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

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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

221834B.11.00

All replacement parts All labour charges All call-out charges

Thank you for installing a new Glow-worm appliance in your home.

Glow-worm appliances' are manufactured to the very highest standard so we are pleased

to offer our customers' a Comprehensive First Year Guarantee.

In the center pages are to be found your Guarantee Registration Card, which we recommend you complete and

return as soon as possible.

If this card is missing you can obtain a copy or record your registration by telephoning the Heatcall Customer

Service number 01773 828100.

Our Guarantee gives you peace of mind plus valuable protection against breakdown by covering the cost of:

Guarantee Registration

This is a Cat II

2H3P

Appliance

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.

T o be left with the user

4040/S

❏

✔

❏

✔

❏

✔

Instructions for Use

Installation and Servicing

FOR 1ST YEAR GUARANTEE PROTECTION

CALL 0208 247 9857

Energysaver

High Efficiency Boiler

G.C. No. 41 319 69

PAS010

221834B

Important Information

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.

CE MARK

This boiler meets the requirements of Statutory Instrument No. 3083 The boiler (Efficiency) Regulations, and therefore is deemed to meet the requirements of Directive 92/42/EEC on the efficiency requirements for new hot water boilers fired with liquid or gaseous fuels.

Type test for purposes of Regulation 5 certified by: Notified body

0086. Product/productioncertifiedby: Notified body 0086. The CE mark on this appliance shows compliance with:

1. Directive 90/396/EEC on the approximation of the laws of the Member States relating to appliances burning gaseous fuels.

2. Directive 73/23/EEC on the harmonization of the Laws of the Member States relating to the electrical equipment designed for use within certain voltage 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.

CERAMIC FIBRE/INSULATION PADS, GLASSYARN.

These can cause 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 handling should not cause discomfort, but follow normal good hygiene and wash your hands before eating, drinking or going to the lavatory. If you do suffer irritation of the eyes or severe irritation to the skin seek medical attention.

THERMOSTATS

These contain very small amounts of xylene in the sealed phial and capillary. If broken, under normal circumstances the fluid does not cause a problem, but in case of skin contact, wash with cold water. If swallowed drink plenty of water and seek medical attention.

CUT OFF DEVICES

Cut off devices with copper phial/bulb only. Bulb contains activated charcoal and very small amounts of

chloroddifludromethane in the sealed phial and capillary. If broken under normal circumstances the fluid does not cause a problem. If there is irritation to the eyes or skin then seek medical attention.

FLUE SEALANT

This contains cyclohexylaminosilane. It may cause irritation of skin of sensitive persons. Wash contact

area with soap and water, if irritation occurs, seek medical advice.

It will cause irritation on contact with eyes. If so, wash eye with large amounts of fresh water for at least 15 minutes. If irritation occurs, seek medical advice.

If swallowed drink plenty of milk and seek medical advice.

Introduction 3 Lighting the Boiler 5

General Data 1 6 Water System 2 8 Boiler Location 3 11 Flue 4 12 Preparation 5 14 Water and Condensate Connections 6 16 Flue Installation 7 17 Gas Connection 8 20 Electrical Connection 9 20 Commissioning 10 22 User Information 11 23

Servicing 12 24 Fault Finding 13 26 Replacement Parts 14 33 Spare Parts 15 39

CONTENTS DESCRIPTION SECTION PAGE No.

INSTRUCTIONS

FOR USE

INSTALLATION

INSTRUCTIONS

SERVICING

INSTRUCTIONS

221834B

0163M

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, 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.

Important Notice

This boiler is for use on natural gas (G20) as distributed in the United Kingdom and Ireland, but may be converted for use on L.P.G. Propane (G31) with the use of a conversion kit, i.e.

Energysaver 40, Kit No.444708. If your boiler has been converted to use L.P.G. Propane the

following note applys: Propane cylinders are under pressure and should never be

stored or used indoors residentially. They should only be kept outside. Under no circumstances should LPG Propane cylinders be

fitted or stored in basement areas or boiler house.

Gas Safety (Installation and Use) Regulations

In your interest and that of gas safety it is the Law that ALL gas appliances are installed by a competent person in accordance with the current issue of the above regulations.

Gas Leak or Fault

If a gas leak or fault exists or is suspected, the BOILER MUST BE TURNED OFF, including the electrical supply and MUST NOT BE USED UNTIL THE FAULT HAS BEEN PUT RIGHT. Advice/help should be obtained from your installation/servicing company or the local gas undertaking.

Maintenance/Servicing

To ensure the continued efficient and safe operation of the boiler it is recommended that it is checked and serviced as necessary at regular intervals. The frequency of servicing will depend upon the particular installation conditions and usage, but in general once a year should be enough.

It is the Law that any servicing must be carried out by a competent person.

To obtain service, please call your installer or Heatcall (Glowworm’s own service organisation) using the telephone number given on the information plate, see diagram 2.

Please be advised that the ‘Benchmark’ logbook should be completed by the installation engineer on completion of commissioning and servicing.

All CORGI Registered Installers carry a CORGI ID card, and have a registration number. Both should be recorded in your boiler Logbook. You can check your installer is CORGI registered by calling CORGI direct on :- 01256 372300.

GREEN LIGHT FOR HIGH FLAME

GREEN LIGHT FOR LOW FLAME

CONTROL THERMOSTAT KNOB

HIGH/LOW CONTROL KNOB

ORANGE DEMAND LIGHT

Diagram 1

Diagram 2

RESET BUTTON

INSTRUCTION LABEL

7891

221834B

Instructions for 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 ventilation openings.

Do not use the cupboard or compartment for storage. Regularly make sure that the air vent openings are clear of

obstructions.

Cleaning

WARNING. This appliance contains metal parts (components) and care should be taken when handling and cleaning, with particular regard to edges.

Clean the casing occasionally by wiping it over with a damp soapy cloth or dry polishing duster.

Do not use an abrasive cleaner.

Protection Against Freezing

If the boiler is to be out of use for any long period of time during severe weather conditions we recommend that the whole of the system, including the boiler, be drained off to avoid the risk of freezing up. Make sure that, if fitted, the immersion heater in the cylinder is switched off.

If you have a sealed water system contact your installation/ servicing company as draining, refilling and pressurising must be carried out by a competent person.

