221723B.10.00 Installation & Servicing Instructions To b e l e f t w i t h t h e u s e r INSET BBU 50 G.C. No. 44 047 02 8023 For Use Only With Specially Designed Fire Fronts 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.
Important Information B.S.I Certification It is important that no alteration is made to the boiler without permission, in writing, from Hepworth Heating Ltd. Any alteration that is not approved by Hepworth Heating Ltd., could invalidate the B.S.I. Certification, the boiler warranty and could also infringe the current issue of the Statutory Requirements, see Section 1.1. CE Mark The boiler meets the requirements of Statutory Instrument, No.
1 General 1 General 1.1 Statutory Requirements References in these instructions to British Standards, Statutory Regulations and Requirements apply only to the United Kingdom. The installation of this back boiler unit must be carried out by a competent person in accordance with the current issue and relevant requirements of: For Ireland the rules in force must be used. Manufacturer’s instructions, supplied.
6173 1 General FIRE FIXING WALL FACE CL FLUE D B G P M WATER CONNECTIONS 22mm COPPER PIPE CL of Flue E R GAS CONNECTION RC (1/2 in BSPT) A N C F K J H L FRONT ELEVATION SIDE ELEVATION DIMENSION 50 / BBU H A B C D E F G H J K L M N P R 550 400 337 245 130 164 146 193 174 39 348 65 530 80 50 OVERALL DIMENSIONS (RIGHT HAND WATER CONNECTION SHOWN) 6302 Diagram 1.
1 General 1.5 Contents of Packaging 5506 Minimum flat area and fixture or surround protection clearance The boiler is delivered in one pack which contains all the parts required for installation. 690 For all types of installation a standard 16inch builder’s opening is required, see diagram 1.2. 800 MIN WIDE FRAME 780 MIN STANDARD FRAME 1.6 Site Requirements C L Note: The depth of the fire opening is IMPORTANT, it MUST therefore conform to the dimensions given in diagram 1.2.
2 Types of Installation PREPARED BOILER BASE In ALL cases there MUST be a non-combustible hearth under the fire front. For minimum dimensions of a hearth see diagram 2.1. 5423 2.1 Hearth Carpet or similar floor covering must not be placed on the hearth. 50mm MIN If the boiler is to be mounted above the prepared hearth the hearth must still conform to the instructions above and the dimensions given in diagram 2.1. HEARTH 2.
3 Flue and Ventilation 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. 3.1 General The general recommendations of the current issue of BS5440 Part 1 should be followed. 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.
3 Flue and Ventilation 3.4 Precast Flue The ventilation openings may be direct to the outside air or with an internal room or space (such as a hall) which itself has a permanent air vent of the same effective area. The permanent air vent should be in a position which will cause the least nuisance to occupants, due to draughts. The appliance is suitable for fitting to a properly constructed non-impeded precast flue.
4 Installation If the heat exchanger connections are opposite hand to that required, turn in the same manner as described in Section 4.3 paragraph 5. 6254 22mm COPPER PIPE SUPPLIED WITH APPLIANCE (Do not cut) UNEQUAL TEE PIECE 4.5 Heat Shield Assembly 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 supplied in the fittings pack. Refer to Section 5.1 and diagrams 5.2 and 5.3.
8025 FITTING THE INJECTOR 22mm CENTRAL HEATING RETURN 22mm COPPER PIPE SUPPLIED WITH APPLIANCE (Do not cut) SECTION A-A 6763 4 Installation INJECTOR (Supplied) 22mm BRAZED JOINT RETURN PIPE ASSEMBLY 28mm FIXED DIMENSION A A UNEQUAL TEE (supplied) 22mm COPPER PIPE SUPPLIED WITH APPLIANCE (Do not cut) 22mm CENTRAL HEATING RETURN 8027 22mm COPPER PIPE SUPPLIED WITH APPLIANCE (Do not cut) 28mm DOMESTIC HOT WATER FLOW 22mm CENTRAL HEATING FLOW (Must run down to allow air in system to escape) ME
Reposition the back boiler unit into the builder’s opening. Connect the system pipework to the back boiler unit/preplumbed pipework. 7980 4 Installation BAFFLES (centre in flueway) Connect gas supply to gas service cock. Leave gas service cock and gas fire front cock in the “OFF” position, see diagram 4.11 and 6.2. If a flexible flue liner is being used, position the liner in to the flue socket.
SENSING TUBE SECURING SCREW REAR Fully fit No. 8 3/8 in. screw into rear of No. 8 3/8 in. socket. Centralise SCREWS flexible flue liner using the two No. 8 1/2 in. SOCKET screws provided. 8029 DRAUGHT DIVERTER 8030 4 Installation FRONT No. 8 1/2 in. SCREWS (BLACK) SENSING TUBE (push fit) Diagram 4.10 6176 (Left hand water connection shown) SENSING TUBE ASSEMBLY GAS SERVICE COCK (OFF) “O” RING SEALS ON THE FLUE BLOCKAGE SAFETY DEVICE Diagram 4.11 SENSING TUBE (push fit) Diagram 4.
5.1 General Froststat Pipestat Double Pole Switchspur Programmer Roomstat WARNING. This boiler must be earthed. ISOLATE THE ELECTRICAL SUPPLY BEFORE DOING ANY WIRING L All of the electrical installation must be correctly earthed and be in accordance with the current issue of BS7671 and be carried out by a competent person. Pump 6452 5 Electrical Wiring L N N The boiler electrical supply is 230V~ 50Hz, fused at 3A.
