221725B.10.00 Installation & Servicing Instructions To b e l e f t w i t h t h e u s e r Glow-worm 56/3e Back Boiler Unit G.C. No. 44 047 04A 6836 This Back Boiler Unit Is To Be Used Only With The Glow-worm Mk.3 Fire Front Range This is a Cat I2H Appliance Customer Services: Tel: (01773) 828100 One Contact Local Service Fax: (01773) 828070 Hepworth Heating Ltd., Nottingham Road, Belper, Derbyshire.
1 General 1 General 1.2 Data The instructions consist of three parts, Installation and Servicing Instructions for the Back Boiler Unit, Installation and Servicing Instructions for the Fire Front and Instructions for Use, 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.
INSIDE DIAMETER OF SOCKET FOR 125mm (5in) NOMINAL DIAMETER FLUE FIRE FIXING WALL FACE CL FLUE E WATER CONNECTIONS 22mm COPPER PIPE GAS CONNECTION RC (1/2 in BSPT) B R H N CL of Flue F 6837 1 General S T A P D G L K C J M SIDE ELEVATION OVERALL DIMENSIONS Dimension A 56/3e B C D E F J FRONT ELEVATION Diagram 1.
1 General 1.6 Water System - Open Vented 1.12 Back Boiler Location This back boiler can be used on an unrestricted open vented system with the water supply taken from a feed and expansion cistern, having a head between 1m (3ft3in) minimum and 27m (90ft) maximum. This back boiler MUST NOT be installed in a private garage or in a room containing a bath or shower or in a room used or intended to be used as sleeping accommodation. Diagrammatic layouts of systems are shown in diagram 1.4 and 1.5.
28mm FRONT OPENING IMPORTANT DIMENSION NOT LESS THAN 145mm 405 mm. MIN. INDIRECT CYLINDER 27 METRES MAXIMUM * CORNER IN-FILL (not required to be full depth of opening) 6242 6408 1 General DISTRIBUTOR TUBE IN RETURN CONNECTION 22mm CENTRAL HEATING RETURN 1.13 BSI Certification This appliance is certificated to the current issue of BS6332 Part 1 invoking the current issue of BS5258 Part 8 for safety and performance.
2 Types of Installation within the opening to allow easy connection of the flue into the back boiler flue socket, see diagram 2.3. 2.1 With Non-combustible Hearth The back boiler must be installed level with the hearth or above it, see diagram 2.1. The surround requires a minimum opening for access as shown in diagram 1.2. For minimum dimensions of a hearth see diagram 2.1. 2.4 Wall Mounted - that is - Without Surround or Hearth 2.
3.1 General The general recommendations of the current issue of BS5440 Part 1 should be followed. SEALING AND CLAMPING PLATE In all cases the flue should be lined, preferably with a flexible liner. It is essential that the flue has an equivalent height of at least 2.5m (8.2ft) measured from the flue connection on the appliance. The first 600mm, at least, above the draught diverter must be vertical. 6197 3 Flue and Ventilation AIR SPACE The flue socket is designed to take flue pipe to BS567.
3 Flue and Ventilation If a flue and false chimney breast are to be constructed all openings for pipework to upper floors etc., must be sealed. The only opening for the back boiler must be at the front, being of the dimensions as shown in diagram 1.2. If a specially built compartment is constructed for the back boiler, it must conform to the requirements of the current issue of BS5440 Part 1 and BS5871. The flue should, preferably, end above ridge height but at least above the eaves of a pitched roof.
4.1 Preparation 22mm COPPER PIPE SUPPLIED WITH APPLIANCE (Do not cut) Remove draught diverter assembly, flueway baffles and fittings pack from carton. Check contents of fittings pack against packed list. 6254 4 Installation INJECTOR UNEQUAL TEE PIECE Remove back boiler body assembly from carton. 4.2 Water Connections IT IS EXTREMELY IMPORTANT THAT NO SERVICE PIPES ARE ROUTED IN FRONT OF THE BOILER.
4 Installation 6842 FITTING THE INJECTOR 22mm COPPER PIPE SUPPLIED WITH APPLIANCE (Do not cut) 22mm CENTRAL HEATING RETURN INJECTOR (Supplied) 28mm UNEQUAL TEE (supplied) 22mm 145 mm MINIMUM 28mm DOMESTIC HOT WATER FLOW 22mm COPPER PIPE SUPPLIED WITH APPLIANCE (Do not cut) 6841 22mm COPPER PIPE SUPPLIED WITH APPLIANCE (Do not cut) 22mm CENTRAL HEATING RETURN 22mm CENTRAL HEATING FLOW (Must run down to allow air in system to escape) METHOD A 28mm DOMESTIC HOT WATER FLOW (Must rise to allow air
4.5 Heat Shield Assembly SECURING SCREW (2) Slacken, Do not remove If the boiler electrical supply cable has to be routed down the left hand side of the combustion chamber you must fit the heat shield assembly and clips supplied in the fittings pack. Refer to Section 5.1 and diagrams 5.2 and 5.3. COMBUSTION CHAMBER EXTENSION 6844 4 Installation 4.6 Circulating Pump Isolating valves, integral if possible, must be fitted each side of the circulating pump. 4.