Boiler Electrical Supply

WARNING. The boiler must be earthed. The boiler must only be connected to a 240V~50Hz supply,

protected by a 3A fuse. All wiring must be in accordance with the current issue of

BS7671. The colours of three core flexible cable are: Brown - live, Blue - neutral, green and yellow - earth. As the markings on your plug may not correspond with these

colours, continue as follows: The wire coloured blue must be connected to the terminal

marked “N” or “Black”. The wire coloured brown must be connected to the terminal

marked “R” or “Red”. The wire coloured green and yellow must be connected to the

terminal marked “E”, “Green” or the earth symbol

Electrical Supply Failure

Failure of the electrical supply will cause the burner to go out. Should this happen, operation of the boiler will normally resume

after the electrical supply is restored. If the burner does not relight after an electrical supply failure the

overheat device may need resetting, press the reset button on the underside of the boiler, see diagram 2.

PERMANENT SURFACE

150

100

500

INCREASE THIS DIMENSION TO

25mm FROM COMBUSTIBLE MATERIAL

CLEARANCE OPPOSITE TO FLUE EXIT MUST BE ADEQUATE FOR THE INTERNAL INSTALLATION

Diagram 3

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 pressurised by a competent person.

Only light the boiler when you are sure that the system and boiler have been filled and pressurised.

The pressure gauge should show at least 0.7bar, anything less than this figure could indicate a leak and you MUST contact your installation/servicing company.

If there is any doubt about the boiler and system being full of water consult your installation/servicing company.

All Systems

Turn the electrical supply on to the boiler and check that any remote controls are set to your requirements (refer to manufacturer’s instructions for these items).

On demand, the orange light will come on. Turn the left hand switch to “high” flame. Turn the control thermostat knob, at the right, clockwise to any

position between “MIN” and “MAX., see diagram 1. The maximum setting is about 82

C (180oF). The boiler will not light between “O” and “MIN”. The boiler lighting operation is now automatic as follows: The fan operates, followed by an ignition spark until the burner

lights on low flame after a short period it will go to high flame and the green light will come on.

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.

When the system controls are satisfied the burner, orange and green lights will go out.

The automatic lighting sequence will operate again when heat is required.

The “high/low” switch should be set to “high” for winter use, but when domestic hot water only is required in the summer it can be turned to “low”.

If no light comes on you should contact your installation/ servicing company, to check the controls, although the system may be working.

To Turn the Boiler Off

For short periods, turn thermostat control knob anti-clockwise until “O” is against the setting point. To relight the main burner, turn the thermostat knob clockwise to any setting between ”MIN” and “MAX”.

For longer periods, turn the thermostat control knob anticlockwise until “O” is against the setting point and switch off the electrical supply to the boiler.

To relight follow the sequence given above. Note: If the burner goes out for any reason, wait 30 seconds

before relighting.

Condensation Pluming

Like all condensing boilers this appliance will produce a plume of condensation from the flue terminal in cool weather. This is due to the high efficiency and hence low flue gas temperature of the boiler.

Instructions for Use

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 Standards.

Where no British Standard exists, materials and equipment should be fit for their purpose and of suitable quality and workmanship.

This boiler must have fully pumped circuits, but is suitable for use with open vented or sealed water systems.

This boiler is not suitable for outdoor locations.

1.1 Sheet Metal Parts

WARNING. When installing or servicing the boiler care should be taken when handling sheet metal parts to avoid any possibility of personal injury.

1.2 Statutory Requirements

The installation of the boiler MUST be carried out by a competent person in accordance with the relevant requirements of the current issue of:

Manufacturer’s instructions, supplied. The Gas Safety (Installation and Use) Regulations, The Building

Regulations, The Building Standards (Scotland) Regulations (applicable in Scotland), local Water Company Bylaws, The Health and Safety at Work Act, Control of Substances Hazardous to Health, The Electricity at Work Regulations and any applicable local regulations.

Detailed recommendations are contained in the current issue of the following British Standards and Codes of Practice, BS4814,

0156M

WATER CONNECTIONS

CONDENSATE DRAIN

GAS CONNECTION

460

360

Ensure flue slopes 2˚ down towards the boiler i.e. 35mm fall per metre of flue length (2

)

124

300

FLUE TERMINAL DETAIL

102

119

640

710

DRAIN CONNECTION

CAPPED OFF

Diagram 1.1

BS5440 Part 1 and 2, BS5449, BS5546, BS6700, BS6798, BS6891 and BS7074 Part 1 and 2, BS7478, BS7593, BS7671.

We also suggest that you have to hand a copy of the British Gas publication, “Guidance Notes for the Installation of Domestic Condensing Boilers”.

Manufacturer’s notes must not be taken as overriding statutory obligations.

BSI Certification

This boiler certificated to the current issue of P.A.S. 010 for performance and safety.

It is important that no alteration is made to the boiler, without permission, in writing, from Hepworth Heating Ltd.

Any alteration that is not approved by Hepworth Heating Ltd., could invalidate the warranty and could also infringe the current issue of the Statutory Requirements.

1.3 Range Rating

The boiler is range rated and is factory preset to maximum, but may be adjusted to suit individual system requirements, refer to Table 2.

1.4 General Data

The data label is positioned on the inner case, visible when the outer case is removed.

All dimensions on diagrams are given in millimetres (except as noted).

The Seasonal Efficiency Domestic Boilers UK (SEDBUK) is

86.7%. The value is used in the UK Government’s Standard Assessment

Procedure (SAP) for energy rating of dwellings. The test data from which it has been calculated have been certified by B.S.I.

221834B

1 General

Rc 1/2 in.

GAS CONNECTION

WATER CONTENT

WATER CONNECTION

28mm copper flow

at right return at left

LIFT WEIGHT

240V ~ 50HZ, fused 3A.

ELECTRICITY SUPPLY

1.6 Litre

(0.35 gal)

31.5 kg

(69.5 lb)

48.0 kg (106 lb)

TOTAL WEIGHT

DATA TABLE 1.

MODEL

RANGE RATING

NOMINAL kW

HEAT INPUT (GROSS) Btu/h

NOMINAL kW HEAT

OUTPUT Btu/h

10.16 10.16 11.86 13.55

34,680 34,680 40,462 46,240

8.79 8.79 10.26 11.72

30,000 30,000 35,000 40,000

9.40 9.40 10.97 12.53

32,100 32,100 37,400 42,800

NOMINAL kW HEAT OUTPUT Btu/h CONDENSING

BURNER m bar SETTING (HOT) PRESSURE in.w.g

9.7 9.7 12.7 16.6

3.88 3.88 5.1 6.64

0.96 0.96 1.1 1.3 34 34 39.9 45.5

APPROX m3h GAS RATE ft3h

LOW MIN MID MAX

TABLE 2.