5 Electrical Wiring Unwind the capillary avoid kinking. Route the capillary well clear of any part of the back boiler which becomes hot. Use the capillary clips, supplied. Secure the capillary and push the phial into the pocket, see diagram 5.4. Again make sure that the capillary is not touching the casting. OVERHEAT CUT-OFF DEVICE (sealed systems only) NOTE: When fitting the phial into the phial pocket use the heat sink compound supplied in the fittings pack. CONTROL THERMOSTAT PHIAL 8031 5.
FLUE BLOCKAGE SAFETY DEVICE KEY br bk b or y g/y p wh r - 6675 5 Electrical Wiring GAS VALVE brown black blue orange yellow green/yellow purple white red p SWITCHED CONTROLLED SUPPLY 230V~50Hz r bk g/y L N br TC-GND TC-SGN b CN3 EVI EVN 3 PIN MAINS SOCKET EV2 CN1 HV FUSE F1A CN4 L CN2 N CN6 N L bk CN5 br br g/y b g/y or b or r p y y RESET / LOCKOUT g/y wh EARTH POST OVER HEAT CUT-OFF SAFETY DEVICE (sealed systems only) wh g/y p p g/y CONTROL BOX AND GAS VALVE WIRING
6 Commissioning 6.1 Commissioning the Back Boiler Turn gas service cock “C” to the “On” position making sure that the fire front service cock “D” is in the “Off” position, see diagram 6.2. 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 Turn control thermostat knob “A” clockwise until “MAX” is against the pointer positioned on the control box front cover “F”. The main burner will light. 6.3 Clearance of Products A clearance of products (spillage) test must be carried out after installation of the back boiler and it's fire. Test for gas soundness using a suitable leak detection fluid. Before fitting the fire, check that the heat exchanger baffles are fitted and seated correctly, see Section 4.9.
PRESSURE LOSS (mm head of water) 6.4 Commissioning the System Set all controls to operate the heating system. Adjust circulating pump and balance the system to give a temperature drop across the boiler of 11oC (20oF). At the appropriate flow rate, the resistance of the back boiler can be found by reference to diagram 6.4. There should be no undue noise in the pipework or heat emitters. There must be NO pumping over of water or entry of air at the open vent pipe above the feed and expansion cistern.
8.3 Controls Assembly and Burner. FILTER SENSING TUBE FITTING RETAINING NUT SECURING SCREW Disconnect the union at the gas service cock, see diagram 8.2. Remove the thermostat phial and overheat cut-off device phial if fitted (sealed systems only), from the phial pockets, unclip the capillary tubes, see diagram 5.4. TUBING NUT Disconnect the mains electrical plug from the control box, see diagram 8.2. 6300 8 Servicing Remove the four combustion chamber securing screws.
8 Servicing 6259 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 8.5. COPPER WASHER GAS MANIFOLD THERMOCOUPLE NUT MAIN BURNER INJECTOR GAS CONTROL VALVE EARTH POST PILOT TUBE NUT Diagram 8.5 SPARK GAP 3 +1 or -0.5 THERMOCOUPLE Diagram 8.
8.7 Flue Blockage Safety Device Assembly DRAUGHT DIVERTER Gain access as relevant part of Section 8.3. Remove any dust and lint, inspect the pilot for damage. Remove the sensing tube adapter, to clean, blow through, do not use a wire or sharp instrument. If necessary replace the flue blockage safety device. SECURING SCREWS (4) 8032 8 Servicing Check for the correct spark gap, see diagram 8.6. To remove the safety device, remove the two securing screws, see diagram 8.7. 8.
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. 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.
9 Fault Finding 9.4 Flue Blockage Safety Device and Ignition Fault Finding 9.2 Thermocouple To test the thermocouple, a meter with a range of 0 - 30mV is required together with a thermocouple interrupter test unit. To check the safety device and ignition, refer to fault finding chart, diagram 9.1. 9.3 Electrical Fault Finding Back Boiler 7427 Refer to diagram 9.1.
10 Replacement of Parts Notes. 10.3 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. 10.4 Ignition Lead Remove the control box lid. c) After replacing any gas carrying parts always test for gas soundness using a suitable leak detection fluid. Also carryout functional check of controls. Remove the lead from the electrode.
10 Replacement of Parts Refer to the relevant parts of Section 8.3 to remove the controls assembly. 6199 10.6 Gas Valve ELECTRICAL PLUG Refer to diagram 10.2. Disconnect electrical plug. Disconnect the thermocouple nut at the gas valve and ease out. Disconnect interrupter electrical connections. Disconnect the pilot tubing nut at the gas valve. LOCKOUT RESET BUTTON Undo the securing screws to separate the valve from the supply pipe flange and gas manifold. Note.
Take care to make sure that the hook at the back of the lid hooks onto the control box before fitting the securing screw. CAPILLARY OVER HEAT CUTOFF DEVICE The capillary tube must not touch any part of the back boiler that becomes hot, re-clip the capillary tube and push the phial into the pocket. SPLIT GROMMET 6682 10 Replacement of Parts NOTE: When fitting the phial use heat sink compound. When refitting refer to diagram 5.4. 10.9 Lockout Reset Button Remove the control box lid, see diagram 10.3.
10.13 Interrupter 6227 10 Replacement of Parts THERMOCOUPLE NUT Refer to diagram 10.10. ELECTRICAL CONNECTIONS Carefully disconnect the thermocouple nut. Remove the electrical connections. INTERRUPTER Remove the interrupter. 10.14 Insulation Follow the relevant instructions in Section 8.3 to remove the controls assembly and burner. Remove the three burner securing screws to remove the combustion chamber front cover from the controls assembly and burner, see diagram 8.2. Refer to diagram 10.11.
11 Spare Parts When spare parts are required apply to your local supplier. Please quote the name of the appliance, Glow-worm Inset BBU 50, with a Dovedale or Chatsworth 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. Key No. Part No. Description GC Part No.
