Glowworm Hideaway 100B User manual

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Hepworth Heating Ltd.,
Nottingham Road, Belper, Derbyshire. DE56 1JT
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One Contact Local Service
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All replacement parts
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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 centre pages are to be found your Guarantee Registration Card, which we recommend you complete and
return as soon as possible.
If this card is missing you can obtain a copy or record your registration by telephoning the Heatcall Customer
Service number 01773 828100.
Our Guarantee gives you peace of mind plus valuable protection against breakdown by covering the cost of:
Guarantee Registration
Balanced Flue Boiler
This is a Cat I2H Appliance
BS 6332
BS 5258
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.
Tobeleftwiththeuser
❏
✔
Instructions for Use
Installation and Servicing
G.C. No. 41 313 26
REGISTER YOUR GLOW-WORM APPLIANCE
FOR 1ST YEAR GUARANTEE PROTECTION
CALL 0208 247 9857
100B
Hideaway
1388
❏
✔
❏
✔

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Important Information
Introduction 3
Lighting the Boiler 4
General Data 1 5
Water Systems 2 7
Flue and Ventilation 3 8
Installation 4 9
Casing Location / Fitting 5 12
Electrical Wiring 6 14
Commissioning 7 15
Servicing 8 17
Replacement Parts 9 18
Fault Finding 10 21
Spare Parts 11 24
CONTENTS DESCRIPTION SECTION PAGE No.
INSTRUCTIONS
FOR USE
INSTALLATION
INSTRUCTIONS
SERVICING
INSTRUCTIONS
Testing and Certification
Thisboileristestedandcertificatedforsafetyandperformance. Itisthereforeimportantthatnoalterationismadetotheboiler,without
permission, in writing, from Hepworth Heating Ltd.
Any alteration not approved by Hepworth Heating Ltd., could invalidate the certification, boiler warranty and may also infringe the
current issue of the Statutory Requirements, see Section 1.4.
CE Mark
This boiler meets the requirements of Statutory Instrument No. 3083 The boiler (Efficiency) Regulations, and therefore is deemed
tomeettherequirementsofDirective92/42/EEContheefficiencyrequirementsfornewhotwaterboilersfiredwithliquidorgaseous
fuels.
Type test for purposes of Regulation 5 certified by: Notified body 0086.
Product/productioncertifiedby: Notified body 0086.
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 the 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.
CERAMIC FIBRE/INSULATION PADS, GLASSYARN.
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. Normal handling should not cause discomfort, but follow normal
good hygiene and wash your hands before eating, drinking or going to the lavatory. If you do suffer irritation of the eyes or severe
irritation to the skin seek medical attention.
THERMOSTATS
These contain very small amounts of xylene in the sealed phial and capillary. If broken, under normal circumstances the fluid does
notcauseaproblem,but in caseofskincontact,washwithcoldwater. If swalloweddrinkplentyofwaterand seekmedicalattention.

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Instructions for Use
General Information
Pleasereadtheseinstructionsand followthemcarefullyforthe
safe and economical use of your boiler.
The boiler is automatic in operation, once the pilot has been lit
and the controls set.
Glow-worm Hideaways are central heating boilers, to provide
heating and if required, an indirect domestic hot water supply.
Important Notice
This boiler is for use only on G20 gas.
Gas Safety (Installation and Use) Regulations
In your own interests and that of safety, is the law that ALL gas
appliances are installed by a competent person in accordance
with the current issue of the above regulations.
Warning
Makesurethatnothingobstructstherearsidegrilleorclearances.
See page 4 for minimum clearances.
Boilers Installed in a Compartment
If the boiler is fitted in a compartment, cupboard etc., do not
obstructthepurposebuiltcompartmentventsorthegrilleonthe
boiler.
Do not use the compartment for storage purposes.
Maintenance
To ensure the continued efficient and safe operation of the
boiler it is recommended that it is checked and serviced as
necessary at regular intervals. The frequency of servicing will
depend upon the particular installation conditions and usage,
but in general once a year should be enough.
It is the law that servicing must be carried out by a competent
person.
If this appliance is installed in a rented property there is a duty
of care imposed on the owner of the property by the current
issue of the Gas Safety (Installation and Use) Regulations,
Section 35.
To obtain service please call your installer or Heatcall (Glow-
worm’s own service organisation) using the telephone number
given on the front panel.
Please be advised that the ‘Benchmark’ logbook should be
completed by the installation engineer on completion of
commissioning and servicing.
All CORGI Registered Installers carry a CORGI ID card, and
have a registration number. Both should be recorded in your
boilerLogbook. YoucancheckyourinstallerisCORGIregistered
by calling CORGI direct on :- 01256 372300.
Boiler Electrical Supply
WARNING. This boiler must be earthed.
The boiler must only be connected to a 230V~50Hz supply
protected by a 3A fuse, maximum.
All wiring must be in accordance with the current issue of
BS7671.
Heatresistantflexiblecablehavingaconductorsizeof0.75mm2,
to the current issue of BS6500 Table 16 must be used.
To Connect an Electrical Plug
The standard colours of three core flexible cable are,
Brown - live, Blue - neutral, Green and Yellow - earth.
As the markings on your plug may not correspond with these
colours, continue as follows:
The Blue cable must be connected to the terminal marked “N”
or “Black”.
TheBrowncablemust beconnectedtotheterminal marked“L”
or “Red”.
TheGreen and yellow cablemust be connected tothe terminal
marked “E” or “Green” or the earth symbol .
To Light the Boiler
WARNING. If the pilot light goes out for any reason, do not
attempt to relight until 3 minutes have elapsed.
Remove the door by pulling forwards with the fascia at the top.
Lift up to disengage from the bottom side lugs.
Refer to diagram 1 to identify controls.
Check that the mains electrical supply to the boiler is switched
OFF.
SETTING
POINT
GAS
CONTROL
KNOB 'A'
THERMOSTAT
CONTROL
KNOB 'B'
GAS CONTROL KNOB
= OFF
= PILOT/IGNITION
= MAIN BURNER
E
9009
PIEZO IGNITION
BUTTON 'C'
Diagram 1
SETTING
POINTS

