Glow-worm BBU 45/4 Installation & Servicing Instructions Manual Download Page 1

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Hepworth Heating Ltd.,

Nottingham Road, Belper, Derbyshire. DE56 1JT

General/Sales enquiries:

Tel: (01773) 824141 Fax: (01773) 820569

One Contact Local Service

Customer Services:

Tel: (01773) 828100

Fax: (01773) 828070

This is a Cat I

Appliance

9701

BBU 54/4

Installation & Servicing Instructions

2000225024C.07.02

T o b e l e f t w i t h t h e u s e r

G.C. No. 44 - 047 - 05

For Use Only With Specially Designed Firefronts

Summary of Contents for BBU 45/4

Page 1: ...824141 Fax 01773 820569 One Contact Local Service Customer Services Tel 01773 828100 Fax 01773 828070 This is a Cat I2H Appliance 9701 BBU 54 4 Installation Servicing Instructions 2000225024C 07 02 To b e l e f t w i t h t h e u s e r G C No 44 047 05 For Use Only With Specially Designed Firefronts ...

Page 2: ...e 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 The adhesives and sealants used in this appliance are cured and give no known hazard in th...

Page 3: ... TheBuilding Regulations The Building Standards Scotland Regulations applicable in Scotland Local Gas Undertaking Bye laws of the Local Water Company The Health and Safety at Work Act Control of Substances Hazardous to Health The Electricity at Work Regulations and any applicable local regulations 1 General Detailedrecommendationsarecontainedinthecurrentissueof the following British Standard codes...

Page 4: ...LE Minimum Miami 4 Heartbeat 4 Contour 4 Firelite 4 13 19 45 000 10 0 4 02 HEAT kW INPUT NETT Btu h HEAT kW OUTPUT Btu h COLD mbar BURNER PRESSURE in w g 205773 Medium Miami 4 Heartbeat 4 Contour 4 Firelite 4 Maximum Miami 4 Heartbeat 4 Contour 4 Firelite 4 Minimum Dovedale 4 Chatsworth 4 Medium Dovedale 4 Chatsworth 4 Maximum Dovedale 4 Chatsworth 4 16 13 55 050 14 51 49 500 11 8 4 74 17 42 59 45...

Page 5: ... the fire fixing wall face which MUST be true 1 6 Water System Open Vented This 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 3ft 3in minimum and 27m 90ft maximum Diagrammatic layouts of systems are shown in diagram 1 4 and 1 5 1 General 6302 PREPARED BASE B A C Diagram 1 3 C L 5506 Minimum flat area ...

Page 6: ...2879 Boiler A draining point is fitted at the bottom of the side of the heat exchanger where the water connections are located see diagram 1 1 When draining is required cover the controls to avoid water damage 1 10 Safety Valve A safety valve need not be fitted to an open vented system 1 11 Boiler Location This back boiler unit MUST NOT be installed in a private garage or in a room containing a ba...

Page 7: ...mensions will allow the standard frame if fitted to overlap the remaining wall covering by 5mm This area to the depth removed should then be rendered with a sand cement mixture 2 4 Without Surround or Hearth If there is to be any combustible material beneath the fire front for example carpet then the base of the builder s opening must not be less than 75mm above the floor covering as shown in diag...

Page 8: ...equately sealed and clamped using proprietary fittings suitable for the flue liner used see diagram 3 2 The flue should preferably end above ridge height but at the least above the eaves of a pitched roof Use a certificated terminal If the flue is to pass through or near any combustible material it should be installed in accordance with the current issue of BS5440 Part 1 If in doubt seek advice fr...

Page 9: ...he total requirement of the back boiler unit and fire 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 This vent MUST NOT be placed in the builder s opening If the a...

Page 10: ...d return pipes must be 28mm Refer to diagram 1 4 for a diagrammatic layout For systems with gravity domestic hot water and pumped heating circuits pipe crossover maybe required This type of installation maybe simplified by the use of a Street elbow For installation of Street elbow see diagram 4 2 Pipes should then be bent accordingly If it is necessary to route pipework from both sides of the buil...