Energysaver 40

BURNER INJECTOR MARKING: 40N

1.5 Gas Supply

The gas installation must be in accordance with the current issue of BS6891.

The supply from the governed meter must be of adequate size to provide a steady inlet working pressure of 20mbar (8in wg) at the boiler.

On completion, test the gas installation for soundness using the pressure drop method and a suitable leak detection fluid, purge in accordance with the above standard.

1.6 Electrical Supply

WARNING. This boiler must be earthed. All system components shall be of the approved type and be

wired and connected in accordance with the requirements of the current issue of BS7671 and any applicable local regulations.

Connection of the boiler 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 double pole isolating switch, provided it has a minimum contact separation of 3mm on both poles. This should be readily accessible and preferably adjacent to the appliance. It should supply the appliance only and be easily identifiable as so doing.

Alternatively, an unswitched shuttered socket outlet and 3A fused 3 pin plug both to the current issue of BS1363 may be used, provided that they are not used in a room containing a bath or shower.

Wiring to the boiler must be PVC insulated type to the current issue of BS6500 Table 16.

1.7 Condensate

The boiler condensate should, if possible, be discharged into the household internal draining system, that is, sink or washing machine drain. If this is not practicable, discharge can be external, into the household drainage system or a purpose designed soakaway

The boiler is fitted with a safety device to prevent the boiler from working if the condensate pipe gets blocked by either ice or debris.

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 should be checked during any

servicing and any debris found removed. Refer to the British Gas publication “Guidance Note for the

Installation of Domestic Condensing Boilers” for further information.

1.8 Heating System Controls

The heating system should have installed: a programmer and room thermostat controlling the boiler.

Thermostatic radiator valves may be installed in addition to the room thermostat.

Note: For further information, see The Building Regulations 1991 - Conservation of fuel and power, 1995 edition - Appendix G, table 4b.

1.9 Anti-theft Kits

Anti-theft kits are available for these appliances, contact Hepworth Heating Ltd. for further information.

221834B

Diagram 2.1

Diagram 2.2

Design Minimum

Flow Rate Flow Rate

1.5

1.0

0.5

50 40 30 20

10 15

20 25 30

Flow rate

(

litres/minute

)

Water pressure loss

(metres head of water)

Water pressure loss

(inches head of water)

0123

Flow rate (gallons/minute)

35 40

2.0

0164M

TABLE 3

BOILER DRAIN POINT

Energysaver 40

15.5L/min 11L/m

4042

2 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.

A draining tap must be provided at the lowest points of the system which will allow the entire system and hot water cylinder to be drained.

Draining taps shall be to the current issue of BS2879.

2.2 Safety Valve

A safety valve need not be fitted to an open vented system.

2.3 Pump

The pump should be fitted in the flow pipe from the boiler and have isolating valves each side, integral if possible.

A variable duty pump should be set to give a temperature difference of 11

C (20oF) between the flow and return, with the

thermostat set at “MAX”, which is about 82

C (180oF), to give

a design flow rate as shown in Table 3. See chart for pressure drop of the boiler, diagram 2.2. High resistance microbore systems may require a higher duty

pump.

2.4 Bypass

A BYPASS MUST BE FITTED, see diagram 2.3 for a suitable position.

The flow rate through the boiler must not be allowed to fall below that given in Table 3.

Where the water system can allow the boiler and pump to operate on bypass only, the bypass

must be placed at least

1.5m away from the boiler.

2.5 Inhibitor

Attention is drawn to the current issue of BS5449 and BS7593 on the use of inhibitors in central heating systems.

If an inhibitor is to be used, contact an inhibitor manufacturer for their recommendations as to the best product to use.

Note: This boiler has a totally copper water system and does not require a special inhibitor normally associated with other types of high efficiency (“condensing”) boilers.

If an existing system is to be reused take special care to drain the entire system, including the radiators, then thoroughly cleaning out before fitting the boiler whether or not adding an inhibitor.

2.6 Open (Vented) Water System

The boiler must be supplied from an unrestricted water supply taken from a feed and expansion cistern situated at a maximum height of 27metres (90ft) above the boiler.

The cold feed must be 15mm minimum size. The vent must rise continuously and be unrestricted. It is important that the relative positions of the pump, cold feed

and open vent are as shown in diagram 2.3.

2.7 Domestic Hot Water Cylinder

The domestic hot water cylinder must be of the double feed fully indirect type. Not the single feed self priming type.

2.8 Domestic Hot Water System - Unvented

Where a storage system will not have a vent to atmosphere the installation must comply with the Building Regulations and local Water Company bylaws, see also the current issue of BS5546 and BS6700.

If fitting to an existing system the local authority should be informed.

2.9 Sealed Water Systems

The installation must comply with the appropriate requirements of the current issue of BS4814, BS5449, BS6759, BS6798 and BS7074 Part 1 and 2.

See diagram 2.4 for a suggested layout.

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 Water System

2.10 Safety Valve

A safety valve must be fitted to a sealed system. It shall be preset, nonadjustable with a lift pressure of 3bar,

incorporating seating of a resilient material, a test device and a connection for drain.

The drain from the safety valve must be routed clear of any electrical fittings and positioned so that any discharge can be seen.

2.11 Expansion Vessel

A diaphragm type expansion vessel, conforming to the current issue of BS4814 (see also BS7074 Part 1 and 2) must be connected at a point close to the inlet side of the circulating pump, see the diagrammatic layout, diagram 2.4 unless laid down differently by the manufacturer.

The expansion vessel volume depends on the total water system volume and the initial system design pressure. For any system an accurate calculation of vessel size is given in the current issue of BS7074 Part 1.

Example: For an initial system design pressure of 0.7bar, the minimum total vessel volume required is 0.063xTotal System volume.

Note: A higher initial design pressure requires a larger volume expansion vessel.

Guidance on vessel sizing is also given in the current issue of BS5449 and BS7074 Part 1.

The charge pressure must not be less than the static head of the system, that is, the height of the highest point of the system above the expansion vessel.

The water content of the boiler is given in the Data Table 1.