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Instructions for Use
Push in slightly and turn gas control knob “A” clockwise until
is against its setting point.
Turn thermostat control knob “B” anticlockwise until “O” is
against its setting point.
Pushinslightlyandturngascontrolknob“A”anticlockwiseuntil
is against its setting point, then depress fully and hold in.
Push in and release piezo ignition button “C” until the pilot
burner lights.
Air may be present in the supply pipe so the lighting of the pilot
may need to be repeated until all the air has been expelled.
When the pilot is alight, view through window “E”, keep gas
control knob “A” fully pushed in for about 15 seconds, then
release.
If the burner fails to stay alight, wait 3 minutes, then repeat the
lightingprocedureonlynowkeepcontrolknob“A”pushedinfor
a little longer before releasing.
Press in and turn gas control knob “A” anticlockwise until is
against its setting point.
Ifthegascontrolknob“A”isturnedto ,asafetylockprevents
it being turned on again for a short period. No attempt should
be made to relight the pilot until 3 minutes have elapsed.
Make sure that the pilot is alight and stable then switch on the
electrical supply.
Set any system controls to “ON” or “HIGH”.
Turn the boiler thermostat knob “B” clockwise until “MAX” is
against its setting point and the main burner will light. Adjust
thermostat to required setting between “MIN” and “MAX”.
“MAX” is about 82oC (180oF).
Refit the door by locating the hooked runner at the bottom into
the slot in the side panels and pushing onto the studs.
To Turn the Boiler Off
For short periods, turn the boiler thermostat control knob “B”
anticlockwise to “O”. The pilot will stay alight. To relight the
main burner turn thermostat control knob “B” clockwise to the
desired setting between “MIN” and “MAX”.
For longer periods, depress slightly and turn gas control knob
“A” fully clockwise until is against its setting point. Turn
thermostat control knob “B” anticlockwise to “O”. Isolate the
boiler from the electrical supply. Follow full lighting procedure
to relight. Refer also to “Protection Against Freezing”.
Gas Leak or Fault
Ifagasleakfaultexistsorissuspectedtheboilermustbeturned
off,includingtheelectricalsupplyandmustnotbeuseduntilthe
fault has been put right. Advice/help should be obtained
from the local gas undertaking or your installation/servicing
company.
Protection Against Freezing
Iftheboileristobeoutofuseforanyperiodoftimeduringsevere
weatherconditionswerecommendthe wholesystemincluding
the boiler, be drained off to avoid the risk of freezing up. If an
immersion heater is fitted to the hot water cylinder make sure it
is switched off.
Sheet Metal Parts
WARNING. Thisboilercontainsmetalparts(components)and
careshouldbetakenwhenhandlingandcleaning,withparticular
regard to edges.
Cleaning
Keep the casing clean by wiping it occasionally with a damp
soapy cloth and dry with a polishing cloth.
Do not use abrasive cleaners.
Replacement Parts/Boiler Identification
If replacement parts are required apply to your local supplier.
Pleasequotethenameoftheboileranditsserialnumberwhich
can be found on the data label, positioned on the boiler top, to
the rear of the inclined flueway cleaning door.
Clearances
Minimumclearancesmustbeleftaroundtheboilerasshownin
diagrams 1.3, 1.4 and 1.5.

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General Data
ABCDE✝FG H J K L M N P
mm 474 214 558 294 359 533 3 300 445 121 156 664 398 398
in. 1811/16 81/222 111/2141/821 1/8113/4171/243/461/8261/8155/8155/8
RANGE RATING
NOMINAL kW
HEAT INPUT
(GROSS) Btu/h
33.18 35.00 36.78
113,200 119,500 125,500
min medium max
BURNER mbar
SETTING
PRESSURE in.w.g
(HOT)
9.3 10.5 11.7
3.7 4.2 4.7
NOMINAL kW
HEAT
OUTPUT Btu/h
26.38 27.84 29.31
90,000 95,000 100,000
205748
INJECTOR
GENERAL DIMENSIONS - given in millimetres (Approx. inches) Diagram 1.1
1071
✽ Refer to BOILER CASING
HEIGHT diagram
M
D
C
C
L
✝ A SPECIAL TOP CASING
TO SUIT 600mm (235/8 in.)
WORKTOPS IS AVAILABLE
WATER CONNECTIONS
Rc1 (1in. B.S.P.T.)
WATER CONNECTIONS Rc1 reduced
with DISTRIBUTOR TUBE to
Rc 3/4(3/4in. B.S.P.T.) (pumped return)
GAS CONNECTION
Rc 1/2(1/2in. B.S.P.T.)
✝ F(MIN.) L
H
A
L
C
B
✽
N
P
C
L
E
J
K
G(MIN.)
G(MIN.)
Important Notice
This boiler is for use only on G20 gas.
Wherever possible, all materials, appliances and components
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.
1.1 Data
Weight of boiler 147.0kg (324lb)
Water content 11.7litre (2.57gall)
Gas connection Rc1/2 1/2inBSP
Water connection Rc1 1 in BSP
Electrical supply 230V ~ 50Hz fused 3A
Burner Aeromatic (2 off)
All dimensions are given in millimetres, except as noted.
The Seasonal Efficiency Domestic Boilers UK (SEDBUK)
is 73.0%.
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.
1.2 Range Rating
Thisboilerisrangeratedandmaybeadjustedtosuitindividual
system requirements.
The Tables give the appropriate settings and ratings.
The boiler heat input is factory preset to its maximum rating.
Thisshouldbeadjustedtosuitindividualsystemrequirements.
Thearrowindicator,fromthelooseitemspack,shouldbestuck
on the data label to indicate the setting.
1.3 Sheet Metal Parts
WARNING. Wheninstallingorservicingthisboiler,careshould
be taken to avoid any possibility of personal injury when
handling sheet metal parts.
1.4 Statutory Requirements
Theinstallationofthisboilermustbecarriedoutbyacompetent
person in accordance with the relevant requirements of the
current issue of:
Manufacturer’s instructions, supplied.
TheGasSafety(InstallationandUse)Regulations, TheBuilding
Regulations, The Bye-laws of the Local Water Company, The
Building Standards (Scotland) Regulations, (applicable in
Scotland), The Health and Safety at Work Act, Control of
SubstancesHazardoustoHealth,ElectricityatWorkRegulations
and any applicable local regulations.
Detailedrecommendationsarecontainedinthecurrentissueof
the following British Standards and Codes of Practice:
BS6798, BS5440 Part 1 and 2, BS5546, BS5449 Part 1,
BS6700, BS6891, BS7478, BS7593, BS7671.
Manufacturers instructions must in not be taken as overriding
statutory requirements.

