Glow-worm 40 manual

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 221834B.11.00 All replacement parts All labour charges All call-out charges Thank you for installing a new Glow-worm appliance in y[...]

2 221834B Impor tant Inf ormation 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[...]

3 221834B 0163M m a x m i n 0 t e m p Instructions for Use Introduction Please read these instructions and follow them for the safe and economical use of your boiler. This boiler is designed to provide central heating from a fully pumped open vented or sealed water system with a fully indirect cylinder. The boiler is fully automatic in operation, h[...]

4 221834B Instructions f or Use 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 ventilati[...]

5 221834B Overheat Safety Cutoff If the cutoff operates on any other occasion than an electrical failure, press the reset button as stated in “ Electrical Supply Failure ” . If the boiler fails to relight contact your installation/servicing company. To Turn the Boiler On Sealed Water Systems. CAUTION A sealed water system must be filled and pre[...]

6 221834B 1 General Important Notice 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 Standa[...]

7 221834B 1 General Rc 1 / 2 in. GAS CONNECTION WATER CONTENT WATER CONNECTION 28mm copper flow at right return at left LIFT WEIGHT 240V ~ 50H Z , fused 3A. ELECTRICITY SUPPLY 1.6 Litre (0.35 gal) 31.5 kg (69.5 lb) 48.0 kg (106 lb) TOTAL WEIGHT 40 DATA TABLE 1. MODEL RANGE RATING NOMINAL kW HEAT INPUT (GROSS) Btu/h NOMINAL kW HEAT OUTPUT Btu/h 10.1[...]

8 221834B Diagram 2.1 Diagram 2.2 Design Minimum Flow Rate Flow Rate 1.5 1.0 0.5 0 50 40 30 20 0 0 5 10 15 20 25 30 Flow rate ( litres/minute ) Water pressure loss (metres head of water) Water pressure loss (inches head of water) 10 60 01 2 3 4 56 Flow rate (gallons/minute) 35 40 70 78 2.0 0164M TABLE 3 BOILER DRAIN POINT Energysaver 40 15.5L/min 1[...]

9 221834B Diagram 2.3 Diagram 2.4 FEED AND EXPANSION CISTERN CYLINDER FLOW RET. FLOW 150 mm MAX BOILER RET. PUMP 450mm MIN. HEIGHT 1150mm MIN. 22mm (MIN) VENT 15mm (MINIMUM) COLD FEED Open (vented) system. Recommended relationship between pump, cold feed and vent. 15mm (MINIMUM) BY-PASS WITH LOCKSHIELD VALVE HEATING 4357A 2 W ater System 2.10 Safet[...]

10 221834B Diagram 2.5 METHOD 1 METHOD 2 METHOD 3 SUPPLY STOP VALVE SUPPLY PIPE HOSE UNIONS SERVICING VALVE TEMPORARY HOSE HEATING SYSTEM HEATING SYSTEM TEMPORARY HOSE HOSE UNIONS SERVICING VALVE SUPPLY PIPE SUPPLY STOP VALVE DOUBLE CHECK VALVE ASSEMBLY HEATING SYSTEM SERVICING VALVE SUPPLY STOP VALVE SUPPLY PIPE HOSE UNIONS DOUBLE CHECK VALVE ASSE[...]

11 221834B Diagram 3.1 Ventilation From Outside Ventilation high level low level From Room cms in 2 cms in 2 Energysaver 40 123 19.1 123 19.1 PERMANENT SURFACE * 5 * 5 55 150 100 500 * INCREASE THIS DIMENSION TO 25mm FROM COMBUSTIBLE MATERIAL CLEARANCE OPPOSITE TO FLUE EXIT MUST BE ADEQUATE FOR THE INTERNAL INSTALLATION 0157M 5 * 5 TABLE 4 3 Boiler[...]

12 221834B S = "External wall face" to "boiler casing" Diagram 4.3 REAR FLUE LENGTHS Diagram 4.1 SIDE FLUE LENGTHS Diagram 4.2 0158M 2 ˚ 35mm 1metre SIDE FLUE FRONT VIEW Make sure flue slopes 2 ˚ down towards the boiler that is 35mm fall per metre of flue length (2 ˚ ) Make sure flue slopes 2 ˚ down towards the boiler that i[...]

