Glow-worm 40 Instructions For Use Installation And Servicing
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Glow-worm 40 Instructions For Use Installation And Servicing

High efficiency boiler
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Installation and Servicing
Energysaver
40
G.C. No. 41 319 69
High Efficiency Boiler
This is a Cat II
Reference 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.
The instructions consist of three parts, User, Installation and Servicing Instructions, 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.
Glow-worm appliances' are manufactured to the very highest standard so we are pleased
In the center pages are to be found your Guarantee Registration Card, which we recommend you complete and
If this card is missing you can obtain a copy or record your registration by telephoning the Heatcall Customer
Our Guarantee gives you peace of mind plus valuable protection against breakdown by covering the cost of:
All replacement parts
All labour charges
All call-out charges
One Contact Local Service
Instructions for Use
To b e l e f t w i t h t h e u s e r
PAS010
Appliance
2H3P
Guarantee Registration
Thank you for installing a new Glow-worm appliance in your home.
to offer our customers' a Comprehensive First Year Guarantee.
return as soon as possible.
Service number 01773 828100.
REGISTER YOUR GLOW-WORM APPLIANCE
FOR 1ST YEAR GUARANTEE PROTECTION
CALL 0208 247 9857
Customer Services:
Tel: (01773) 828100
Fax: (01773) 828070
Hepworth Heating Ltd.,
Nottingham Road, Belper, Derbyshire. DE56 1JT
General/Sales enquiries:
Tel: (01773) 824141 Fax: (01773) 820569
221834B.11.00

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  • Page 1 Instructions for Use Installation and Servicing To b e l e f t w i t h t h e u s e r Energysaver G.C. No. 41 319 69 High Efficiency Boiler This is a Cat II Appliance 2H3P Reference in these instructions to British Standards and Statutory Regulations/Requirements apply only to the United Kingdom.
  • Page 2 TESTING AND CERTIFICATION This boiler is tested and certificated for safety and performance. It is therefore important that no alteration is made to the boiler, without permission, in writing, from Hepworth Heating Ltd. Any alteration not approved by Hepworth Heating Ltd., could invalidate the certification, boiler warranty and may also infringe the current issue of the Statutory Requirements, see Section 1.2.
  • Page 3 The boiler is fully automatic in operation, having two user controls, high/low control on the left and the control thermostat on the right, see diagram 1. The “high/low” control can set to “Low” during the summer months.
  • Page 4 Boiler Clearances If fixtures are positioned close to the boiler, space must be left as shown in diagram 3. Enough space must also be left in front of the boiler to allow for servicing. Boilers Installed in a Compartment or Cupboard If the boiler is installed in a cupboard or compartment do not obstruct any ventilation openings.
  • Page 5 The burner will remain alight until switched off by the control thermostat or other remote control. If the control thermostat is turned “Off”, by hand, wait at least 30 seconds before turning on again. When the boiler thermostat is satisfied the burner and green light will go out.
  • Page 6 This boiler is for use only on G20 gas, but may be converted for use on G31 gas (L.P.G.) with an available conversion kit. Energysaver 40, Kit No. 444708 The boiler is delivered in one pack. Wherever possible, all materials and components to be used shall comply with the requirements of applicable British Standards.
  • Page 7 Hepworth Heating Ltd. for further information. 1 General DATA TABLE 1. MODEL TOTAL WEIGHT LIFT WEIGHT WATER CONTENT CONNECTION WATER CONNECTION ELECTRICITY SUPPLY TABLE 2. Energysaver 40 RANGE RATING NOMINAL HEAT INPUT (GROSS) Btu/h NOMINAL HEAT OUTPUT Btu/h NOMINAL HEAT OUTPUT Btu/h CONDENSING...

  • Page 8: Water System

    Note. The boiler has 28mm copper connections, which can be reduced to 22mm for the Energysaver 40, provided the system resistance does not exceed the chosen pump duty. 2.1 Draining Tap The boiler is provided with a draining point at the lower left hand side of the burner manifold, to be used for draining the boiler, see diagram 2.1.
  • Page 9 MAKE-UP BOTTLE (if required) NON-RETURN VALVE (Make-up alternatives) 2 Water System 450mm MIN. HEIGHT 1150mm MIN. AUTO VENT 40/50-15mm (min) 15mm (min) 60-15mm (min) BY-PASS WITH LOCKSHIELD VALVE FLOW RETURN DRAIN COCK BOILER Open (vented) system. Recommended relationship between pump, cold feed and vent.
  • Page 10 2.12 Pressure Gauge A pressure gauge with a set pointer and covering at least 0 to 4bar (0 to 60lb/in ) shall be fitted permanently to the system is a position where it can be seen when filling the system. 2.13 Domestic Hot Water Cylinder SINGLE FEED INDIRECT CYLINDERS ARE NOT SUITABLE.