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BOILER CASING HEIGHT(S) Diagram 1.2
MAX.900 (351/2in.)
MID. 890 (35in.)
MIN. 860 (34in.)
MAX.867 (341/8in.)
MID. 857 (333/4in.)
MIN. 827 (321/2in.)
BOILER
WITH TOP
CASING
BOILER
WITHOUT
TOP CASING
BOILER CASING ALTERNATIVE
HEIGHT POSITIONS
MIN.
MAX.
MIN.
MAX.
MID. MID.
To
floor
level
FLOOR
LEVEL
0982
General Data
Diagram 1.4
MINIMUM CLEARANCES
UNDER WORKTOP, FIXTURES
0865
10
(3/8in.) 10
(3/8in.)
3 (1/8in.)
BOILER
WITH
TOP
CASING
BOILER
WITHOUT
TOP
CASING
CUPBOARD
CUPBOARD
CUPBOARD 10 (3/8in.)
WORKTOP OR FIXTURE
10
(3/8in.)
1387
WORKTOP
10
(3/8in.) 10
(3/8in.)
BOILER BOILER
5
(3/16 in.)
CUPBOARDS
Diagram 1.3
MINIMUM CLEARANCES
LEVEL WITH WORKTOP
494 MIN.
(197/16 in.)
494 MIN.
(197/16 in.)
1.5 B.S.I. Certification
This boiler is certificated by B.S.I. for safety and performance.
Itis,therefore, importantthatnoalterationis madetotheboiler,
without permission, in writing, from Hepworth Heating Ltd.
Any alteration not approved by Hepworth Heating Ltd., could
invalidatetheB.S.I.certification,boilerwarrantyandcouldalso
infringe the Statutory Requirements.
1.6 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
toprovideasteadyinletworkingpressureof20mbar(8inwg)at
the boiler.
On completion test the gas installation using the pressure drop
method and suitable leak detection fluid, purge in accordance
with the current issue of BS6891.
1.7 Electrical
WARNING. This boiler must be earthed.
The electrical installation must be carried out by a competent
person.
Allexternalcomponentsshallbeoftheapprovedtypeandshall
be connected in accordance with the current issue of BS7671
and any local regulations which apply.
Connection of the boiler and any system controls to the mains
supplyshouldbethroughanunswitchedshutteredsocketoutlet
and 3A fused 3 pin plug both to the current issue of BS1363.
Alternatively, a 3A fused double pole isolating switch may be
used, having a minimum double pole contact separation of
3mm, serving the boiler and system controls only.
Heat resistant flexible cable of at least 0.75mm2(24/0.20mm)
toBS6500Table16,mustbeusedforallconnectionswithinthe
boiler casing.
1.8 Boiler Location
This boiler is not suitable for outside installation.
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 the boiler in a room
containing a bath or shower. Any electrical switch or boiler
control utilising mains electricity should be so situated 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.
Theboilermust stand on a levelfloor,conforming with the local
authority requirements and building regulations. The base
temperature is within the requirements of BS5258. The boiler
may be stood on a wooden floor but a metal base plate is
required to protect plastic tiles and similar floor coverings.
Suitable clearance needs to be available at the sides of the
boiler to facilitate direct connection of pipework and making
good around the flue assembly. The actual clearance required
will vary with site conditions.
Thecasingcanbefittedtotheboileratvariousheights. Thetop
casing can be discarded, if preferred, when fitting the boiler
under a worktop or fixture. See diagram 1.2.
When the boiler is to be installed level with work surfaces etc.,
minimum clearances should be provided as shown in diagram
1.3. Work tops which overhang the cupboard sides almost in
contact with the casing top, require a larger minimum air gap.
Flush sided fixtures require the same overall minimum space
but can have a reduced air gap on one side.
Boilerstobeinstalledunderworktopsorfixtures,withorwithout
the casing top fitted, should be positioned to provide minimum
clearances as shown in diagram 1.4.
Tofacilitateminimumclearancesitmaybenecessarytomodify
the kitchen units or fixtures, depending upon which type of
connections are used.
A front access clearance should be provided as shown in
diagram 1.5.
Theminimumgapbehindthetopcasingisasshownindiagram
1.1. Theboilercanbesitedfurtherawayfromthewallifrequired
to align with kitchen units etc. Refer to Section 3.5.
Combustible wall material must be 25mm (1in) away from flue
components. Refer to Section 3.5.

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FRONT CLEARANCE Diagram 1.5
0906
700 (271/2 in.) BOILER
WALL OR
FIXTURE
1 General Data
2Water Systems
Diagram 2.1
0869
27metre
Max.
PUMP
To Heating
Circuit
INDIRECT
CYLINDER
22mm VENT
15mm COLD FEED
REFER TO BS 5546
28mm
Distributor tube in
pumped return
connection
BOILER
C
L
DRAIN OFF
COCK
Diagram 2.2
FULLY PUMPED SYSTEM
(DIAGRAMMATIC)
0870
1 metre
MIN.
27metres
MAX.
PUMP
To Heating
Circuit
TO INDIRECT
CYLINDER
22mm VENT
15mm
COLD FEED
Distributor tube in
pumped return
connection
BOILER
C
L
DRAIN OFF
COCK
A special top casing, part No. 424820, can be purchased to
enable the boiler casings to be arranged flush with 600mm
(235/8in) deep work tops and kitchen units.
Wheretheinstallationoftheboilerwillbeinanunusuallocation,
specialproceduresarenecessary,thecurrentissueofBS6798
gives guidance on this.
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. Detailsofessentialfeaturesofcupboarddesignaregiven
in the current issue of BS6798.
If the boiler is to be installed in a compartment, make sure that
nothing will obstruct the openings/vents in the compartment.
1.9 Heating System Controls
The heating system should have installed: a programmer and
room thermostat controlling the boiler.
Thermostatic radiator valves may be installed in addition to the
room thermostat.
2.1 Water Pressure Head
This boiler shall only be connected to a cistern supply, with a
minimum head of 1 metre (3ft) and a maximum of 27 metres
(90ft) and having an open vent in the system.
The boiler must not be connected to a sealed water system.
2.2 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 in the system, contact should be
madewithaninhibitormanufacturersotheycanrecommended
their most suitable product.
Whenusingin an existing system take specialcareto drain the
entiresystem,includingtheradiators,thenthoroughlycleaning
out before fitting the boiler, whether or not adding an inhibitor.
2.3 Gravity Domestic and Pumped Heating
Itisrecommendedthatacylinderthermostatis used to prevent
the stored water temperature becoming unnecessarily high.
The primary flow and return must be 28mm. The
installation must comply with the current issue of BS5546 and
BS6700, see diagram 2.1.
Iftheaboveconditionscannotbemet,itissuggestedthatafully
pumped system be used.
Fully Pumped System
Whereasinglepumped,flowandreturnistakenfromtheboiler,
refer to diagram 2.2.
2.5 Circulation Pump
The pump should be set to give a temperature difference of
11oC(20oF)acrossthesystem. At the appropriate flowratethe
resistance through the boiler can be found from the pressure
loss graph, diagram 2.3.
If possible use a pump with integral valves, if not fit valves as
close as possible each side of the pump.
Note: If the pump is to be fitted inside the boiler casing a heat
shield kit is required. Kit No. 425839.
Note: For further information, see The Building Regulations
1991-Conservationoffuelandpower,1995edition-Appendix
G, table 4b.