5609

3 LITRES (0.66 gals) MAKE-UP BOTTLE (if required)

NON-RETURN VALVE

AUTO AIR VENT

FLOW

DRAIN COCK

BOILER

SAFETY VALVE

(Make-up alternatives)

EXPANSION VESSEL

PRESSURE GAUGE

CIRCULATING PUMP

FILLING POINT

AIR RELEASE POINT

HEATING

CIRCUIT

40/50-15mm (min) 60-15mm (min)

BY-PASS WITH LOCKSHIELD VALVE

RETURN

15mm (min)

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 ASSEMBLY

OVERFLOW

CISTERN

COMBINED CHECK VALVE AND VACUUM BREAKER

PRESSURE REDUCING VALVE

0051

2 Water Sytem

2.12 Pressure Gauge

A pressure gauge with a set pointer and covering at least 0 to 4bar (0 to 60lb/in2) 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. The hot water cylinder must be of the indirect coil type. It must

be suitable for working at a gauge pressure of 0.35bar above the safety valve setting.

2.14 Water Makeup

Provision should be made for replacing water loss from the system using a make up bottle or filling loop mounted in a position higher than the top point of the system, connected through a non-return valve to the return side of either the heating circuit or the hot water cylinder.

Alternatively, provision for make up can be made using a filling loop.

2.15 Filling a Sealed Water System

Provision for filling the system at low level must be made. Three methods are shown in diagram 2.5. There must be no permanent connection to the mains water supply, even through a nonreturn valve.

221834B

Diagram 3.1

Ventilation From Outside

Ventilation high level low level From Room cms in

cms in

Energysaver 40

123 19.1 123 19.1

PERMANENT SURFACE

150

100

500

INCREASE THIS DIMENSION TO

25mm FROM COMBUSTIBLE MATERIAL

CLEARANCE OPPOSITE TO FLUE EXIT MUST BE ADEQUATE FOR THE INTERNAL INSTALLATION

0157M

TABLE 4

3 Boiler Location

NOTE:

The boiler may be installed in any room although particular attention is drawn to the requirements of the current issue of BS7671 with respect to the installation of a boiler in a room containing a bath or shower. Any electrical switch or boiler control using mains electricity should be so situated that 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 mounted on a flat wall which is sufficiently robust to take its total weight, see Data Table 1.

3.1 Boiler Clearances

The boiler must be positioned so that at least the minimum operational and servicing clearances are as shown in diagram

3.1. Additional clearances may be required around the boiler for

installation purposes, dependent upon site conditions.

3.2 Timber Frame Buildings

If the boiler is to be installed in a timber frame building it should be fitted in accordance with the Institute of Gas Engineers document IGE/UP/7/1998. If in doubt seek advice from the local gas undertaking or Hepworth Heating Ltd.

3.3 Room Ventilation

The boiler is room sealed, so when installed in a room or space a permanent air vent is not required.

3.4 Cupboard or Compartment Ventilation

Where the boiler is fitted in a cupboard or compartment, permanent high and low level ventilation must be provided. The ventilation areas required are given in Table 4.

Where the installation of the boiler will be in an unusual location, special procedures are necessary, refer to the current issue of BS6798 for guidance.

Make sure that the cupboard or compartment air vents are positioned to be clear of obstructions at all times.

A compartment used to enclose the boiler must be designed and constructed specifically for this purpose.

The doorway opening should be of sufficient size to allow for easy removal of the boiler.

Energysaver 40

62 9.6 62 9.6

221834B

S = "External wall face" to "boiler casing"

Diagram 4.3

REAR FLUE LENGTHS

Diagram 4.1

SIDE FLUE LENGTHS

Diagram 4.2

0158M

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 is 35mm fall per metre of flue length (2

)

300mm

10.5mm

REAR FLUE

SIDE VIEW

R = Wall Thickness

STD Flue pack 80mm to 331mm

4 Flue

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

) indeed sealing of the fan to flue elbow may become more difficult as the angle is increased.

The air and flue duct connect to the top of the boiler using an elbow which can be positioned to the side or rear.

The rear and side flue assemblies are designed for internal installation, but if necessary, due to insufficient clearances (boiler/flue terminal location) they can be installed from the outside.

For a wall thickness up to 300mm the flue can be fully installed from the inside.

For a wall thickness over 300mm the external cut hole will need to be made good from the outside.

The standard flue is able to provide the duct lengths as shown in diagram 4.2 for a rear flue and diagram 4.3 for a side flue.

If a longer flue duct is required, do not extend the ductings. A 1, 2 or 3metre long flue system and terminal can be supplied.

STD Flue pack

75mm to 442mm

3m Flue pack 75mm to 2933mm

2m Flue pack 75mm to 1953mm

3m Flue pack 80mm to 2821mm

2m Flue pack 80mm to 1841mm

1m Flue pack 75mm to 953mm

1m Flue pack 80mm to 841mm

'R'

'S'

6861

6860

221834B

Diagram 4.4

0103M

B,C

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 SURFACE FACING THE

TERMINAL 600

I FACING TERMINALS 1200

K VERTICAL FROM A TERMINAL 1500

L HORIZONTALLY FROM A TERMINAL 300

MINIMUM SITING DIMENSIONS FOR FANNED FLUE TERMINALS POSITION

MINIMUM SPACING

in mm

H,I

4 Flue

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. Note. The flue will produce a plume of condensation in cold

weather, so special care must be taken in siting the flue terminal so as not to cause a nuisance to adjacent property.

Where the terminal is fitted within 600mm (24in) below plastic guttering an aluminium shield 1500mm (5ft) long should be fitted to the underside and immediately beneath the guttering or eaves.

Where the terminal is fitted within 450mm (18in) below eaves or painted guttering an aluminium shield 750mm (2ft6in) long should be fitted to the underside and immediately beneath the guttering or eaves.

4.2 Terminal Guard

A terminal guard is required if persons could come into contact with the terminal or the terminal could be subject to damage.

If a terminal guard is required, it must be positioned to provide a minimum of 50mm clearance from any part of the terminal and be central over the terminal, see diagram 4.4.

A suitable terminal guard can be obtained from: Tower Flue Components Ltd.,

Morley Road, Tonbridge, Kent. TN9 1RA

their reference, CGD K3 BL

0161M

* It may be necessary to increase this dimension to prevent staining of adjacent walls depending on weather conditions.

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/

INNER CASE

6289

6290

6288

5 Preparation

BASE TRAY

WALL TEMPLATE

TOP CARTON WRAP

BOILER MOUNTING

BRACKET

INSTRUCTIONS

TOP FITTING

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:

Take the template and temporarily position it on the wall see diagram 5.4, making sure that the minimum clearances are maintained.