Page 11: ...ingOperations 1992 Regulations the following lift operation exceeds the recommended weight for a one man lift Carefully lift the back boiler by the heat exchanger casting and place centrally in the builders opening The installation centre line is indicated on the base by a notch on the front of the plate and the fire fixing wall face positioning line by the front corner edges of the base see diagr...

Page 12: ...AFFLES centre in flueway HEAT EXCHANGER Diagram 4 5 9388 DRAUGHT DIVERTER BODY SECURING SCREWS 2 NOTE PLACE BAFFLES IN REAR AND CENTRE FLUE WAYS Firelite 4 Contour 4 Miami 4 Heartbeat 4 and Black Beauty 4 only andtighten makingsurethesensingtubeiscorrectlypositioned see diagram 4 7 Where a flexible flue liner is being used fully fit the No 8x3 8 in self tapping screw provided into the rear of the ...

Page 13: ...ible flue liner using the two No 8 1 2 in screws provided Left hand water connection shown 4 Installation Diagram 4 9 9584 COMBUSTION CHAMBER SCREW 4 GAS MANIFOLD SCREW Diagram 4 6 10260 SILICONE TUBE TUBING NUT SENSING TUBE Diagram 4 10 BLANKING PLATE SECURING SCREW COMBUSTION CHAMBER 10112 LOCATING NIB SENSING TUBE SECURING BRACKET SECURING SCREW SENSING TUBE FLUE BLOCKAGE SAFETY DEVICE ...

Page 14: ...tions for the combustion chamber extension are given in the Use Installation and Servicing instructions of the above fire fronts NOTE The boiler electrical supply cable must not be routed along the back of the appliance The cable must be kept well clear of hot surfaces When fitting the back boiler unit do not trap the cable 5 2 Control Thermistor Phial Route the cable well clear of any part of the...

Page 15: ... to ensure electrical safety must 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 cable 2 Test the earth continuity and short circuit of all cables 3 Test the polarity of the mains 4 With the mains supply off Plug the mains supply plug into the control box socket...

Page 16: ...ER CONTROL THERMISTOR EARTH POST GAS VALVE FLUE BLOCKAGE SAFETY DEVICE AND PILOT b br g y g y g y b br bk r b wh bk y g bk wh bk bk or KEY Black bk Blue b Brown br Green g Yellow y Green Yellow g y White wh Orange or OVERHEAT CUT OFF SAFETY DEVICE SEALED SYSTEM ONLY b br ...

Page 17: ...T be adjusted or disconnected It must be serviced strictly in accordance with the instructions in this book Any unauthorised interference could result in the device failing to operate creating a potentially dangerous situation If replacing use only the correct and approved parts CAUTION The following work should be carried out by a competent person Identify the back boiler controls by reference to...

Page 18: ...m 6 1 Turn the control thermistor knob A fully clockwise to maximum on the back boiler user control After a delay the unit will restart the ignition sequence This is indicated by the green light on the boiler user interface coming on see diagram 6 1 The main burner will light Test for gas soundness using a suitable leak detection fluid The back boiler is supplied preset to a maximum heat output se...

Page 19: ...ry tests to be carried out will be found under TEST FOR CLEARANCE OF PRODUCTS in the Fire Front Installation Instruction Booklet Note This test must only be carried out after the fire front has been fitted to the back boiler unit 6 4 Commissioning the System Setallcontrolstooperatetheheatingsystem Adjustcirculating pump and balance the system to give a temperature drop acrosstheboilerof11o C 20o F...

Page 20: ...eneral once a year should be enough 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 It is the law that any servicing must be carried out by a competent person Set any remote controls for the system to settings requested by the user Advise t...

Page 21: ...ise reassembly of all components is in the reverse order to that for removal 8 1 Isolation of Services With the fire front removed see fire front instructions Refer to diagram 6 1 to identify the controls Turn control thermistor knob A anti clockwise to Reset position Isolate the electrical supply to the back boiler Turn appliance gas service cock C to the OFF position see diagram 6 2 8 2 Sensing ...