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2 Water Systems
3 Flue and Ventilation
PRESSURE LOSS OF BOILER Diagram 2.3
1370
1.0
0.8
0.6
0.4
0.2
0
30
20
10
0
010 20 30 40 50
FLOW RATE (LITRES/MINUTE)
WATER PRESSURE LOSS (metre HEAD OF WATER)
WATER PRESSURE LOSS (INCHES HEAD OF WATER)
1.2
40
012345678 109
FLOW RATE (GALLON/MINUTE)
2.6 Cylinder
Forall systems supplying domestic hotwater the cylinder must
be indirect and to the appropriate British Standard.
2.7 Safety Valve
A safety valve need not be fitted to an open vented system.
2.8 Draining Tap
A drain tap must be provided at the lowest points of the system
which will allow the entire system, including the boiler and
domestic hot water cylinder to be drained. Drain taps shall
comply with the current issue of BS2879.
3.1 Flue
Detailed recommendations for flues are given in the current
issue of BS5440 Part 1.
Theboilermustbeinstalledsothattheflueterminalisexposed
totheexternalair. Itisimportantthatthepositionallowsthefree
passage of air across it at all times.
3.2 Terminal Positioning
The minimum acceptable spacings for the terminal to
obstructions,otherterminalsandventilationopeningsaregiven
in diagram 3.1.
Carportorsimilarextensionsofaroofonly,orroofandonewall,
require special action with regard to openings, doors and
windows under the roof. Care is required in protecting plastic
roofs. If the car port consists of a roof and two or more walls
seek advice form the local gas undertaking.
Wheretheterminaliswithin850mm(34in)belowplasticguttering,
orwithin450mm(18in)ofpaintedeavesorgutteranaluminium
shield1.5metres(5ft)longshouldbefittedtotheundersideand
immediately beneath the guttering.
The air inlet/products outlet duct and the terminal of the boiler
must not be closer than 25mm (1in) to combustible material.
3.3 Timber Frame Buildings
If the boiler is to be installed in a timber frame building it should
be fitted in accordance with the Institute of Gas Engineers
documentIGE/UP/7/1998. Ifindoubtseekadvicefromthelocal
gas undertaking or Hepworth Heating Ltd.
3.4 Terminal Guard
A terminal guard is required if persons could come into contact
with the terminal or the terminal could be subject to damage.
If a terminal guard is required, it must be positioned to provide
aminimumof50mmclearancefromanypartoftheterminaland
be central over the terminal.
A suitable guard is available from
Tower Flue Components Ltd.,
Morley Road,
Tonbridge,
Kent.
TN9 1RA
reference type “F”
3.5 Flue Duct Length
Thefluelengthsquotedbelowallowtheminimumrearclearance
of 3mm (1/8inch) behind the boiler, although the boiler can be
installed further away from the inside wall. In such cases any
extra clearance behind the boiler must be added to the wall
thickness to obtain the flue duct length.
Check the wall thickness/flue duct length where the boiler is
fitted. Flues available are:
Standard pack - 280 to 410mm (11 to 16inches).
Short pack - 150 to 280mm (6 to 11inches)
Extension Kit (+standard pack) 410 to 610mm
(16 to 24inches)
The short flue pack, part No.425504 and the extension kit, part
No.424873 are available to order. Standard pack is part
No.424886.
3.6 Room Ventilation
The boiler is room sealed and does not require the room or
space containing it to have permanent air vents.

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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
3 Flue and Ventilation
1112
ADIRECTLY BELOW AN OPENABLE mm
WINDOW, AIR VENT, OR ANY
OTHER VENTILATION OPENING 300
BBELOW GUTTER,DRAIN/SOIL PIPE 300
CBELOW EAVES 300
DBELOW A BALCONY OR CAR PORT 600
E FROM VERTICAL DRAIN PIPES
AND SOIL PIPES 75
FFROM INTERNAL OR EXTERNAL
CORNERS 600
GABOVE ADJACENT GROUND OR
BALCONY LEVEL 300
HFROM A SURFACE FACING
THE TERMINAL 600
IFACING TERMINALS 600
JFROM OPENING (DOOR/WINDOW)
IN CARPORT INTO DWELLING 1200
KVERTICAL FROM A TERMINAL 1500
LHORIZONTALLY FROM A TERMINAL 300
MINIMUM SITING DIMENSIONS FOR
BALANCED FLUE TERMINALS
Diagram 3.1
FROM
OUTSIDE
COMPARTMENT AIR VENT TABLE
COMPARTMENT
VENTILATION
REQUIREMENTS
169cm226in2169cm226in2
VENTILATION
FROM ROOM
OR SPACE 338cm252in2338cm252in2
HIGH LEVEL LOW LEVEL
VENT AREA VENT AREA
4 Installation
POSITION MINIMUM
SPACING
3.7 Cupboard/Compartment Ventilation
Wheretheboilerisfittedinacupboardorcompartment,thehigh
and low level permanent air vents must have effective areas in
accordance with the Compartment Air Vent Table.
Boththehighlevelandthelowlevelairventsmustcommunicate
withthesameroom,ormustbothbeonthesamewalltooutside
air.
Before fixing the boiler make sure that the location selected is
in accordance with the requirements of Section 1.8.
4.1 Unpacking
Remove the packaging and then the boiler from its pallet by
removing the screws.
Theboilercasingpanelsarepackedseparatelywithinthemain
carton. Theyaredesignedtoenablegasandwaterconnections
to be made before fitting the casing.
The casing brackets, distributor tube and loose items, in a
plastic bag, are packed in the corner fitment.
4.2 Casing Brackets
Fit the two upper and two front casing brackets as shown in
diagram 4.1 using eight of the No.8 screws.
Pushthecaptivenuts,suppliedloose,ontothecasingbrackets
as shown in diagram 4.1.
4.3 Planning Water Connections - Gravity
Domestic and Pumped Heating.
It is important that all connections are made as shown in
diagram 4.2.
Heatingflow,eitheroneofthetwoupperfrontconnectionsmay
be used.
Domestic gravity flow, any one of the three remaining upper
connections may be used.
Heating return, the water distributor tube MUST be fitted into
eitheroneofthefrontlowerconnectionsonallinstallations,see
diagram 4.3. The distributor tube is packed in the top fitment.