6845 FIXING HOLE (5 OFF) FIXING HOLE (5 OFF) Minimum of 2 must be used FIRE FIXING WALL FACE HEAT EXCHANGER CASTING FIXING WALL FACE 6846 4 Installation TOP VIEW INSIDE BUILDERS OPENING 6177 Diagram 4.7 CUT-OUT A Line the appliance up with the wall fixing face BAFFLES MIDDLE FLUEWAY BACK FLUEWAY Diagram 4.6 HEAT EXCHANGER Diagram 4.8 DRAUGHT DIVERTER ASSEMBLY SPIGOT DUCT SECURING SCREW (2) 6847 Pipework removed for clarity SECURING SCREW (2) Pipework removed for clarity Diagram 4.
4 Installation 6848 SENSING TUBE BRACKET SECURING SCREW Fully fit No. 8 3/8 in. screw into rear of socket. Centralise flexible flue liner using the two No. 8 1/2 in. screws provided. REAR 6849 DRAUGHT DIVERTER No. 8 3/8 in. SCREW SOCKET FRONT No. 8 1/2 in. SCREWS (BLACK) SENSING TUBE (push fit) 6873 Diagram 4.
5 Electrical Wiring If right hand access is required fit the three clips from the fittings pack to the combustion chamber extension and route the cable down the right hand side of the combustion chamber. Keep the cable well clear of hot surfaces, see diagram 5.3. 5.1 General WARNING. This boiler must be earthed. ISOLATE THE ELECTRICAL SUPPLY BEFORE DOING ANY WIRING NOTE: The boiler electrical supply cable must not be routed along the back of the appliance.
5.3 Boiler Control Box CONTROL THERMOSTAT PHIAL Taking care that the POWER IS OFF, wire the incoming mains cable to the mains plug supplied in the fittings pack. Do not connect the mains supply plug to the control box socket, see diagram 5.5. RETAINING PIN 6203 5 Electrical Wiring C NOTE: The ignition sequence is fully automatic and will commence when mains voltage is applied. OVERHEAT CUT-OFF DEVICE 5.
CONTROL BOX AND GAS VALVE WIRING FLUE BLOCKAGE SAFETY DEVICE 7885 5 Electrical Wiring GAS VALVE p 230V~50Hz SWITCHED CONTROLLED SUPPLY SL r KEY br b y r g/y wh SL - brown bk - black blue or - orange p - purple yellow red green/yellow white Switch Live bk g/y br L b bk N TC-GND TC-SGN CN3 EVI EVN EV2 CN1 HV FUSE F1A 3 PIN MAINS SOCKET br g/y CN4 L CN2 N CN6 b CN5 br b or wh Orange link or OVER HEAT CUT-OFF SAFETY DEVICE (sealed systems only) wh r p y y RESET / p p LOCKOUT E
6 Commissioning Turn gas service cock “D” to the “On” position making sure that the fire front service cock “D” is in the “Off” position, see diagram 4.12. 6.1 Commissioning the Back Boiler Before commissioning the back boiler, the whole of the system should be thoroughly flushed out with cold water with the circulation pump removed. Replace the pump, fill the system and examine for water soundness. Vent air from the system and pump.
6 Commissioning 6.3 Clearance of Products The back boiler is supplied preset to a maximum heat output setting of 15.8 kW (54000 Btu/h) but may be adjusted to suit design requirements. A clearance of products (spillage) test must be carried out after installation of the back boiler and it's fire. This value 15.8 kW must not be exceeded when using the boiler in combination with a Brown Ember 3, Black Ash 3 or Saxony 3 fire front.
7 Fire Installation Fire Front Installation and Servicing Instructions are packed with the fire. 7.1 Completion - After Installation of the Fire Front Instruct and demonstrate to the user, the efficient and safe operation of the boiler, heating and hot water system and fire front. Hand the Instructions for Use to the user, making sure that they are understood.
Servicing Notes INTERNAL FILTER a) To ensure the continued efficient and safe operation of the appliance it is recommended that it is checked and serviced as necessary at regular intervals. The frequency of the servicing will depend upon the particular installation conditions and usage, but in general once a year should be enough. SENSING TUBE FITTING RETAINING NUT 6851 8 Servicing BRACKET SECURING SCREW TUBING NUT b) It is the Law that servicing must be carried out by a competent person.
8 Servicing 8.4 Burner Disconnect the pilot tube nut and the thermocouple nut from the gas control valve, see diagram 8.5. Remove the screws which locate the gas manifold to burner, see diagram 8.5. The gas control valve can now be lifted clear of the burner. Clean the burner as necessary, do not use a brush with metallic bristles.