13 221834B Diagram 4.4 0103M A A F G E A G G G B,C B,C F F K K K C G L L A DIRECTLY BELOW AN OPENABLE WINDOW, AIR VENT, OR ANY OTHER VENTILATION OPENING 300 B BELOW GUTTER, DRAIN/SOIL PIPE 75 C BELOW EAVES 200 E FROM VERTICAL DRAIN PIPES AND SOIL PIPES 75 F FROM INTERNAL OR EXTERNAL CORNERS 300 G ABOVE ADJACENT GROUND OR BALCONY LEVEL 300 H FROM A [...]

14 221834B Diagram 5.1 Diagram 5.2 Diagram 5.3 SECURING SCREW(4) INNER FITTING ➁ M5x10mm ➀ SELF TAPPER Note: Casing securing screws supplied in loose items pack. Fit in order of numerical sequence. No.10 x 3 / 4 INNER CASE 6289 6290 6288 5 Preparation BASE TRAY WALL TEMPLATE TOP CARTON WRAP BOILER MOUNTING BRACKET INSTRUCTIONS TOP FITTING 5.1 U[...]

15 221834B Diagram 5.5 Diagram 5.4 WALL THICKNESS 115 DIAMETER 125 DIAMETER 135 DIAMETER 2 ˚ See template for centre line positions 75 300 680 REAR FLUE 0249M 0248M "x" 2 ˚ SIDE FLUE 'H'= 0.035x 124mm 56.5mm MIN 115 Minimum hole 125 up to 300mm wall 135 up to 680mm wall 5 Preparation 5.3 Flue Hole Cutting Having marked out the[...]

16 221834B OLIVE FLOW RETURN 28mm O.D. COPPER TUBING WATER CONNECTIONS FLUE GAS SAMPLE POINT UNION NUT 4037 6 W ater and Condensate Connections It is, therefore, recommended that any external condensate drain pipe is insulated to prevent it freezing up. Alternatively, a larger diameter pipe can be used and insulated. The condensate drain pipe shoul[...]

17 221834B Diagram 7.1.A FAN BRACKET FAN BRACKET SECURING SCREW (2) FAN SECURING SCREW (3) 4444 7 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 a[...]

18 221834B Diagram 7.3 Diagram 7.4 Diagram 7.5 "N" "N" minus 42mm "N" AIR DUCT/TERMINAL AND FLUE DUCT ASSEMBLY SEAL WITH TAPE SUPPLIED 3mm DRILL SIZE FLUE ELBOW ASSEMBLY SEALANT AIR DUCT/ TERMINAL AND FLUE DUCT ASSEMBLY BOILER CENTRE LINE BOILER CENTRE LINE "N" minus 57mm STANDARD FLUE TERMINAL LONG FLUE TERM[...]

19 221834B Diagram 7.8 Diagram 7.9 ✽ STD FLUE TERMINAL = 63 ✽ LONG FLUE TERMINAL = 61 ✽ FLUE TERMINAL FLUE DUCT "Q" "Q" minus 25mm FOAM SEAL 6867 6868 7 Flue Installation Diagram 7.7 FOAM SEAL 10mm "Q" 6866 Diagram 7.6 FLUE DUCT SEALANT AIR DUCT/ TERMINAL ASSEMBLY FLUE DUCT 4080 7.6 Wall Liner If a wall liner is [...]

20 221834B 9 Electrical Connection Diagram 9.1 PULL SLIGHTLY FORWARD AND UP LOCATING SLOTS SECURING SCREW (2) CONTROL BOX 4051 8 Gas Connection Diagram 8.1 PLUGS BURNER PRESSURE TEST POINT SECURING SCREW GAS SERVICE COCK (SHOWN OFF) SECURING SCREWS (4) SOLENOID SECURING SCREW SUPPORT BRACKET SECURING SCREW 9022 UNION CONNECTOR Make the gas connecti[...]