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CASING BRACKETS FITTING Diagram 4.1
4 Installation
0888
FRONT
CASING
BRACKET
No.8 SCREW (8)
CAPTIVE
NUT
UPPER CASING
BRACKET
CAPTIVE
NUT
DISTRIBUTOR TUBE Diagram 4.3
1277
UPPER
MARKER
UPPER MARKER must
lie between the two outer
NOTCHES
DISTRIBUTOR
TUBE
must be in pumped
return connection
BOILER
Diagram 4.2
WATER CONNECTIONS - GRAVITY
DOMESTIC, PUMPED HEATING
ALTERNATIVE
HEATING
RETURN
With distributor
tube (not
shown)
ALTERNATIVE
HEATING FLOW
(Thermostat
phial and pocket
must be adjacent
to heating flow
connection)
DOMESTIC
GRAVITY
RETURN TO
ANY OF THE
3 REMAINING
LOWER CONNECTIONS
1309
DOMESTIC GRAVITY
FLOW TO ANY OF THE
3 REMAINING UPPER
CONNECTIONS
Domesticgravityreturn,anyoneofthethreeremaininglower
connections may be used for the gravity domestic hot water
return.
Fit plugs into all unused connections.
NOTE, if only limited clearance is available it is recommended
that the front tappings are used.
4.4 Planning Water Connections - Fully
Pumped Systems
It is important that all connections are made as shown in
diagram 4.4.
Flow, either one of the two upper front connections may be
used,
Return the water distributor tube MUST be fitted into the return
connectiononallinstallations,seediagram4.3. Thedistributor
tube is packed in the top fitment.
4.5 Thermostat Pocket
Fit the thermostat phial pocket, supplied in the top fitment, into
the front tapping adjacent to the heating flow connection and
plug the other front pocket connection.
Carefully unwind the thermostat capillary, insert phial fully into
the pocket and secure with the location washer behind the
retainingsplitpin,suppliedinthelooseitemspack,seediagram
4.5.
4.6 Pump Within Boiler Casing
If the pump is to be fitted inside the boiler casing, see diagram
6.2, ensure that a heat shield kit is obtained and fitted
(Kit No. 425839).
The kit contains a flueway cleaning door with heat shield
(attached).
4.7 Positioning/Connecting Boiler
If the boiler casings are to fit flush with any kitchen units, the
distancetheboilerisawayfromthewallmustbemeasuredand
dimension “G”increased by this amount, see diagram 1.1.
Having selected the position of the boiler, mark out and cut a
hole through the wall where the boiler is to be installed, to the
dimensionsshownindiagram4.6,aftercheckingthatsufficient
clearanceswillbeleftaroundtheboilerasdescribedinSection
1.8 “Boiler Location”, refer also to Section 3.5 “Flue Duct
Length”.
Fit the distributor tube, see diagram 4.2 or 4.4 for position, see
diagram 4.3 for alignment. Fit appropriate fittings and plugs
into the boiler connections.
IMPORTANT NOTE, do not route any pipes across the front of
the boiler thermostat pocket, the controls, burner supply pipe,
combustion chamber cover or flueway cleaning door. The gas
supplypipeshouldbe run along the left-hand side oftheboiler.
Iftheflueductlengthnecessitatestheuseoftheflueextension
kit, that is 410 to 610mm (16 to 24inches) this will need to be
assembled before positioning the boiler. Read the separate
instructionssuppliedwiththekit inconjunctionwithSection4.8
“Balanced Flue Terminal”.
When suitable installation clearances are available, position
the boiler in readiness to connect pipework.
If suitable clearances are not available it will be necessary to
preplumbthegasandwaterconnectionsbeforepositioningthe
boiler.
When the front tappings are used it is essential that any
pipeworkoffittingsbeassembledasshownindiagram4.7,that
is, do not stick out more than shown.

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4 Installation
Diagram 4.5
SECURING THE
THERMOSTAT PHIAL
1870
THERMOSTAT
CAPILLARY LOCATION
WASHER
PHIAL
POCKET
RETAINING
SPLIT PIN
Diagram 4.4
WATER CONNECTIONS
FULLY PUMPED SYSTEMS
1310
ALTERNATIVE
FLOW
(Must be adjacent
to THERMOSTAT
PHIAL POCKET)
ALTERNATIVE
RETURN
With distributor
tube (not shown)
;;
;;; ;;; ;;; ;;; ;;; ;
Diagram 4.6
PREPARED HOLE IN
THE WALL DIMENSIONS
BALANCED
FLUE DUCT
FROM BOILER
360
(141/4in.)
485
(19 in.)
PREPARED
HOLE IN
THE WALL
3 (1/8 in.)
MIN.
1384
360
(141/4in.)
When using a rear tapping with Rc1 (1inch BSP) fittings for
28mm o.d. pipework it is recommended that a short nipple and
a R thread (BSP) copper elbow is used. If the pipework is
required to run back to the wall make sure that it will clear the
boiler air duct and, if working to minimum clearance does not
stick out too far from the boiler, see diagram 4.8.
Make the water connections to the system pipework.
Maketheconnectionto the gas supply attheuniongas service
cock. Test the complete gas installation for soundness and
purge in accordance with the current issue of BS6891.
Whenthe boiler is finallypositioned with the balancedflue duct
sticking out into the prepared hole in the wall and pipework
connected, make good to the inside of the wall face around the
boiler flue assembly.
4.8 Balanced Flue Terminal
Takethebalancedflueassemblyfromitscartonandremovethe
four screws to release the outer baffle, see diagram 4.9.
Removethefourouterwire guards thenpullofftheinnerbaffle/
flue duct assembly.
Place the air duct assembly into the prepared hole, from the
outside,engagingitovertheboilerairduct. Slideituntilthewall
plate contacts the outer wall surface.
Cut and fix four pieces of the yellow tape provided into the four
cornersatthe jointintheairduct, runningthetapeontheinside
oftheductabout25mm(1inch)alongthejointfromthecorners.
Fix four further pieces along the joints overlapping the corner
tapes, to make a good seal.
Cement around the wall plate to make good and provide a
weatherproof seal.
Refittheinnerbaffle/flueductassemblyovertheboilerflueduct
and slide in until the baffle contacts the wire guards.
Sealtheflueductjointontheinsideusingthesemi-transparent,
heat resistant, tape provided, in a similar way to the air duct
sealingprocedure,makingsure that a good sealismadeat the
corners.
Refit the wire guards, outer baffle and secure with the screws
previously removed.

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4 Installation
5 Casing Location / Fitting
Diagram 4.7
PIPEWORK CASING
CLEARANCES
57 MAX.
(2 1/4in.)
'A'
VIEW ON ARROW 'A'
57 MAX.
(2 1/4in.)
1524
BOILER
Diagram 4.8
REAR CONNECTION
PIPEWORK (28mm)
1525
57 MAX.
(2 1/4in.)
VIEW ON
ARROW 'B'
'B'
BOILER
57 MAX.
(2 1/4in.)
FOR
MINIMUM
CLEARANCE
Diagram 4.9
TERMINAL AND AIR DUCT -
STANDARD OR SHORT
1280
BOILER
AIR DUCT WALL
PLATE INNER BAFFLE/
FLUE DUCT
ASSEMBLY
AIR DUCT
ASSEMBLY
WIRE GUARDS SCREW (4)
OUTER
BAFFLE
5.1 Side Vent Grille
One side vent grille is supplied with the boiler and can be fitted
attherearoftheleftorright-handsidecasing. Thegrilleisfitted
on the opposite side to any pipework connections.
Ifrequired,fitthegrille,usingplasticpegsatthetopandbottom,
seediagram5.1,priortofixingthesidecasing. Theplasticpegs
areatightfit,sotheyarebestpushedhomewithaflatfacedtool.
Discard the grille if water connections are made on both sides
of the boiler or if the boiler is screened by fixtures.
5.2 Side Casings
Fit each side casing by locating the lugs into the appropriate
slots in the boiler plinth, see diagram 5.2, depending on the
required casing height, see diagram 1.2.
Secure the side casings to the casing brackets at the front and
top.