  • Page 11: Boiler Location

    3 Boiler Location INCREASE THIS DIMENSION TO 25mm FROM COMBUSTIBLE MATERIAL CLEARANCE OPPOSITE TO FLUE EXIT MUST BE ADEQUATE FOR THE INTERNAL INSTALLATION Ventilation From Room Energysaver 40 Ventilation From Outside Energysaver 40 PERMANENT SURFACE Diagram 3.1 TABLE 4 high...
  • Page 12 NOTE: The flue must be installed in accordance with the current issue of BS5440 Part 1. Important. The flue must be installed with a fall of 35mm per metre (2 ) towards the boiler, see diagram 4.1. It is of no advantage to exceed this angle (2 the fan to flue elbow may become more difficult as the angle is increased.
  • Page 13 4.1 Terminal Position The minimum acceptable spacings from the terminal to obstructions and ventilation openings are as shown in diagram 4.4. The boiler must be installed so that the terminal is exposed to the external air. It is important that the position of the terminal allows the free passage of air across it at all times.
  • Page 14 5.1 Unpacking: diagram 5.1 Open top carton, remove top fitting, wall template, loose items fittings pack and boiler mounting bracket. Remove carton wrap and spacing pieces Lift off white outer case front. Remove protective packing piece. Remove the cover of the inner case, see diagram 5.3. 5.2 Rear and Side Flue Application Having selected the location and flue application, with due regard to the terminal position:...
  • Page 15 5.3 Flue Hole Cutting Having marked out the flue centre cut a hole for the flue see diagram 5.5 for minimum core drill size for various wall thicknesses. This will allow for the 35mm per metre (2 Note: If required, an optional Wall Liner Kit, part No.900862, is available, complete with fixing instructions.
  • Page 16 28mm outside diameter copper tubing to BS2871. The 28mm connections can be reduced to 22mm for the Energysaver 40, provided the system resistance does not exceed the chosen pump duty. The right hand connection is the flow from the boiler.

  • Page 17: Flue Installation

    7.1 Rear Flue Mark and cut the air duct terminal assembly, see diagram 7.1 and the flue duct, diagram 7.2 to the lengths required, cutting square and removing any burrs. Refer to diagram 7.3, mark through the holes in the flue elbow assembly and drill the duct as shown, making sure of the correct alignment of the “Top”.
  • Page 18 FLUE DUCT "Q" plus 82mm "Q" DRILL SIZE AIR DUCT/TERMINAL AND FLUE DUCT SEAL WITH ASSEMBLY TAPE SUPPLIED FLUE ELBOW ASSEMBLY SEALANT 221834B 7 Flue Installation FLUE DUCT Diagram 7.2 AIR DUCT/ TERMINAL AND FLUE DUCT ASSEMBLY Diagram 7.3 LONG FLUE TERMINAL STANDARD FLUE TERMINAL...
  • Page 19 FLUE DUCT SEALANT AIR DUCT/ TERMINAL FLUE DUCT ASSEMBLY FOAM SEAL 10mm "Q" 7 Flue Installation Diagram 7.6 STD FLUE TERMINAL = 63 LONG FLUE TERMINAL = 61 FLUE TERMINAL FLUE DUCT 7.6 Wall Liner If a wall liner is used, fit self adhesive seal as follows : For wall thicknesses up to 300mm fit the self adhesive seal to the air duct, see diagram 7.7, make sure the joint is on top.

  • Page 20: Gas Connection

    Make the gas connection to the gas service cock, see diagram 8.1 MULTI-FUNCTIONAL CONTROL SECURING SCREWS BURNER PRESSURE TEST POINT SECURING SCREW WARNING: This boiler must be earthed. Remove the screws as diagram 9.1. Pull the control box forwards to release from the rear slot, allow to pivot and place into position as shown in diagram 9.1.
  • Page 21 9.1 Pump and External Controls Connection The pump must be connected directly to the control box, as shown in diagram 9.2. Any external controls must only be connected to interrupt the Red Link between terminals 1 and SL. Thread the cable(s) through the large cable clamp in the side of the control box.
  • Page 22 MAINS voltage, terminals will become live. Check that the mains electrical supply to the boiler is switched off and that the control thermostat is turned to “O”, see diagram 10.1. For future reference stick the self adhesive arrow indicator, from the loose items pack, to the data label against the rating that the boiler is going to be set to.

  • Page 23: User Information

    Wait for 30 seconds. Turn the gas cock to “ON” and the burner should NOT relight. Turn the control thermostat knob to “OFF” and then “ON” again and the burner WILL now relight. Turn “high/low” switch to “low” and observe low flame, then return switch to “high”.
  • Page 24 Notes To ensure the continued efficient and safe operation of the boiler it is recommended that it is checked and serviced at regular intervals. The frequency of servicing will depend upon the particular installation and usage, but in general once a year should be enough.
  • Page 25 Brush from back to front NOT left to right. Do not use a brush with metallic bristles. Remove the paper and any debris. 12.2 Burner Clean the fins of the burner with a suitable soft brush, any debris can be allowed to fall into the mixing chamber. Do not use a brush with metallic bristles.