For a rear flue, mark the position of the flue as diagram 5.4.

LOOSE ITEMS PACK

CONTROLS FITTING

For a side flue, extend the centre line horizontally (taking into account the required fall towards the boiler) left or right to the corner of the adjacent surface where the flue is required to exit to the outside. Alternatively, the increase in the centre height over a distance “X” is given by H = 0.35X. Mark the position of the centre of the flue as in diagram 5.4.

221834B

Diagram 5.5

Diagram 5.4

WALL THICKNESS

115 DIAMETER

125 DIAMETER

135 DIAMETER

2˚

See template for centre line positions

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 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

) fall towards the boiler.

Note: If required, an optional Wall Liner Kit, part No.900862, is available, complete with fixing instructions.

5.4 Wall Mounting Bracket

Reposition the template, making sure of dimensional alignment with the flue centre lines

Mark the boiler securing screws and mounting plate position, see diagram 5.6.

Drill holes and plug, fit the securing screws allowing sufficient clearance to accept the keyhole fixing brackets and secure the boiler mounting bracket to the wall.

221834B

OLIVE

FLOW

RETURN

28mm O.D. COPPER TUBING

WATER CONNECTIONS

FLUE GAS SAMPLE POINT

UNION NUT

4037

6 Water 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 should be checked during any

servicing and any debris found removed. Refer to the British Gas publication “Guidance Notes for the

Installation of Domestic Condensing Boiler” for advice on the disposal of boiler condensate.

Diagram 6.1

0170

Diagram 5.7

4043 S

CLEAR TUBES

ELECTRICAL CONNECTIONS

SECURING SCREWS (3)

RED TUBE

Diagram 5.6

TEMPLATE

BOILER TOP FIXING POINTS

7dia.

3/16dia. PLUG

NO. 12x2in.

BOILER MOUNTING BRACKET

5mm

MOUNTING BRACKET FIXING POINT(S)

3/16dia. PLUG

5 Preparation

6 Water Connections

Make the water connection to the heating system, see diagram

6.1. The boiler has compression connections with nuts and olives

supplied loose in the fittings pack, to accept 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.

6.1 Condensate Connection

The condensate drain connection is at the bottom right of the boiler.

The drain ends in a spigot which is suitable for push fit 22mm (

/4in) plastic overflow pipe, for example, Hepworth Polypipe, Uponor, Osma, Orcaster. If using Marley, Terain or Hunter tubing, which is slightly larger, use the silicone sealant provided in the fittings pack to make a leak proof joint to the drain connection on the boiler.

The condensate discharge pipe should have a fall of 2

It is not necessary to provide air breaks, or traps in the discharge pipe since the boiler has an integral 50mm trap and siphon.

The boiler is fitted with a safety device to prevent the boiler from working if the condensate pipe gets blocked by either ice or debris.

AIR PRESSURE TUBES

5.5 Boiler Preparation

Lift the boiler into position above the boiler mounting bracket, lowering the boiler into position at the same time locating the key hole slots of the boiler on to the securing screws, when located secure the screws, see diagram 5.6.

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 assembly and drill the duct as shown, making sure of the correct alignment of the “Top”.

7.2 Side Flue

Mark and cut the air duct terminal assembly, see diagram 7.4 and flue duct, diagram 7.5 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 flue duct as shown, making sure of the correct alignment of the “Top”.

7.3 Internal Flue Assembly

If access to the outside wall is not practical, the flue system can be installed from inside. Use of the optional wall liner kit recommended.

Apply sealant to the flue duct, locate into the air duct terminal, see diagram 7.6.

Apply sealant to the flue elbow spigot and then locate the flue and air duct terminal assembly to the flue elbow as shown in diagram 7.3, making sure of the alignment of the “Top”.

Secure the air duct/terminal assembly to the flue elbow and flue duct assembly with the two self tapping screws supplied in the loose items pack and then seal with the tape provided.

Place the flue assembly into the flue hole. Make sure that the flue terminal is correctly positioned and projecting the correct distance from the outside wall face, see diagram 7.9.

7.4 External Flue Installation

Locate the air duct/terminal assembly into the flue elbow assembly as shown in diagram 7.3, making sure of correct terminal alignment of the “TOP”.

Mark the position of the air duct terminal assembly securing holes and drill two 2.8mm diameter holes through the air duct/ terminal assembly.

Apply sealant to the flue duct and locate into air duct terminal, see diagram 7.6.

From outside, place the air duct/terminal assembly and flue duct into the flue hole. Make sure that the flue terminal is correctly positioned and projecting the correct distance from the outside wall face, see diagram 7.9.

Apply sealant to the flue elbow spigot and then locate the flue and air duct terminal assembly as shown in diagram 7.3, make sure of the correct alignment of the “Top”.

Secure the air duct terminal to the flue elbow with the two self tapping screws supplied in the loose items pack, then seal with the tape provided.

7.5 Flue Elbow

Fit the flue elbow gasket, from the fittings pack, to the casing top.

The two fan bracket securing screws should be loosened, but not removed, before slackening the three fan securing screws.

After locating the flue elbow into the outlet of the fan, secure the flue elbow onto the top panel with the four M4x14 screws provided.

Then push fan upward, making sure that the flue elbow spigot engages inside the fan outlet and compresses the gasket.

Diagram 7.1

"Q"

STANDARD FLUE TERMINAL

LONG FLUE TERMINAL

"Q" plus 67mm

6862

Complete assembly by fully tightening the two fan bracket securing screws.

Finally tighten the three fan securing screws. Fit the inner case door.

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

"N" minus 57mm

STANDARD FLUE TERMINAL

LONG FLUE TERMINAL

6864

4079

6885

7 Flue Installation

Diagram 7.2

"Q" plus 82mm

FLUE DUCT

"Q"

FLUE DUCT

6863

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 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. For wall thicknesses over 300mm see diagram 7.8.

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 connection to the gas service cock, see diagram 8.1

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. Using PVC insulated cable to the current issue of BS6500

Table 16, and of a suitable length, thread the cable through the small cable clamp and connect to the appropriate terminals, see diagram 9.2.

Standard colours are, brown - live (L), blue - neutral (N), green/ yellow - earth (E) .

The mains cable outer insulation must not be cut back external to the cable clamp.