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SIDE VENT GRILLE Diagram 5.1
SIDE VENT GRILLE
(If required, will fit to
left or right side casing)
PLASTIC PEG
SIDE CASING
(R.H. SHOWN)
0885
5 Casing Location / Fitting
TOP CASING FITTING Diagram 5.3
STRAP FITTING (No top casing) Diagram 5.4
0909
PEG POSITIONS IN TOP CASING
A = FRONT EDGE FLUSH
B = 10mm (3/8in) FRONT OVERHANG
AB AB
SIDE CASING
DOOR BOILER SHOWN WITH
ROLLED EDGE FLUSH
SIDE CASING
DOOR BOILER SHOWN WITH
SQUARE EDGE FLUSH
AB AB
No.8 SECURING
SCREW
SIDE CASING
(R.H.)
CAPTIVE
NUT
STRAP fitted when no
top casing
B
A
B
A
SIDE
CASING
(L.H.)
TOP CASING
PLASTIC PEG (4)
0914
SIDE CASINGS FITTING Diagram 5.2
MAX.
MIN.
MID.
MAX.
SIDE
CASING
(L.H.)
MAX.
MID.
MIN.
MIN.
BOILER PLINTH
FRONT
CASING
BRACKET
MID.
No. 8 SCREW
(4)
UPPER
CASING
BRACKET
LOCATING
LUG AND SLOTS
0886
5.3 Top Casing
Thetopcasingcanbefittedinfouralternativepositions,thatis,
with either a rolled or square front edge, flush with the door or
overhanging it by 10mm (3/8inch).
Select either a rolled or square front edge and for a flush fitting
top casing, fit four plastic pegs into holes “A”as shown in
diagram 5.3. For overhanging top casing, fit four plastic pegs
into holes “B”. The plastic pegs are a tight fit so they are best
pushed home with a flat faced tool.
Fitthetopcasingbyengagingthepegsintotheholesintheside
casings and then make sure that they are fully engaged by
pushing the pegs down.
For boilers fitted under work tops, not using the casing top, the
strap should be fitted as diagram 5.4.

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AP
AP
PP
CB
CB
CB
CB
230
(9) 25
(1)
230
(9)
230
(9)
6 ElectricalWiring
MAINS INLET
CONNECTOR Diagram 6.1
0878
NL
CABLE
CLAMP
COVER
SLOTS
LUGS
E
6.1 Control Box Cable Connection.
WARNING. This boiler must be earthed.
Remove the screw and cover from the mains inlet connector,
supplied loose, see diagram 6.1.
Usingheatresistantflexiblecableofasuitablelengthandrating
as stated in Section 1.7 “Electrical”connect the three wires to
the appropriate terminals in the connector.
Engage slots and lugs, replace cover and secure with screw.
Connect the mains inlet connector to the control box and use
threeofthecableclips, from thelooseitemspack,pushedonto
the edge of the right-hand panel in position CB as shown on
diagram 6.2 to ensure the cable does not touch any hot
surfaces.
6.2 Pump Cable Connection
Heatresistantcableasabove must beusedifthepumpisto be
fitted inside the casing.
SupportthecableinasimilarmannertoControlBoxConnection,
only fit clips to the casing at P or AP as diagram 6.2.
6.3 System Controls
Theelectricalinstallationmustbemadeinaccordancewiththe
current issue of BS7671.
The electrical isolator must isolate both the appliance and
system controls.
6.4 Testing
Checks to ensure electrical safety should be carried out by a
competent person.
In the event of an electrical fault after installation of the boiler,
preliminary system checks must be carried, that is, earth
continuity, polarity and resistance to earth, as described in the
British Gas Multimeter Instruction Book or equal publication.
9016
CABLE CLIP POSITIONS Diagram 6.2
Fit 4 control
box feed cable
clips at positions
CB
Alternative pump
cable clips (if feed is
on the left hand side)
at positions AP
Fit 2 pump cable
clips at positions P

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7 Commissioning
Diagram 7.1
BOILER COMPONENTS
L
J
J
H
M
K
(Shown
closed) E
9017
B
C
AFN
G
SETTING
POINT
SETTING
POINT
K
(Shown
open)
= OFF
= PILOT/IGNITION
= MAIN BURNER
Please ensure the “Benchmark”logbook is completed and left
with the user.
7.1 Preliminaries
With the pump removed the whole of the system should be
thoroughly flushed out with cold water.
Refitthepumpandfillthesystem. Examineforwatersoundness
and vent all air from the system and pump. Make sure that all
valves are open.
7.2 Initial Lighting, Testing and Adjustment
CAUTION. The following procedure should be carried out by
a competent person.
Identify the boiler controls by reference to diagram 7.1.
Check that the gas service cock “K”is closed, indicator slot
vertical.
Makesure that thethermostat phial isfully inserted in the phial
pocket “J”and is securely located by the retaining split pin.
Check that the mains electrical supply is switched off.
Set thermostat control knob “B”to “O”.
Remove the burner pressure test point screw “G”and connect
a suitable pressure gauge.
Open gas service cock “K”, indicator, horizontal.
Turn gas control knob “A”to' ' pilot/ignition position and
depress.
Atthesametimepushandreleasepiezoignitionbutton“C”until
the pilot burner lights, view through window “E”. At this stage
airmaybepresentinthatgaspipes,sothisoperationmayneed
toberepeatedseveraltimes. Whenthepilotburnerlights,keep
controlknob“A”fullypushedinforabout15seconds. Ifthepilot
burner fails to stay alight, repeat the lighting procedure only
now keep the control knob pushed for a little longer.
Ifthegascontrolknob“A”isturnedto' 'asafetylockprevents
it being turned on again until 3 minutes have elapsed.
Makesurethatthepilotisalightandstable,seediagram7.2for
the approximate flame length. Switch on the electrical supply.
Set any remote controls so that they are calling for heat. Turn
controlknob“A”to' 'mainburnerposition. Setthethermostat
controlknob“B”between“MINand“MAX”,themainburnerwill
light. “MAX”is about 82oC (180oF).
Test for gas soundness around boiler gas components with a
suitable leak detection fluid.
Ten minutes after lighting, check the burner setting pressure
and adjust, if necessary, as follows, remove cover “F”, see
diagram 7.1 and turn adjustment screw anti-clockwise to
decrease, see Data Table or refer to “L”Data Label for setting
pressure. After adjusting replace cover.
Ifanydoubtexists,thegasrateshouldbecheckedatthemeter.
This should be in the range of :-
HIDEAWAY 100B 3.2m3/h to 3.5m3/h(112 to 124 ft3/h)
Stick the self-adhesive arrow indicator, from the loose items
pack, to the data label against the rating the boiler is going to
be set to.
Allowthewatersystemtoreachmaximumworkingtemperature
andexamineforwatersoundness. Thesystemshouldthenbe
turned off and drained rapidly, whilst still hot, to complete the
flushing process.
The system should then be filled again, vented and examined
for water soundness.
A GAS CONTROL KNOB H CONTROL BOX
B TERMOSTAT CONTROL J PHIAL POCKET
C PIEZO IGNITION BUTTON (alternative positions)
E VIEWING WINDOW K GAS SERVICE COCK
F GOVERNOR ADJUSTMENT L DATA LABEL
COVER M GAS CONTROL VALVE
G BURNER PRESSURE N PILOT ADJUSTMENT
TEST POINT SCREW

