of the boiler.
Advise that to ensure the continued efficient and safe
operation of the boiler it is recommended that it is
checked and serviced at regular intervals.
The frequency of servicing will depend upon the
particular installation and usage, but in general once a
year should be enough.
It is the law that any servicing must be carried out by a
competent person.
Advise the user of the precautions necessary to prevent
damage to the system and building in the event of the
heating system being out of use during frost and freezing
conditions.
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.
Reminder, leave these instructions with the user for use
during future service calls.
9 Instruct User in Correct Operation of the Boiler

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10 Servicing and Replacement of Parts
Servicing and replacement of parts must be carried out
by a competent person.
Before commencing a service or replacing parts isolate
the gas and electrical supplies.
Unless stated otherwise replacement of parts is in the
reverse order to removal.
10.1 Heating Body - Service
Remove controls cover by pulling it forward and off.
Remove outer casing by releasing screw at the bottom
and unhooking at the top.
Remove the inner case by releasing screws at top and
bottom, see diagram 10.1.
To remove the flue hood release the wing nuts and lift
off securing angle and flue hood.
Remove the combustion chamber front panel by undoing
the wing nut at the bottom front and the four screws
securing it to the combustion chamber sides.
Remove the two screws and washers securing the pilot
burner and shield to the main burner, see diagram 10.2.
Pull the pilot assembly forward enough to allow the
main burner to be freed from the injector. Raise the
burner up at the front, withdraw forward. Take care not
to damage the insulation and the pilot burner and
electrode assemblies.
Place a sheet of paper in the combustion chamber and
brush away any deposits.
Remove the paper and debris.
10.2 Main Burner
Follow the instructions generally as Section 10.1.
With the main burner removed brush or vacuum any
deposits away, ensure that the flame ports are clean.
Do not use a brush with metallic bristles.
10.3 Main Injector
Follow the instructions generally as Section 10.1.
With the main burner removed the injector can be
unscrewed and replaced as necessary using a new sealing
washer.
If cleaning do not use a wire or sharp instrument on the
hole.
When replacing the main burner ensure that it is pushed
fully home onto the injector and that the guides are
engaged on the injector manifold.
10.4 Pilot Burner and Injector
Follow the instructions generally as Section 10.1.
With the main case and controls cover etc., removed as
above pull off ignition lead from electrode.
Unscrew the tubing nut at the base of the pilot burner
releasing the pilot pipe. Remove the pilot injector by
unscrewing if from the pilot burner.
Release the wing nuts securing the flue hood, see
diagram 10.1.
Remove combustion chamber front panel as above.
Remove the two screws and washers securing the pilot
burner and pilot shield to the main burner, see
diagram 10.1.
Remove the pilot shield complete with the electrode.
PILOT ASSEMBLY
WING NUT (2)
Diagram 10.1ACCESS for SERVICING
Casing not illustrated
for clarity
COMBUSTION
CHAMBER
FRONT
PANEL
SECURING
SCREW (4)
WING NUT
M3
SCREW
IGNITION
LEAD
(clear end)
MICA WINDOW
PILOT
INJECTOR
PILOT
TUBING
NUT
ADAPTOR
OLIVE THERMOCOUPLE
THERMOCOUPLE
NUT
PILOT
SHIELD
SECURING
SCREWS ELECTRODE
1049
SECURING ANGLE
HOOK
BOLT (2)
FLUE
HOOD
FRONT
PANEL
Diagram 10.2
0947

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Diagram 10.3
Diagram 10.5
THERMOSTAT
PHIAL/OVERHEAT
CUT-OFF
10 Servicing and Replacement of Parts
Unscrew the thermocouple nut.
The pilot burner can now be lifted away.
Take care not to damage the electrode.
When replacing ensure that the spark gap is as shown in
diagram 10.3.
10.5 Thermocouple
Generally follow the instructions given in Section 10.1.
Release, but do not remove, the two screws securing the
front plate and rear gland plates. Pull the front gland
plate forward, see diagram 10.4. Disconnect the
thermocouple at the gas valve and remove.
Use the old thermocouple as a pattern when fitting the
new one. Do not tighten more than a quarter turn
beyond finger tight at the gas valve.
Check the electrode spark gap, see diagram 10.3.
10.6 Electrode
Generally follow the instructions given in Section 10.1.
Unscrew the electrode from the pilot shield.
When refitting check that the spark gap is as in
diagram 10.3.
10.7 Over Heat Cutoff
Generally follow the instructions in Section 10.1.
Remove the two screws securing the over heat cutoff
clamp, see diagram 10.5.
Release connections at the gas valve, see diagram 10.6.
Release but do not remove the two screws securing the
front and rear gland plates, see diagram 10.4 and
withdraw the cutoff leads.
When refitting smear a little of the heat sink compound,
supplied, between the face of the cutoff and the water
pipe, make sure that it is correctly located on the pipe.
PILOT FLAME & SPARK GAP
14 to 17 mm
14 to 17 mm
ELECTRODE THERMOCOUPLE
SPARK GAP
3 to 4 mm
RELEASE SCREWS
DO NOT REMOVE
AND PULL FRONT
GLAND PLATE FORWARD
REAR
GLAND
PLATE
HEAT
EXCHANGER
THERMOSTAT
PHIAL
OVERHEAT
CUT-OFF
RETAINING
CLIP
CUT-OFF
SECURING
SCREW(S)
GLAND PLATE Diagram 10.4
IGNITION
LEAD
OVERHEAT
CUT-OFF LEADS THERMOSTAT
CAPILLARY
THERMO-
COUPLE
PILOT
TUBE
1053
FRONT GLAND
PLATE
0394
0951

