Glow-worm Economy Plus 41 319 04 Installation & Servicing Instructions Manual Download Page 1

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Supplied By www.heating spares.co Tel. 0161 620 6677

220459C.03.96

To b e l e f t w i t h t h e u s e r

Installation & Servicing Instructions

This is a Cat I

Appliance

BS6332
BS5258

Balanced Flue Boilers

With Honeywell Control

G.C. No. 41 319 04

G.C. No. 41 319 62

60B

75B

2404

One Contact Total Service

Hepworth Heating Ltd.,

Nottingham Road, Belper, Derbyshire. DE56 1JT

General/Sales enquiries :

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

Customer Services:

Tel: (01773) 828100

Fax: (01773) 828070

Summary of Contents for Economy Plus 41 319 04

Page 1: ...s This is a Cat I2H Appliance BS6332 BS5258 Balanced Flue Boilers With Honeywell Control G C No 41 319 04 G C No 41 319 62 60B 75B 2 2404 One Contact Total Service Hepworth Heating Ltd Nottingham Road...

Page 2: ...stallation and Use Regulations be handed to the user on completeion of the installation 1 General Notes and Information This boiler is suitable for fully pumped systems only Important Notice The boile...

Page 3: ...t inner case Injector 60B Bray 30 1700 75B Bray 30 2200 1 3 Range Rating This boiler is range rated and may be adjusted to suit individual system requirements Table 1 gives the ratings and settings 1...

Page 4: ...and system controls to the mains supply must be through a common isolator and must be fused 3A maximum This method of connection should be preferably by a fused double pole isolating switch provided i...

Page 5: ...t 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 The boiler must be...

Page 6: ...eas required are given in Table 2 2 5 Timber Frame Buildings If the boiler is to be installed in a timber frame building it should be fitted in accordance with the British Gas publication Guide for Ga...

Page 7: ...e installation should comply with the requirements of the current issue of BS4814 BS5449 BS6759 BS6798 and BS7074 Part 1 and 2 See diagram 3 3 for a suggested layout 3 LITRES 0 66 gals MAKE UP BOTTLE...

Page 8: ...S7074 Part 1 Example For an initial system design pressure of 0 7bar the minimum total vessel volume required id 0 063xTotal System volume Note A higher initial design pressure requires a larger volum...

Page 9: ...is flush to the internal wall Fit the second half of the liner B from inside so that it is flush with the outside brickwork Mark the two liner positions and remove from hole Align the marks on the li...

Page 10: ...sive seal D to the terminal wall plate A see diagram 4 2 Attach a length of strong cord or similar to the terminal through the small hole E provided in the top centre baffle see diagram 4 2 Attach a s...

Page 11: ...from the wall face to accept the keyhole slots on the boiler Hook the boiler onto the screws fit the bottom screw and tighten all three 5 5 Standard and Short Flue Only Push the flue duct G into the t...

Page 12: ...the terminal with the unflanged end entering the terminal Make sure that the lower flange of the duct fits behind the combustion chamber rear panel Fit the two screws through the flue duct flange and...

Page 13: ...disengage the hinge at the rear see diagram 7 1 Take care not to damage the thermostat and capillaries Thread the mains lead through the clamp at the rear of the control box cover and connect to the t...

Page 14: ...LY FUSED AT 3A L N L N CIRCULATION PUMP CHASSIS EARTH POST GRN YEL GAS VALVE BROWN BLUE PURPLE RED RED BROWN 7 3 9 8 6 COMBINED THERMOSTAT AND PUMP OVERUN BROWN BLUE GRN YELLOW Remove Red Link between...

Page 15: ...ram 8 1 Turn boiler thermostat to O the Off position Remove the gas pressure test point screws K and fit a suitable pressure gauge Turn the electrical supply on and check that the pump is working OPEN...

Page 16: ...ed adjusting the pump and lockshield valve as necessary Having achieved a satisfactory condition operate the boiler with the bypass valve fully closed on minimum load normally this will be central hea...

Page 17: ...on 10 1 With the main burner removed brush or vacuum any deposits away ensure that the flame ports are clean Do not use a brush with metallic bristles 10 3 Main Injector Follow the instructions genera...

Page 18: ...tructions given in Section 10 1 Unscrew the electrode from the pilot shield When refitting check that the spark gap is as in diagram 10 3 10 7 Over Heat Cutoff Generally follow the instructions in Sec...

Page 19: ...ains L N and E b pump at terminal 8 7 and earth stud c cables at gas valve d disconnect any remote controls at terminal 9 and SL When replacing refer to diagram 7 2 for electrical connections Smear th...

Page 20: ...if necessary Overheat cutoff operates Change faulty overheat cutoff before boiler cycles on maximum boiler thermostat setting The correctly set overheat Change faulty heating body cutoff operates prem...

Page 21: ...cut off connectors at points A and B at the gas valve see diagram 3 4 Test continuity of the overheat cut off Is there continuity YES NO NO 11 7 Thermocouple and Over Heat Cutoff To test the thermoco...

Page 22: ...etween 6 and N Isolate the supply Remove gas valve cover Restoresupply Is there 240V between L and N on gas valve Faulty gas valve renew Faulty gas valve harness renew Turn ON thermostat Does main bur...

Page 23: ...agram 11 5 FUNCTIONAL FLOW Diagram 11 4 Does pump run Turn ON thermostat Is there 240V between 7 and N YES NO With thermostat set to MAX allow appliance temperature to reach max When appliance cuts ou...

Page 24: ...n gas valve knob is released PILOT SATISFACTORY Does pilot flame envelop thermocouple Check aeration If necessary Clean pilot rectify blockage in pilot injector or replace Check thermocouple circuit u...

Page 25: ...6189 Boiler thermostat assembly 355 501 4 800014 Over heat cutoff assembly 313 064 5 800015 Gas valve assembly incs 14 313 067 6 900000 Thermocouple 394 162 6 381 651 7 203415 Pilot burner 394 161 8 2...

Page 26: ...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 handlin...

Page 27: ...Supplied By www heating spares co Tel 0161 620 6677 27 220459C...

Page 28: ...Supplied By www heating spares co Tel 0161 620 6677 28 220459C Because of our constant endeavour for improvement details may vary slightly from those given in these instructions...

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Glow-worm Economy Plus 41 319 04, Installation & Servicing Instructions Manual

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