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7 Commissioning
PILOT FLAME DIMENSION Diagram 7.2
PLINTH / DOOR FITTING Diagram 7.3
FLAME
DIMENSION
SPARK GAP
DIMENSION
0937
Pilot shield
omitted
for clarity
13 (1/2in.)
APPROX.
3-4mm.
(1/8in.)
PILOT
BURNER
ASSEMBLY
VIEWING
WINDOW
1356
VIEW 2
VIEW 1
VIEW 2
PLINTH
FRONT
LOWER
HOOK
VIEW 1
UPPER
HOOK DOOR
FASCIA
STUD
7.3 Operational Checks
Check operation of the flame failure device as follows, with the
main burner alight, turn the gas valve control knob “A”fully
clockwise to its stop' ' , this will extinguish the main and pilot
burners. The safety device should close before 60 seconds
have elapsed, a click from the gas valve will indicate it has
closed.
Remove the pressure gauge and refit the pressure test point
screw “G”, make sure that a gas tight seal is made.
Turn thermostat “B”to “O”then relight the pilot burner as
Section 7.1.
Relight the main burner.
Check that the boiler thermostat and all automatic controls are
operating correctly.
Do not attempt to adjust the thermostat calibration screw.
Relight the main burner and check for gas soundness with a
suitable leak detection fluid.
7.4 Completion and User Information
Instructanddemonstratetheefficientandsafeoperationofthe
boiler, heating and hot water system.
Hand the Instructions for Use to the user, for their retention,
making sure that they are understood.
Advise that to ensure the 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
theinstallationconditionsandusage,butingeneralonceayear
should be enough.
It is that law that any servicing must be carried out by a
competent person.
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.
Fittheplinthfrontbylocatingthesidesovertheboilerplinththen
lowering to engage the upper and lower hooks, see diagram
7.3.
Fitthedoorbylocatingthehookedrunneratthe bottomintothe
slotsinthesidecasingsandpushingonto thestudsontheside
casings.
Reminder - Leave these instructions and the “Benchmark”
logbook with the user.

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8 Servicing
ACCESS TO FLUEWAY Diagram 8.3
0908
FLUEWAY
CLEANING
DOOR
SELF-
TAPPING
SCREW (4)
ACCESS FOR SERVICING Diagram 8.2
9018
GRAPHITE
COATED NUT TIE
BAR
SECURING
SCREW (5)
BAFFLE
TRAY
PIPE
SUPPORT
BRACKET
COMBUSTION
CHAMBER
COVER
It is the law that servicing must be carried out by a competent
person.
Beforecommencinganyservicing,turnoffthegassupplyatthe
gas service cock, see diagram 8.1 and isolate the electrical
supply to the boiler.
Alwaystestforgassoundnessaftercompletinganyservicingor
replacement of parts.
8.1 Gain Access to the Boiler
Pull the door forward at the top to disengage studs and lift to
release from the slots, see diagram 7.3.
Lift the plinth front up and forwards to withdraw, see diagram
7.3.
Ifthetopcasingisremovedduringservicingcaremustbetaken
nottodamageorloseany plastic pegswhenreplacingit. Refer
to Section 5.3 “Top Casing”when refitting.
8.2 Boiler Flueways
Unscrewtheunionnutsecuring the gas service cock to thegas
valve, see diagram 8.1.
Remove the mains inlet connector by pulling downwards, see
diagram 8.1
Remove split pin on the thermostat phial pocket and withdraw
the phial and capillary, see diagram 4.5.
Remove the five screws retaining the combustion chamber
cover and burner assembly, see diagram 8.2.
Easethegasservicecockawayfromthegasvalveandunhook
thepipesupportbracketfromthetiebartoenabletheassembly
of cover, control box, gas valve and burners to be withdrawn
forwards.
Remove graphite coated nut to release baffle tray and remove
from combustion chamber, taking care not or damage the
insulation material in the sides of the chamber.
Removetheself-tappingscrewswhichretainthefluewaycleaning
door and lift door clear, see diagram 8.3.
Remove the baffles from the heat exchanger, see diagram 8.6.
Placea sheet of paperin the combustion chamberto catch any
flue debris.
Access for flueway cleaning is made through the cleaning door
and combustion chamber apertures.
Thoroughly clean boiler flueways and fins from top and bottom
with a suitable stiff brush. Remove any debris from the base of
the combustion chamber.
Check that the flueways are clear, view with the aid of a mirror
or reflector.
8.3 Burners and Injectors
Refer to Section 8.2 for instructions on how to remove cover,
burners and controls assembly.
Removethetwoscrewsandnutssecuringeachburnersupport
bracket to the combustion chamber cover, see diagram 8.4.
Removethegraphitecoatednutsonsupplyfeedpipeattherear
of the burner to release the burners, taking care not to damage
the pilot burner and shield when removing.
Remove the nuts, washers and burner end caps, see diagram
8.5.
Remove the distributors from inside the burners then clean the
burners and components thoroughly with a vacuum cleaner.
Checkthatthemainburnerinjectorsarenotblockedordamaged.
Cleanorrenew asnecessary. Donotcleanwithawireorsharp
instrument, see diagram 8.4.
8.4 Service Checks
Inspect the thermocouple and pilot burner, clean or renew as
necessary.
Diagram 8.1
ISOLATION OF
GAS AND ELECTRICITY
9012
GAS
SERVICE
COCK
(turn off)
(shown
closed)
MAINS INLET
CONNECTOR
(pull downwards)