21 221834B ✽ Diagram 9.2 ✽ RED LINK SL TO 1 REMOTE CONTROLS SL PL PN 1 L N MAINS SUPPLY CABLE PUMP CABLE PUMP AND REMOTE CONTROLS GROMMET MAINS SUPPLY CABLE GROMMET CHASSIS EARTH POST 4052 9 Electrical Connection 9.1 Pump and External Controls Connection The pump must be connected directly to the control box, as shown in diagram 9.2. Any extern[...]

22 221834B Diagram 10.2 HIGH SETTING ADJUSTMENT (BRASS NUT) LOWER SETTING ADJUSTMENT (INNER SCREW) 9023 m a x m i n 0 t e m p Diagram 10.1 GREEN LIGHT FOR HIGH FLAME HIGH/LOW CONTROL KNOB CONTROL THERMOSTAT KNOB GREEN LIGHT FOR LOW FLAME ORANGE DEMAND LIGHT 0163M 10 Commissioning Please ensure the “ Benchmark ” logbook is completed and left wit[...]

23 221834B 10 Commissioning this is quite normal and it will disappear after a short period of time. Refit the electrical controls box. 10.5 Heating System Check that all remote controls are calling for heat. Allow the system to reach maximum temperature and examine for water leaks. The boiler should then be turned off and the system drained off as[...]

24 221834B Diagram 12.3 FLUE HOOD FLUE HOOD SECURING SCREW (2) 4055 S ELECTRICAL CONNECTIONS SECURING SCREWS (3) AIR PRESSURE TUBES RED TUBE CLEAR TUBES 4043 S 12 Servicing Diagram 12.1 SECURING SCREW (2) BYPASS HEAT SHIELD SECURING SCREW(2) 4054 Notes To ensure the continued efficient and safe operation of the boiler it is recommended that it is c[...]

25 221834B Diagram 12.4 Diagram 12.6 Diagram 12.5 CONDENSATE TRAY PRIMARY HEAT EXCHANGER BURNER VIEWING WINDOW SECURING SCREW (2) SECONDARY HEAT EXCHANGER BAFFLE 4056 4057 4058 12 Servicing 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[...]

26 221834B 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. Refer to Fault Finding, Wiring, diagram 13.2 and Functional Flow d[...]

27 221834B PUMP OVERRUN OPERATION 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. FAULT FINDING Turn boiler control therm[...]

28 221834B Diagram 13.1 Before detailed checking of electrical components ensure that remote controls are calling for heat. 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 p[...]

29 221834B Has boiler been operating for 10 seconds yet ? Does gas ignite ? 2 YES NO YES Isolate supply NO Replace PCB Examine electrode and leads. Repair/replace as necessary Reconnect supply Is APS neon lit ? Is fan running ? Replace APS 1 Is there 240V at the fan ? Replace ignition PCB Flue hood overheating- blocked secondary heat exchanger (cle[...]

30 221834B Diagram 13.1 Does the burner remain alight ? Isolate supply Check continuity between 4 and 1 on High/Low switch. Switch ok ? Replace High/Low switch NO YES 2 Replace gas valve YES NO NO YES NO NO Turn High/Low switch to “ High ” . Check and adjust “ High ” gas pressure (see data tables) Is gas pressure OK? Adjust gas pressure Doe[...]

31 221834B 13 Fault Finding Diagram 13.2 b 1 2 3 4 5 6 7 8 9 10 KEY: b - BLUE bk - BLACK br - BROWN g/y - GREEN/ YELLOW g - GREY SL PL PN 1 L N FAN AIR PRESSURE SWITCH EARTH POST MAINS 240VAC 50Hz PUMP SUPPLY EARTH POST CHASSIS EARTH CONDENSE CUT-OFF SPARK ELECTRODE OVERHEAT CUT-OFF BOILER CONTROL THERMOSTAT 2 AMP FUSE CONTROL P.C.B. HIGH/LOW (FLAM[...]

