221780A.07.00 Installation and Servicing Instructions To be left with the user Glow-worm 45/2 Back Boiler Unit GC No 44 315 39 8010 For use with specially designed Glow-worm fire fronts only References 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.
6070 1 General CL CL FLUE FLUE GAS CONNECTION Rc 1/2 (1/2 in. BSPT) M C WATER CONNECTION Rc1 (1in. BSPT) ON RIGHT-HAND SIDE OR LEFT-HAND SIDE (R.H. SHOWN) L N F Q A INSIDE DIAMETER OF SOCKET FOR 125mm (5in) NOMINAL DIAMETER FLUE H J K B Dimension A B C '45/2' 45/2 BACK BOILER BOILER 547 357 146 BACK GENERAL DIMENSIONS All dimensions are in millemetres G D E P Diagram 1.
1 General 1.2 Data RANGE RATING TABLE 1 1 Gas connection Rc /2 ( /2inBSPT) Water connection Rc1 (1inBSPT) Electrical supply 230V~50Hz fused 3A Weight, about 42.5kg (93.7lb) Water content 5.6Litres (1.23gall) Injector 3.3mm Minimum Medium RANGE RATING NOMINAL kW HEAT INPUT (GROSS) Btu/h NOMINAL kW HEAT Btu/h OUTPUT BURNER mbar SETTING PRESSURE in.w.g INJECTOR MARKING Dimensions are given in millimetres (except as noted). Data Label: Bottom left of control tray. 1.
1 General 1.7 Sealed Water System 1.12 Back Boiler Location A kit and instructions, part number 426520, is available to enable the back boiler to be used on a sealed water system. 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. Please give the serial number of the back boiler when ordering the kit. 1.13 BSI Certification 1.
1 General CE Mark 1.14 Inhibitor The CE mark on this appliance shows compliance with: Attention is drawn to the current issue of BS5499 and BS7593 on the use of inhibitors in central heating systems. 1. Directive 90/396/EEC on the approximation of the Laws of the Member States relating to appliances burning gaseous fuels. If an inhibitor is to be used, contact a manufacturer for their recommendations as to the best product to use. 2.
3 Flue and Ventilation 1592 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. AIR SPACE The flue socket is designed to take flue pipe to BS567.
3 Flue and Ventilation 3.4 Ventilation - Back Boiler and Fire Front 3.5 Extract Fans It is important that the room in which the back boiler unit is installed has adequate air inlets to ensure correct operation as specified in the current issue of BS5440 Part 2. If an extract fan is fitted in the premises, there is a possibility that if adequate air inlet openings are not provided spillage of the products of combustion could occur.
4 Installation Mark through the fixing holes each side of the combustion chamber, see diagram 4.4. Remove the back boiler. Drill two holes to accept the plugs and fixings provided. 4.4 Pumped Heating and Hot Water The pumped flow connection must be diametrically opposite to the pumped return connection. If access to the fixing holes shown in diagram 4.4 is difficult, use the alternative method described in Section 4.8 otherwise proceed as Section 4.9. Refer to diagram 1.4 for a diagrammatic layout.
4.8 Alternative Back Boiler Fixing REAR No.8 X 3/8 SCREWS Position the back boiler as described in Section 4.7 paragraphs 1 to 3. Fully fit No.8 X 3/8 screw into rear of socket. Centralise flexible flue liner using the 2 No. 8 x 1/2 screw provided. Carefully disconnect the electrical plug from the gas valve and undo the four screws securing the combustion chamber extension and remove, see diagram 4.8. Mark position of fixing holes on each side of the floor protection plate, see diagram 4.9.
5.1 General GAS VALVE ELECTRICAL PLUG WARNING. This boiler must be earthed. ISOLATE THE ELECTRICAL SUPPLY BEFORE DOING ANY WIRING. 8012 5 Electrical Wiring CAPILLARY CUT-OUT 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. The mains supply required is 230V~ 50Hz, fused at 3A. A double pole isolating switch, having a minimum contact separation of 3mm in both poles should be used.
8082 5 Electrical Wiring BLACK BLUE N E VIEW OF PLUG WHEN REMOVED GREEN/ YELLOW GREEN/YELLOW L N Ls C L N E NC BLACK BROWN GAS VALVE 230V ~ 50Hz MAINS SUPPLY FUSED AT 3 AMP THERMOSTAT Diagram 5.4 Checks to ensure electrical safety must be carried out by a competent person. 8021 5.4 Testing - Electrical CONTROL BOX After installation of the system, preliminary electrical system checks as below should be carried out, 1. Test insulation resistance to earth of mains cable. 2.