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10 Servicing and Replacement of Parts
GAS VALVE ASSEMBLY Diagram 10.6
10.8 Gas Valve
Gain access generally as Section 10.4.
Remove the screw to release the gas valve cover.
Disconnect all leads and pipes at the gas valve.
Undo the four screws each side of the gas valve to
release the gas service cock and burner supply tube, take
care not to damage the “O” rings.
Fit the new valve and remake all connections.
Do not tighten the thermocouple nut more than a quarter
turn beyond finger tight at the gas valve.
It will be necessary to purge the pipework and valve
before relighting, refer to Commissioning.
10.9 Electrical Control Box
Remove the controls cover and outer casing as
Section 10.1.
Remove the retaining clip from the boiler thermostat
phial pocket and withdraw the phial, see diagram 10.5.
Release but do not remove the two screws securing the
front and rear gland plates. Pull the gland plates
forward.
Remove the control box by undoing the two fixing
screws at the front and lower the front of the box until it
is clear of the cover. Push box toward the rear of the
boiler to disengage the hinge and lower, see diagram 7.1.
Withdraw the thermostat capillary through the bottom of
the air duct.
Disconnect cables (a) mains, L.N. and E. (b) pump at
terminal 8, 7 and earth stud, (c) cables at gas valve, (d)
disconnect any remote controls at terminal 9 and SL.
When replacing refer to diagram 7.2 for electrical
connections. Smear the thermostat phial with heat sink
compound and ensure that it is secured, with the retainer,
into the phial pocket.
10.10 Piezo Unit
Gain access as Section 10.4.
Disconnect the ignition lead and remove backing nut
from the piezo unit.
10.11 Ignition Lead
Remove the controls cover and outer casing as
Section 10.1.
Release, but do not remove, the two screws securing the
front and rear gland plates. Pull the gland plates
forward, see diagram 10.4.
Remove the ignition lead, when replacing ensure that the
clear end is fitted to the electrode.
10.12 Thermostat
Gain access as under Section 10.4.
Remove and support control. See Section 10.9.
Remove the control knob and electrical connections
from the thermostat.
Release, but do not remove, the two screws securing the
front and rear gland plates. Pull the gland plates
forward, see diagram 10.4.
Remove the two screws screws securing the thermostat
to the control box. The thermostat may now be removed
withdrawing the capillary through the bottom of the air
duct.
When replacing smear the thermostat phial with the heat
sink compound supplied, before fitting and securing in
the pocket.
EXT. SCREW (4)
'O' RING
'O' RING
EXT.
SCREW (4)
THERMOCOUPLE
NUT
ELECTRICAL
CONNECTOR (2)
INTERRUPTER
PILOT
TUBE
NUT
GAS
VALVE
CONNECTORS
GAS SERVICE
COCK
(SHOWN OFF)
2414

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11 Fault Finding
Fault and Cause Remedy
11.1 Pilot goes out after a period of
remaining alight
Front cover not fitted correctly Fit parts correctly.
Flue parts not fitted or sealed properly. Seal cavity or fit parts flue parts correctly as described
in installation instructions.
Electrical supply failure causing overheat cutoff to operate. Relight pilot.
Overheat cutoff operating. Refer to 11.3 below
Pump wired incorrectly. Refer to diagram 7.2 and wire accordingly.
11.2 Main burner will not ignite
External controls not on. Check that any external controls are calling for heat.
Boiler thermostat not on. Check that boiler thermostat is on. See also
Section 11.9.
11.3 Thermostat will not cut out
Thermostat phial not fitted in pocket. Fit phial in pocket.
Faulty thermostat Replace thermostat.
11.4 Overheat cutoff cuts out prematurely
Air in heating body. Vent system. Alter system layout if necessary.
Water circulation low or stopped.
Pump not working correctly. Check pump is wired
directly to the boiler. Alter system if necessary.
Overheat cutoff operates Change faulty overheat cutoff.
before boiler cycles on
maximum boiler thermostat setting.
The correctly set overheat Change faulty heating body.
cutoff operates prematurely.
There is no air in the heating body and the water
circulation is satisfactory.
11.5 Insufficient heat
Thermostat set too low. Increase setting.
Inlet gas pressure inadequate. Increase gas pressure.
Burner setting incorrect. Check burner pressure against
(ensure thermostat is on data badge.) Reset only if more maximum setting than 10% away
from required figure.
11.6 Appliance noisy in operation*
Overgassed. Check burner pressure against data badge and adjust
only if more than 10% away from the stated required
figure.
Complete lack of water flow. Check system controls for correct installation or
correct type of controls.
Air in system. Remove air from system. When system is first
commissioned the air dissolved may take some time
to boiler out, therefore attempts should be made to
vent air during the first weeks of the installation.
Check venting of system, as air bubbles can remain
suspended in the water if system is not well vented.
Water flow rate. Check that flow rate is correct. Check that pump is
correct size and is correctly adjusted.
Bypass not fitted or correctly set.