  • Page 26: Fault Finding

    INJECTOR MANIFOLD SECURING SCREW (3) CONDENSE DRAIN TRAP 13.1 Electrical Important. On completion of the Service/Fault Finding task which has required the breaking and remaking of the electrical connections the earth continuity, polarity, short circuit and resistance to earth checks must be repeated using a suitable multimeter.
  • Page 27 The control thermostat has a pump overrun facility built into it, when the control thermostat is set at maximum only, the pump overrun will keep the pump running to allow the boiler to cool down after which it will stop, providing the remote controls are NOT calling for heat.
  • Page 28 Check that the gas supply is free of obstructions and purged of air. Check the overheat thermostat and fluehood thermostat have not operated. Isolate the electrical supply and physically check ALL cables, connections and the printed circuit board (PCB) fuse. Check...
  • Page 29 13 Fault Finding Is fan running ? Is there 240V at the fan ? Is there 240V at C ? Will flue hood thermostat reset? - is there 240V at the fan? Replace fan valve? Does discharge tube on ignition PCB flash ?
  • Page 30 Does the burner remain alight ? Is condense drain blocked, repair. Does burner remain alight ? Is the low gas pressure setting correct (see data tables)? Adjust as necessary. Does burner remain alight? Will burner remain alight if gas pressure is temporarily increased? Faulty injector - Replace (Reset pressure)
  • Page 31 FLAME NEON EARTH LAMP POST LINK STAT EARTH POST OVERHEAT CUT-OFF AIR PRESSURE SWITCH HIGH FLAME NEON DEMAND NEON INTER- CONNECTION P.C.B. LAMP CONDENSE CUT-OFF 2 AMP FUSE CONTROL SPARK P.C.B. ELECTRODE BOILER CONTROL THERMOSTAT Diagram 13.2 CHASSIS EARTH 221834B...
  • Page 32 Amp Con HIGH/LOW SWITCH Lamp(1) GV2(1 ) I.C. P.C.B. CONNECTIONS: ie STAT (Pin No. from bottom) MAIN TERMINAL STRIP CONNECTIONS CONTROL THERMOSTAT CONNECTIONS PRINTED CIRCUIT BOARD CONNECTIONS RED LINK MAY HAVE BEEN REMOVED TO FIT REMOTE CONTROLS RED LINK DEMAND NEON...

  • Page 33: Replacement Of Parts

    When replacing the cap make sure that it is firmly in place and that the ring tag is pointing away from the casing side. 13 Fault Finding FLUE HOOD OVERHEAT THERMOSTAT Diagram 13.4 14 Replacement of Parts SECURING SCREW (2)
  • Page 34 Remove the electrical connections from the control thermostat body. Remove the two control thermostat securing screws. Release the gland plate assembly, see diagram 14.2. Release and remove the control thermostat phial from the pocket. Withdraw the capillary through the gland plate and controls box grommet.
  • Page 35 CONTROL THERMOSTAT SECURING SCREW (2) OVERHEAT CUT OFF LOCKNUT HIGH/LOW CONTROLS CONTROL FASCIA KNOB SECURING CONTROLS SCREW (3) FASCIA 14.5 “High/Low” Control: diagram 14.4 and 14.6 Remove the fascia as described in Section 14.4. Remove the four screws securing the lights bracket.
  • Page 36 Follow the relevant parts of Servicing Section and remove the bypass heat shield, fan/flue hood, combustion chamber front panel, heat exchanger baffle, spark electrode, injector and thermostat phials. Release the flexible tube from the condense drain trap, this is a push-fit.
  • Page 37 Follow the relevant parts of Servicing Section and remove the bypass heat shield, fan/flue hood, combustion chamber front panel, heat exchanger baffle, spark electrode, injector and thermostat phials. Release the flexible tube from the condense drain trap, this is a push-fit.
  • Page 38 14.12 Insulation - Rear - diagram 14.10 With the heat exchangers and burner assembly removed, as Sections 14.10 and 14.11, the rear insulation pad can be removed as shown. 14.13 Insulation: Combustion Chamber Front Panel: diagram 14.11 Remove the two screws from the viewing window then slide the insulation pad out.

  • Page 39: Spare Parts

    Thermostat - control Thermostat - over heat cutoff Overheat Thermostat High/low control Thermostat control knob Air pressure switch Gas manifold assembly - 40 - Nat Fuse Sight glass Gasket - sight glass - not shown Ignition lead Control board (PCB)
  • Page 40 15 Spare Parts Diagram 15.1 Because of our constant endeavour for improvement details may vary slightly from those in the instructions. 221834B...

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Energysaver 40

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