When making connections, make sure that the earth conductor is made of a greater length than the current carrying conductors, so that if the cable is strained the earth conductor would be the last to become disconnected.

It is essential that the polarity is correct.

MULTI-FUNCTIONAL CONTROL

SECURING SCREW

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 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.

9.2 Testing - Electrical

Checks to ensure electrical safety should be carried out by a competent person.

In the event of an electrical fault 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. The installer is requested to advise and give guidance to the

user of the controls scheme used with the boiler.

221834B

Diagram 10.2

HIGH SETTING ADJUSTMENT (BRASS NUT)

LOWER SETTING ADJUSTMENT (INNER SCREW)

9023

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 with the user.

10.1 Preliminaries-All Systems

Commissioning should be carried out by a competent person in accordance with current issue of BS6798.

Make sure that the system has been thoroughly flushed out with cold water without the pump in place.

Refit the pump, fill the system with water, making sure that all the air is properly vented from the system and pump.

Before operating the boiler check that all external controls are calling for heat.

10.2 Sealed Systems

Fill the system until the pressure gauge registers 2.7bar (40lbf/ in2). Clear any air locks and check for leakage.

Check the operation of the safety valve, preferably by allowing the water pressure to rise until the valve lifts. This should be within +/-0.3bar (+/-4.3lbf/in2), of the preset pressure. Where this is not possible a manual check should be carried out.

Release the cold water to initial design pressure.

10.3 Initial Lighting, Testing and Adjustment

WARNING: The multifunctional control, fan and control box operate on 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.

Turn on the supply at the gas service cock. Loosen the burner pressure test point screw and fit a suitable

pressure gauge, see diagram 8.1. Turn the electrical supply on to the boiler and check that all

remote controls are calling for heat. The orange demand light will come on, see diagram 10.1. Turn the left hand switch to “High” flame. Turn the control thermostat knob, at the right, clockwise to any

position between “MIN” and “MAX”, see diagram 10.1. The maximum setting is about 82

C (180oF). The boiler will not light between “O” and “MIN”. The boiler lighting operation is now automatic. The fan operates, followed by an ignition spark until the burner

lights on “Low” flame after a short period it will go to “High” flame the green light is on.

The burner will remain alight until switched off by the control thermostat or other remote control.

The automatic lighting sequence will operate again when heat is required.

10.4 Testing - Gas

With the boiler on proceed as follows: Test for gas soundness around the boiler gas components

using a suitable leak detection fluid, in accordance with the current issue of BS6891.

Check the burner pressure at least 10 minutes after the burner has lit, refer to Data label.

If the main burner pressure requires adjustment, see diagram

10.2. The brass nut, controls the main (high) burner pressure. The centre, plastic posidrive screw controls the “Low” burner

pressure. The centre, plastic posidrive screw must be held in position

whilst adjusting the main (high) burner pressure, brass nut. After adjustment the low pressure must be checked, by turning

the “high/low” to “low” setting. Should any doubt exist about the gas rate, check it using the gas

meter test dial and a stop watch, at least 10 minutes after the burner has lit, make sure that all other gas burning appliances are off.

The rates are as shown in Table 2. Turn the control thermostat knob to “Off”. Remove the pressure

gauge from the test point and refit the screw, making sure that a gas tight seal is made.

When the control thermostat is turned to “Off”, by hand, wait at least 30 seconds before turning “On” again.

There may be an initial smell given off from the boiler when new,

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 rapidly as possible whilst still hot.

Refill the system, vent and again check for water soundness. For sealed water systems adjust to initial design pressure. The

set pointer on the pressure gauge should be set to coincide with the indicating pointer.

The overrun thermostat will keep the pump running when the boiler shuts down, so long as the temperature within the boiler is above a predetermined level.

When commissioning the system the boiler should be fired with the bypass fully closed on full service, that is, central heating and domestic hot water. The system should then be balanced, adjusting the pump and lockshield valves as necessary to achieve flow rates, refer to Section 2.4.

Having achieved a satisfactory condition, operate the boiler with the bypass closed on minimum load, normally central heating only with one radiator operating in the main living area. The valve should be opened gradually to achieve the appropriate flow rate as quoted in Section 2.4. If necessary readjust the pump.

Under NO circumstances should this valve be left in the FULLY Closed position.

10.6 Condensate Check

After 30 minutes of running, turn the boiler off and remove the inner case.

Check that there are no condensate leaks from the fan outlet/ flue elbow or fan inlet/flue hood joints. Also check for leaks from the condensate drainage system.

10.7 Operational Checks

Adjust the control thermostat and any system controls to their required settings and set “high/low” switch to “high”.

Do not attempt to adjust the thermostat calibration screw. Operate the boiler again on full service and check that the

balancing is satisfactory, making further adjustments as necessary to the system, radiator valves and bypass.

There must be no pumping over of water or entry of air at the vent above the feed and expansion cistern.

If thermostatic radiator valves are fitted care must be taken to make sure that there is an adequate flow rate through the boiler and bypass when the valves are closed. For guidance on the use of thermostatic radiator valves refer to the current issue of BS7478 and British Gas “Guidance Notes for Installation of Domestic Condensing Boilers”.

To check the operation of the flame supervision device, with the burner alight, turn gas service cock to “Off” the burner will go out. There will be one attempt to relight, indicated by a 5 second ignition phase.

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”. Refit the outer case, see diagram 5.2, and secure the case with

the screws from fittings pack.

11 User Information

Advise the user, that 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 conditions and usage, but in general 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 servicing is a carried out by a competent person.

Reminder - Leave these instructions and the “Benchmark” logbook with the user.

11 User Information

Instruct and demonstrate the efficient and safe operation of the boiler, heating system and if fitted the domestic hot water system.

Advise the user that, like all condensing boilers this appliance will produce a plume of condensation from the flue terminal in cool weather. This is due to the high efficiency and hence low flue gas temperature of the boiler.

Show the user the position of “Lighting Instructions” - refer to Instructions for Use.

Advise the user that for summer use the “high/low” switch can be turned to “low”.

Advise the user of the precautions necessary to prevent damage to the system and building in the event of the heating system being out of use during frost and freezing conditions.

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 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.

It is the Law that any servicing is carried out by a competent person.

Note. For obtaining a products of combustion reading use the connection on top of the boiler, see diagram 6.1.