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8 Servicing
9 Replacement Parts
6039
Diagram 8.4
REMOVAL OF BURNER
COMBUSTION CHAMBER
COVER
SUPPLY
PIPE MAIN
BURNER (2)
INJECTOR (2)
GRAPHITE
COATED NUT (2+2) SCREW
(2+2)
BURNER
SUPPORT
BRACKET (2)
BURNER SERVICING Diagram 8.5
6040
BURNER
WASHER
SECURING
NUT
BURNER
END CAP
Diagram 8.6
6143
BAFFLES
HEAT EXCHANGERS
Check the condition of the insulation panels in the combustion
chamber, renew if necessary.
Check the condition of the seals on the cleaning door and the
combustion chamber cover, renewing if necessary.
8.5 Re-assembly
Make sure that the baffle tray is replaced and secured with the
graphite coated nuts, previously removed.
Makesurethatthethermostatphialisfullyinsertedintothephial
pocket and secured, with the location washer behind the
retaining split pin, see diagram 4.5.
Make sure flueway baffles are positioned as diagram 8.6
8.6 Operational Checks
Lighttheboilerandcarryouttheoperationalchecksasdescribed
in Sections 7.2 and 7.3.
Before removing or replacing any parts, turn the gas off at the
gas service cock, see diagram 8.1 and isolate the electrical
supply to the boiler.
ALWAYS test for gas soundness after replacing any gas
carrying component.
Unless stated otherwise replacement of parts is in the reverse
order to removal.
9.1 Gas Valve
Gain access to boiler, see Section 8.1.
Disconnectthegasvalveplug, thermocouplenutandpilottube
connections at the gas valve, see diagram 9.1.
Supportthevalveandremovethefourright-handflangescrews
to disconnect the gas valve from the burner supply pipe.
Ease the gas service cock union out and remove the valve
taking care not to damage the “O”ring seal at the flange.
Inspecttheconditionofthe“O”ringsealandrenewifnecessary.
Remove the union half and refit into the replacement valve on
the inlet, left-hand side. Use a little jointing compound, on the
external thread only, to ensure gas soundness.
Itwillbenecessarytopurgeair from the gas lineafterchanging
the gas valve, refer to Section 7.2.
9.2 Injectors
Gain access to the boiler as Section 8.1
Unscrewtheinjectorsfromthemanifoldandrenewasnecessary.
When replacing the injectors use a little jointing compound, on
the external thread only, to ensure gas soundness.
Replace thermostat phial as Section 8.5.
9.3 Thermocouple
Gain access to the boiler as Section 8.1.
Disconnect the thermocouple by unscrewing nuts at the gas
valve and pilot burner, see diagrams 9.1 and 9.2. Withdraw the
thermocouple.
When replacing tighten the thermocouple nut only a quarter turn
beyond finger tight.
9.4 Pilot Burner
Gain access to the boiler as Section 8.1.
Removethecoverandburnercontrolsassembly,asSection8.2.
Disconnect the ignition lead at the electrode, see diagram 9.2.
Disconnect the thermocouple nut at the pilot burner.
Disconnectthepilottubenut,easeoutthetubeandinjectorwhich
is hooked on to the pilot tube.

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9 Replacement of Parts
9013
Diagram 9.1REMOVAL OF GAS VALVE
PILOT ASSEMBLY Diagram 9.2
0935
PILOT
INJECTOR
PILOT
TUBE
PILOT
BURNER
ASSEMBLY
PILOT
SHIELD
SPARK
ELECTRODE
SECURING SCREW (2)
AND NUT (2)
THERMOCOUPLE
IGNITION LEAD
(CLEAR END)
GAS
VALVE
PLUG
GAS
VALVE GAS
OUTLET
FLANGE
SCREW
(4)
PILOT TUBE
NUT
INSULATION PANELS Diagram 9.3
SIDE
INSULATION
PANEL
1281
SCREW
REAR
INSULATION
PANEL
CLIP
BAFFLE
TRAY
GRAPHITE
COATED NUT
Remove the nut retaining the spark electrode and remove.
Remove the two screws and nuts securing the pilot burner and
shield to the combustion chamber cover.
Hook pilot injector over pilot tube olive when refitting.
Check that the pilot flame length is as shown in
diagram 7.2.
Replace thermostat phial as Section 8.5.
9.5 Spark Electrode
Gain access to the boiler as Section 8.1.
Disconnect the thermocouple nut and withdraw thermocouple
from pilot burner, see diagram 9.2.
Disconnect the nut retaining the spark electrode and remove.
When re-assembling check that spark gap is as shown in
diagram 7.2
9.6 Insulation Panels
Gain access to the boiler as Section 8.1.
Remove the burner assembly as Section 8.2.
Remove the two screws retaining each side insulation panel
withinthecombustionchamberandremovepanel,seediagram
9.3.
Release the rear insulation panel upper clips and lift panel out.
Refit thermostat phial as Section 8.5.
9.7 Boiler Thermostat
Follow the relevant instructions in Section 8.1.
Remove the mains inlet connector by pulling downwards, see
diagram 8.1.
Remove the retaining split pin from the phial pocket then
withdraw the phial and capillary, see diagram 4.5.
Pull off the thermostat control knob.
Gain access to inside of the control box by removing the
securing screw located at the top of control box and unhooking
at the bottom, see diagram 9.4.
Remove the two screws which secure the boiler thermostat to
the control box, see diagram 9.4.
Tilt the thermostat so that the electrical connections can be
removed.
Withdraw boiler thermostat from control box complete with
capillary tube and phial.
Refer to diagram 9.5 to connect electrical connectors.
ReplacethethermostatphialastherelevantpartofSection8.5.
Make sure that the capillary is positioned so that it passes
through the cut out in the control box, see diagram 9.4.
9.8 Piezo Unit
Pull door forward at the top to disengage the studs and lift to
release from slots, see diagram 7.3.
Remove mains inlet connector by pulling downwards, see
diagram 8.1.
Gain access to inside of the control box by removing the
securing screw located at the top of control box and unhooking
at the bottom, see diagram 9.4.
Disconnect the ignition lead at the piezo unit.
Note: To ease the removal of the piezo unit it is advisable to
temporarily remove the boiler thermostat from the control box.
Depress the retaining tabs and remove the Piezo unit.
9.9 Ignition Lead
Gain access to the boiler as Section 8.1.
Disconnect the ignition lead at the piezo unit, see diagram 9.4
and section 9.8.
THERMOCOUPLE
NUT

Supplied By www.heating spares.co Tel. [phone]
20
221764B
9 Replacement of Parts
Disconnect the lead at the spark electrode, see diagram 9.2.
When reconnecting lead make sure that the clear end is fitted
to the spark electrode.
9.10 Electrical Control Box
Gain access to the boiler as Section 8.1.
Disconnect the mains inlet connector, see diagram 8.1.
Remove the retaining split pin from the phial pocket then
withdraw phial and capillary, see diagram 4.5.
Disconnectthegasvalveplug from the valve, see diagram 9.1.
Releasethecontrolboxbyremovingthesecuringscrewlocated
at the top of control box and unhooking at the bottom, see
diagram 9.4.
Pull the ignition lead off piezo unit, see diagram 9.4.
Whenrefittingcontrol boxmakesurethe thermostatcapillaryis
positioned so that it passes through the cut out in the control
box, see diagram 9.4.
Refit thermostat phial, refer to Section 8.5.
7995
ELECTRICAL
CONNECTORS
ELECTRICAL
CONTROL BOX
COVER
COVER
SECURING
SCREW (4)
ELECTRICAL
CONTROL BOX
THERMOSTAT
SECURING
SCREW (2)
THERMOSTAT
CONTROL KNOB
PIEZO
UNIT
HOOK
IGNITION LEAD
(BLACK END)
CUT-OUT FOR
CAPILLARY
SECURING SCREW
THERMOSTAT
AND CAPILLARY
Diagram 9.4
CONTROL BOX
Diagram 9.5
CONTROL BOX AND GAS VALVE WIRING
6284
CHASSIS
EARTH
230V~ 50Hz
MAINS SUPPLY
FUSED AT 3A
BLUE
BLACK
GREEN / YELLOW
BROWN
C
THERMOSTAT
GAS VALVE
N
E
NL
VIEW OF PLUG
WHEN REMOVED
LGREEN/
YELLOW
N/C