Page 22: ...lve see diagram 8 3 Disconnect the ignition lead at the electrode and the sensing lead at the sensor see diagram 8 6 Remove the screws which locate the gas manifold to burner see diagram 8 3 The control box and 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 6 Lint Arrester Remove the four securing screws to disengag...

Page 23: ...t to clean the injector hole Diagram 8 6 Diagram 8 7 9595 FLUE BLOCKAGE SAFETY DEVICE EARTH POST ELECTRODE SPARK GAP 3 1 or 0 5 SECURING SCREW 2 PILOT TUBE NUT SENSOR Diagram 8 5 9607 MAIN BURNER INJECTOR 8 Servicing Diagram 8 4 9593 LINT ARRESTER SECURING SCREW 4 9520 IGNITION LEAD SENSING LEAD Diagram 8 3 9587 GAS CONTROL VALVE PILOT TUBE NUT GAS MANIFOLD SECURING SCREWS 13mm ...

Page 24: ...agram 8 7 To remove the safety device disconnect the pilot tube nut and two securing screws see diagram 8 7 8 11 Sensing Lead Inspect the sensing lead for wear or damage clean or replace as necessary see diagram 8 7 8 12 Back Boiler Flueways Firelite 4 Contour 4 Miami 4 Heartbeat 4 and Black Beauty 4 only Lift out the flue baffles see diagram 8 8 Place a sheet of paper in the base of the combustio...

Page 25: ...park start after 5 seconds Check ignition lead connection Remake connection Check thermistor is not open circuit Check PCB fuse Is O H link circuit open Check that there is 200V dc between Blue Brown Connector X2 Does the pilot light Replace PCB Replace fuse Replace thermistor Replace PCB Replace Gas Valve Does detection occur prior to Lockout Check polarity of supply Are ignition sense correctly ...

Page 26: ...he breaking and remaking of electrical connections the checks for earth continuity short circuit polarity and resistance to earth must be repeated 9 2 Electrical Fault Finding Back Boiler Refer to diagram 9 1 9 3 Flue Blockage Safety Device and Ignition Fault Finding To check the safety device and ignition refer to fault finding chart diagram 9 1 br BROWN b BLUE wh WHITE KEY bk BLACK or ORANGE 3 W...

Page 27: ...k anticlockwise to 0 Off position see diagram 6 2 10 1 Sensing Tube Assembly Refer to Section 8 2 10 2 Flue Blockage Safety Device Follow the instructions in Section 8 2 and 8 4 to remove the sensing tube assembly and controls assembly and burner Refer to diagram 10 1 Remove the ignition lead from the electrode Disconnect the sensing lead Disconnect the pilot pipe nut Remove the safety device secu...

Page 28: ...ectricalconnectionfromtheP C B seediagram 10 4 Note When fitting the new control thermistor make sure that the thermistor lead is placed through the appropriate slot in the right hand side of the control box Refit the electrical connections Refit the control box cover Make sure the cable does not touch any part of the back boiler 10 9 Control Board PCB Remove the control box cover and control box ...

Page 29: ...e plug Secure the new overheat cut off safety device with the retaining clip to the flow pipe in the same position as where the old one was see diagram 10 5 Ensure that it is seated correctly on the flow pipe NOTE Avoid hot areas when routing the overheat cut off safety device lead 10 11 Insulation Follow the relevant instructions in section 8 to remove the controls assembly and burner Combustion ...

Page 30: ...59497 Control thermistor 8 Boiler user control 9 S227038 Overheat Cut off Safety Device 9606 Diagram 11 1 3 7 5 4 8 1 9 6 When spare parts are required apply to your local supplier Please quote the name of the appliance 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 qu...

Page 31: ...31 2000225024C ...

Page 32: ...32 2000225024C Because of our constant endeavour for improvement details may vary slightly from those shown in these instructions ...

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