32 221834B Diagram 13.3 13 F ault Finding 554 8 I.C. P.C.B. CONNECTIONS: ie STAT (Pin No. from bottom) PLASTIC OVERHEAT CONTROL THERMOSTAT FAN NO C NC MAIN TERMINAL STRIP CONNECTIONS CONTROL THERMOSTAT CONNECTIONS PRINTED CIRCUIT BOARD CONNECTIONS 9 8 7 PUMP PUMP OVERRUN ✽ RED LINK MAY HAVE BEEN REMOVED TO FIT REMOTE CONTROLS 3 1 4 OVERHEAT THERM[...]

33 221834B Diagram 13.4 Diagram 13.5 4067 S INSTRUCTION LABEL RESET BUTTON 7891 FLUE HOOD OVERHEAT THERMOSTAT RESET BUTTON 13 F ault Finding Notes: Replacement of parts must be carried out by a competent person. Before replacing any parts isolate the boiler from the electrical supply and turn the gas supply off at the gas service cock, see diagram [...]

34 221834B Diagram 14.3 SUPPORT POST (4) IGNITION LEAD ELECTRICAL PLUG (5) I.C.B TERMINAL STRIP CONTROL P.C.B. SUPPORT POST (2) ELECTRICAL PLUG 4065 14 Replacement of P ar ts 14.3 Printed Circuit Boards (PCBs): diagram 14.3 Release the control box as Section 9. Control PCB: diagram 14.3 (top) Disconnect the electrical plug on the board. Release fro[...]

35 221834B Diagram 14.4 CONTROL THERMOSTAT SECURING SCREW (2) OVERHEAT CUT OFF LOCKNUT RETAINING PIN OVERHEAT CUT OFF PHIAL CONTROL THERMOSTAT PHIAL 4078 14 Replacement of P ar ts Diagram 14.4A Diagram 14.5 SECURING SCREW (2) 4067 S CONTROLS FASCIA SECURING SCREW (3) HIGH/LOW CONTROL KNOB CONTROLS FASCIA CONTROL THERMOSTAT KNOB RESET BUTTON FLUE HO[...]

36 221834B Diagram 14.8 CONDENSATE TUBE UNION CONNECTIONS SECURING SCREWS (6) INJECTOR MANIFOLD SPARK ELECTRODE Diagram 14.6 Diagram 14.7 SECURING SCREW (2) SECURING SCREW (4) LIGHTS BRACKET LOCKNUT HIGH/LOW CONTROL AIR PRESSURE SWITCH ELECTRICAL CONNECTIONS (3) GREY BROWN CLEAR RED AIR PRESSURE SWITCH TUBES GREY YELLOW 14 Replacement of P ar ts 14[...]

37 221834B Diagram 14.9 UNION CONNECTION PRIMARY HEAT EXCHANGER UNION CONNECTION BURNER SECONDARY HEAT EXCHANGER UNION CONNECTION 14 Replacement of P ar ts Heat Exchanger - Primary - diagram 14.10 Disconnect the three union connections. 14.11 Burner: diagram 14.9 Note: To carryout the following operations it will be found more convenient if the who[...]

38 221834B Diagram 14.13 Diagram 14.14 VIEWING WINDOW/INNER CASE FRAME VIEWING WINDOW/COMBUSTION CHAMBER FRONT PANEL FRAME GLASS GASKET CONDENSATE SENSOR SCREW SECURING SCREW (2) GLASS GASKET SECURING SCREW (2) 14 Replacement of P ar ts 14.12 Insulation - Rear - diagram 14.10 With the heat exchangers and burner assembly removed, as Sections 14.10 a[...]

39 221834B Part No. Key No. Description GC Part No. 15 Spare P ar ts 1 230530 Multifunctional control 2 800476 Thermostat - control 278 094 3 800477 Thermostat - over heat cutoff 278 095 4 800466 Overheat Thermostat 278 047 5 450260 High/low control 278 276 6 800467 Thermostat control knob 278 049 7 202135 Air pressure switch 313 303 8 203153P Gas [...]

40 221834B Because of our constant endeavour for improvement details may vary slightly from those in the instructions. Diagram 15.1 5 12 8 10 3 14 13 6 9 15 Spare P arts 7 15 6291 4 11 16 1 3 2[...]