6 Commissioning If flue blockage safety device sensing tube is not fitted, remove the plastic ferrule from the bulkhead connector on the air duct, replace ferrule after testing/commissioning. 6.1 Commissioning the Back Boiler The Back Boiler is fitted with a flue blockage safety device which will shut it down if there is a lack of oxygen. Turn gas service cock “K” to Back Boiler only “On” position, see diagram 6.2.
6 Commissioning 3924 S The rate of the back boiler should be within the range, 1.15 m3/h to 1.75 m3/h 40.5 ft3/h to 61.8 ft3/h Note, if the gas rate is checked, make sure that all other gas appliances and pilot lights are turned off. GAS SERVICE COCK UNION Turn control thermostat knob “B” anti-clockwise to “O” “Off” position. Remove pressure gauge and replace test point screw make sure that a gas tight seal is made. Replace governor cover screw “F”.
6.4 Commissioning the System 5197 6 Commissioning 20mm Set all controls to operate the heating system. Adjust 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. FLAME DIMENSION Pilot Shield omitted for clarity There should be no undue noise in the pipework or heat emitters.
8.1 Servicing Notes. (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. (b) It is the Law that servicing must be carried out by a competent person. (c) Remove the fire front.
8 Servicing 5199 Clean the lint arrester as necessary. EARTH POST Inspect the main burner injector for damage or blockage, clean or replace as necessary using a small amount of approved jointing compound, on the external thread. SPARK GAP +1 3 -0.5 Inspect the ignition lead for wear or damage, clean or replace as necessary, see diagram 8.4. FRONT VIEW Inspect the thermocouple for wear or damage, clean or replace flue blockage safety device as necessary, see diagram 8.4.
GUIDE CHANNELS SECURING SCREW (2) STAINLESS STEEL SECURING SCREWS(2) 1620 5079 8 Servicing DIVERTER PLATE FLUE BAFFLE FIRE FRONT SENSING TUBE Diagram 8.6 FLUE BAFFLE 5201 FLUE COLLECTOR ASSEMBLY 6048 Diagram 8.8 SECURING SCREW FLUEWAY BAFFLES Diagram 8.7 Diagram 8.9 9 Replacement of Parts 8033 9.1 Notes on Replacing Parts. (a) Replacement of parts must be carried out by a competent person.
9.2 Flue blockage Safety Device Assembly 8019 9 Replacement of Parts NOTE: It is important that the thermostat is fitted the same way as shown in diagram Gain access as the relevant part of Section 8.3. Remove lead from electrode. Pull off back boiler lower sensing tube. ELECTRICAL CONNECTIONS Undo the pilot tube securing nuts and the thermocouple nuts at gas valve, see diagram 8.4.
9 Replacement of Parts 9.8 Control Thermostat 9.9 Viewing Window Disconnect the gas valve electrical plug, see diagram 5.2. Gain access as the relevant parts of Section 8.3. Remove the split pin to release the control thermostat phial, see diagram 5.6. If the phial pocket and/or the electrical supply is on the right hand side, release the capillary and/or the main lead from the clips, see diagram 5.1. Remove the old self adhesive aluminium foil gasket and the old mica window.
4484A 10 Fault Finding Isolate Isolate power supply to the control box. Gain access to the control box and physically check all wires and connections. connections. Check Checkfuses. fuses.Check Flue Blockage Safety Device filter is not blocked, clear if necessary. Check Check that that all all remote remote controls, controls, (eg (eg room room and and // or or cylinder cylinder thermostats), thermostats), are are making making contact contact for for duty. duty.
6131 10 Fault Finding Disconnect appliance thermocouple from the gas valve. Check that all connections are clean and in good condition. Fit test meter interrupter into the magnet unit. Fit appliance thermocouple into the test meter interrupter. Check that the flue blockage safety device sensing filter is clean, if not remove / clean and replace. Hold down control knob on gas valve. Ignite pilot burner and allow thermocouple to attain operating temperature. Measure the OPEN CIRCUIT voltage.
5278A 10 Fault Finding PILOT WILL NOT LIGHT START HERE Check gas line-open all cocks, rectify any blockages, purge out any air. Does pilot light? NO Does pilot stay alight when gas valve knob is released? NO YES Apply match to pilot burner instead of pressing piezo unit button. Does pilot light? NO PILOT SATISFACTORY YES Undo tubing nut at pilot burner. Press gas valve knob.
11 Spare Parts When spare parts are required apply to your local supplier. Please quote the name of the appliance, Glow-worm 45/2BBU, also the serial number of the back boiler, to be found on the data label on the combustion chamber extension, see diagram 6.1. 8034 If ordering from British Gas the GC number should also be quoted, together with the GC number of the part. 2 3 8 9 6 1 5 10 4 7 Diagram 11.1 Key No 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. INSULATION PADS/CERAMIC FIBRE, GLASSYARN These can cause irritation to skin, eyes and the respiratory tract.