8.5 Lint Arrester GAS SECURING MANIFOLD SCREWS Remove the four securing screws to disengage the two lint arresters, see diagram 8.6. THERMOCOUPLE NUT 6886 8 Servicing Clean the lint arresters as required. 8.6 Main Burner - Injector Inspect the main burner injector for damage or blockage, clean or replace as necessary. If replacing ensure the new copper washer is fitted, see diagram 8.7. Do not use a wire or sharp instrument to clean the injector hole. 8.
8 Servicing 6207 8.8 Ignition Lead Inspect the ignition lead for wear or damage, clean or replace as necessary. 8.9 Back Boiler Flueways Remove the spigot duct, see diagram 8.10. Remove the draught diverter plate by slackening the two side securing screws and removing the rear securing screw, see diagram 8.10. Lift out the flueway baffles, see diagram 8.11. Place a sheet of paper in the base of the combustion chamber. FLUE BLOCKAGE SAFETY DEVICE Clean the boiler flueways with a suitable stiff brush.
9 Fault Finding 9.1 Electrical Carry out the preliminary electrical system checks as contained in a multimeter instruction book. Refer to electrical fault finding chart, diagram 9.1 and functional flow wiring diagram 9.2. On completion of the fault finding task which has required the breaking and remaking of electrical connections, the checks for earth continuity, short circuit, polarity and resistance to earth must be repeated. 9.
7301 9 Fault Finding Ensure all connections are correctly made, that gas supply is available free of obstruction and purged of air. Ensure that external controls, if fitted, are calling for heat. Connect a multimeter set to mVDC to pins YES TC-GND and TC-SGN on CN1 on the control board (PCB). Does sparking take NO place, does milli-voltage increase towards 5mV? START ≈ 30 seconds after a call for heat, does the control board (PCB) start to spark. NO Faulty control board (PCB). Replace. Pilot not lit.
7186 9 Fault Finding Ls CONTROL BOARD (PCB) br KEY br BROWN b BLUE w WHITE FUSE TYPE T1A CN5 CN3 EV1 TH TH CN3 EV2 bk BLACK or ORANGE LINK (OVERHEAT THERMOSTAT IF FITTED) or br w w b CONTROL THERMOSTAT PILOT SOLENOID MAIN SOLENOID bk b HV CN4 b 5 WAY SOCKET CONNECTIONS SPARK ELECTRODE N PCB CONNECTIONS N FUNCTIONAL FLOW 221725B Diagram 9.
10 Replacement of Parts Notes. 10.4 Electrode a) Replacement of parts must be carried out by a competent person. Proceed as in Section 10.2. b) Unless stated otherwise all parts are replaced in the reverse order to that of removal. 10.5 Ignition Lead c) After replacing any gas carrying parts always test for gas soundness using a suitable leak detection fluid. Also carry out functional check of controls. Remove the control box refer to the relevant parts of Section 8.3.
Remove the interrupter. THERMOCOUPLE NUT Remove the liner and union nut. Transfer the interrupter to the replacement gas control valve. ELECTRICAL CONNECTIONS Transfer the liner and union nut using a small amount of approved jointing compound on the external threads only to the replacement gas control valve. INTERRUPTER GAS SERVICE COCK 6882 10 Replacement of Parts LINER Fit the new 'O' ring seal supplied with new gas control valve. Note.
10 Replacement of Parts 6199 Release the wires from the mains terminal strip. MULTI PIN CONNECTOR Carefully pull the board from its supports. When refitting refer to the wiring diagram 5.6. 10.11 Over Heat Cut-off Device (Sealed systems only) Remove the combustion chamber extension, see diagram 4.5. LOCKOUT RESET BUTTON Remove the control box refer to the relevant parts of Section 8.3. Remove the over heat phial and unclip the capillary tube, see diagram 5.4. Remove the locknut, see diagram 10.7.
10.13 Interrupter SOLENOIDS Remove the combustion chamber extension, see diagram 4.5. SECURING SCREW 6888 10 Replacement of Parts Refer to diagram 10.9 Carefully disconnect the thermocouple nut. Remove the electrical connections. Remove the interrupter. 10.14 Insulation Follow the relevant instructions in Section 8.3 to remove the controls assembly and burner. Remove the five burner securing screws to remove the combustion chamber front cover from the controls assembly and burner, see diagram 8.2.
11 Spare Parts When spare parts are required apply to your local supplier. Please quote the name of the appliance, Glow-worm 56/3e BBU, with a relevant BBU Fire Front, also the serial number of the boiler, to be found on the data label on the appliance. If ordering from the local gas undertaking the appropriate appliance GC number should also be quoted together with the GC number of the part. Part No. Description GC Part No.
Control of Substances Hazardous to Health Information for the Installer and Service Engineer. Under Section 6 of The Health and Safety at Work Act 1974, we are required to provide information on substances hazardous to health. The adhesives and sealants used in this appliance are cured and give no known hazard in this state. RADIANTS, FUELBEDS, ARTIFICIAL FUEL After handling wash hands thoroughly.