Should the gas pressure need adjusting refer to Section 10.4. Isolate the boiler from the electrical supply. Before starting a service, remove the casing, refer to diagram

5.1. Turn the gas supply off at the gas service cock, see diagram 8.1. Unless stated otherwise, parts removed for servicing should be

replaced in the reverse order to removal. After completing any servicing of gas carrying components,

ALWAYS test for gas soundness and carry out functional check of controls.

Also check for condensate leaks at fan outlet/flue elbow and fan inlet/flue hood joints.

It should be noted that the burner is water cooled and a system drain down is necessary if the burner is removed.

12.1 Heat Exchanger Cleaning

Remove the inner case cover, see diagram 5.3. Remove the bypass heat shield, see diagram 12.1. Note. The flue hood top will “spring” up. Disconnect the fan air pressure tubes, combustion sampling

tube, electrical connections and remove the three fan securing screws, fan and the flue hood.

Note. On reassembly it is suggested that the two top securing screws for the bypass heat shield and the flue hood be partially engaged before fitting of the bypass heat shield, see diagram

12.3. Carefully remove the combustion chamber front panel, see

diagram 12.4. Remove the loose baffle from the condensing section, see

diagram 12.5. When replacing note that it is marked “Front”.

Place a container under condense drain trap, see diagram

12.8, and remove red cap. Flush loose debris from secondary heat exchanger with

water poured from above, and allow the water to drain through the flexible condensate tube at the right hand side of the heat exchanger into the container.

Check that this tube is not partially blocked and the water runs freely.

If there is any build up of debris in the condensate trap, the trap should be removed and flushed out.

Important: With use a white oxide coating will form on the aluminium parts - this should only be removed if the coating is blocking the gaps between the fins.

When cleaning take care that the water does not overflow the condensate catchment tray.

Place a sheet of paper over the burner, see diagram 12.6. Clean the primary heat exchanger, with a suitable soft brush,

see diagram 12.6.

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 with a suitable soft brush, any debris can be allowed to fall into the mixing chamber.

Do not use a brush with metallic bristles. Note: The burner is water cooled and a system drain down is

required if removing.

12.3 Injector

Remove the injector by releasing the three screws at the injector manifold burner box, the two screws at the inner case base sealing plate, see diagram 12.7, and the four screws at the multifunctional valve, see diagram 8.1.

Make sure that the “O” ring is in place in the flanged connection when refitting

Clean the holes by blowing through. Do not use a wire or sharp instrument on the holes.

12.4 Spark Electrode

Remove the silicone sleeving and disconnect the ignition lead, see diagram 12.9.

Remove the two securing screws. Withdraw the electrode taking care not to damage the insulation

material. Inspect and clean taking care not to damage the ceramic body.

When replacing make sure that the spark gap is as shown.

12.5 Condensate Drain

Remove the cap at the base of the condensate drain trap, see diagram 12.8 and carefully flush through, from the condensate collecting tray, diagram 12.6, taking care not to allow any water to overflow the tray.

When refitting the cap make sure a water tight seal is made.

12.6 Operational Checks

After completing a service, before fitting the casing, check the inner case seal to ensure that it is in good condition, renew if necessary.

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 diagram 13.3.

Note. Failure of an indicator light does not warrant the replacement of an otherwise satisfactory part.

13.2 Electrical Supply Failure

Failure of the electrical supply will cause the burner to go out. Operation will normally resume on restoration of the electrical

supply. If the boiler does not relight after an electrical supply failure the overheat device may need resetting.

To reset, press the reset button on the underside of the boiler, see diagram 13.4.

If the cutoff operates at any other time press the reset button and the burner should relight. If the fault persists refer to Fault Finding Chart.

There is a further cutoff mounted on the flue hood, see diagram

13.5 which also may need resetting.

13.3 Condensate Sensor

Refer to fault finding chart. The boiler is fitted with a safety device to prevent the boiler from

working if the condensate pipe gets blocked. Remove the condensate drain cap, diagram 14.2. If condensate is backing up to the sensor, the drain is blocked

and it must be cleared before the boiler will work. Inspect external condensate pipe and clear away any debris or ice.

Release ice blockage by using warm cloths on the pipe.

Diagram 12.9

Diagram 12.8

SECURING SCREW (2)

SILICONE SLEEVING

IGNITION AND SENSING LEAD

SPARK ELECTRODE

SPARK GAP 3mm to 4mm

GASKET

SECURING SCREW (3)

CONDENSE DRAIN TRAP

CAP

WASTE OUTLET

4060

4061

12 Servicing

Diagram 12.7

INJECTOR MANIFOLD

SECURING SCREW (3)

SECURING SCREW (2)

4059

13 Fault Finding

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 thermostat to maximum, with the remote controls calling for heat, does the

pump continue to run after the appliance has shut down on boiler control thermostat ?

Turn off remote controls,

does pump stop after a short

period of time

Is there 240V~ on L ?

Is there 240V ~on

9 connection on thermostat ?

Faulty permanent

live feed.

Replace

Faulty pump overrun.

Replace control thermostat

Pump overrun in order

Is there 240V ~ on PL for pump ?

Faulty pump/wiring ? Replace or repair as necessary

YES

Faulty

connections

between thermostat and interconnection

PCB. Repair

Faulty

connections

between

thermostat and

interconnection

PCB. Repair

PM5

13 Fault Finding

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 printed circuit board (PCB) fuse. Check

the air tubes to air pressure switch.

Is there 240V between L + N

Isolate supply

Check continuity

of overheat thermostat.

Thermostat ok ?

Is thermostat

neon on ?

Correct power supply problem

Isolate supply

Is there

continuity

between

and

C on APS

Replace APS

Check continuity of

control thermostat

between 3 and 6

ok ?

Replace control

thermostat

YES

Check wiring

and IC PCB

'stat' plug for

defects.

Repair or

replace wiring/

PCB if

necessary

YES

Replace

overheat

thermostat

YES

PM5

13 Fault Finding

221834B

Has boiler been operating for 10

seconds yet ?

Does gas ignite ?

YES

Isolate supply

Replace PCB

Examine electrode and

leads. Repair/replace

as necessary

Reconnect supply

Is APS neon lit ?

Is fan running ?

Replace APS

Is there 240V at the fan ?

Replace ignition

PCB

Flue hood overheating-

blocked secondary heat

exchanger (clean/replace)

Replace flue hood

thermostat

Will flue hood

thermostat reset?

- is there 240V at the fan?

Is there 240V

at C ?

YES

Replace fan

Switch High/Low Switch

to 'low'

Is there a spark at

electrode ?

Can the “low” gas

pressure be set

(see data tables)

at test point on gas

valve?

YES

Diagram 13.1

Check continuity of

both main coils

Coils ok?

Replace

ignition

PCB

Replace as

necessary

YES

Does gas

ignite?

Faulty injector

Replace

YES

Does discharge tube on

ignition PCB flash ?

PM5

13 Fault Finding

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

YES

Replace gas valve

YES

Turn High/Low switch to

“High”.

Check and adjust “High”

gas pressure

(see data tables)

Is gas pressure OK?

Adjust gas

pressure

Does “High” neon light ?

Is condense drain

blocked, repair.

Does burner remain

alight ?

Is the low gas pressure

setting correct (see Data

Tables) at the test point

on the gas valve ?

YES

Boiler satisfactory

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)

YES

Faulty PCB flame detection -

Replace PCB

(Reset pressure)

PM5

13 Fault Finding

221834B

13 Fault Finding

Diagram 13.2

12345678910

KEY:

b - BLUE bk - BLACK br - BROWN g/y- GREEN/ YELLOW g - GREY

SL PL

1 L

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 (FLAME) SWITCH

DEMAND NEON

LOW FLAME NEON

MAIN PLUG

HIGH/LOW (FLAME) PLUG

INTER-

CONNECTION

P.C.B.

PLASTIC OVERHEAT

HIGH FLAME NEON

RED LINK

MULTI-FUNCTIONAL CONTROL

REMOVE RED LINK IF REMOTE

SWITCH IS TO BE FITTED

REMOTE SWITCH

TB1

LAMP

GV1

GV2

CM1

STAT

PCB

y g/y

g/y

3 1

r - RED y - YELLOW p - PURPLE w - WHITE o - ORANGE

9024

221834B

Diagram 13.3

13 Fault Finding

554

I.C. P.C.B. CONNECTIONS: ie STAT (Pin No. from bottom)

PLASTIC

OVERHEAT

CONTROL THERMOSTAT

FAN

NO C

MAIN TERMINAL STRIP CONNECTIONS CONTROL THERMOSTAT CONNECTIONS PRINTED CIRCUIT BOARD CONNECTIONS

PUMP

OVERRUN

✽ RED LINK MAY HAVE BEEN REMOVED TO FIT REMOTE CONTROLS

OVERHEAT THERMOSTAT

AIR PRESSURE SWITCH

✽ RED LINK

FUSE TYPE F2A

IGNITION P.C.B.

LOW FLAME NEON

Lamp N(2)

HIGH FLAME

NEON

Lamp(1)

HIGH/LOW

SWITCH CONDENSE CUT-OFF

Amp Con

Stat(2)

Lamp N(1)

Stat(4) Lamp(3)

Lamp N(3)

DEMAND

NEON

Stat(1)P.C.B.(2)

P.C.B.(4) CM1(1)

P.C.B.(1)

CM1(2)

P.C.B.(3) GV1(1)

GV1(3)

GV1(2)

GV2(1 ) GV2(2)

br b

Stat(3)

KEY:

r - RED br - BROWN p - PURPLE b - BLUE bk - BLACK y - YELLOW w - WHITE g - GREY

bbk

bk bk

CM1(3)

221834B

Diagram 13.4

Diagram 13.5

4067 S

INSTRUCTION LABEL

RESET BUTTON

7891

FLUE HOOD OVERHEAT THERMOSTAT

RESET BUTTON

13 Fault 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 8.1.

Unless stated otherwise, all parts are replaced in the reverse order to removal.

After replacing any parts always test for gas soundness and if necessary carry out functional check of controls.

For the following the front case and inner case cover will need to be removed, diagrams 5.2 and 5.3.

14.1 Spark Electrode

Replace as described in Section 12.4.

14.2 Ignition Lead: diagram 14.2

Release the control box as Section 9. To disconnect the ignition lead from the control board, remove

the PCB from the mounting pegs, the front two have detachable grips, the rear two are plain supports.

When refitting lead make sure that there is enough length through the gland plate assembly.

Condensate Sensor: diagram 14.2

Refer to the relevant part of Section 14.2 to remove the screw. The sensing screw is fitted to a push fit cap which can be levered

off for easy access. Note. The condensate flexible tube is a push fit and can be

removed from the condensate drain trap to improve access to the screw.

When replacing the cap make sure that it is firmly in place and that the ring tag is pointing away from the casing side.

Diagram 14.2

IGNITION SENSING LEAD

5549

SECURING SCREW (2)

CONDENSATE FLEXIBLE TUBE

SPARK ELECTRODE

CONDENSATE DRAIN CAP

14 Replacement of Parts

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 Parts

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 from its two support post and carefully pull the board

away noting that the ignition lead is still connected. It may be necessary to hold some of the wires above the PCB

clear with an electrical screwdriver on removal or refitting. Release and carefully pull the board away from its supports,

noting that the ignition lead is still connected. Disconnect the ignition lead.

Interconnecting PCB: (ICB) diagram 14.3 (bottom)

Disconnect the electrical plugs and cables from the terminal strip.

Release and carefully pull the board away from its supports. When refitting refer to wiring diagram 13.2.

14.4 Control Thermostat and Overheat Cutoff

Release the control box, see Section 9.

Control Thermostat: diagram 14.4A and 14.4

Pull off the control thermostat and High/Low knobs. Remove the three fascia securing screws and fascia. 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. Slide control thermostat body away from control box. On replacement smear the phials with the heat sink compound

supplied before replacing in the phial pocket. When refitting refer to wiring diagram 13.2

Overheat Cutoff: diagram 14.4A and 14.4

Remove the electrical connections. Remove the locking nut. Release the gland plate assembly. Release and remove the overheat cutoff phial from the pocket. Withdraw the capillary through the gland plate and controls box

grommet. On replacement smear the phials with the heat sink compound

supplied before replacing in the phial pocket. When refitting refer to wiring diagram 13.2 Neatly secure any surplus capillary.

Flue Hood Overheat Cutoff: diagram 14.5

Remove electrical connections and unfasten the screws to release.

Note: the polarity of the connections is not important.

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 Parts

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 HOOD OVERHEAT THERMOSTAT

4066

ELECTRICAL CONNECTION (5)

ELECTRICAL CONNECTIONS

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. Remove the locknut to release the “High/Low” control. Disconnect the three in-line electrical connectors. When refitting refer to wiring diagram 13.2

14.6 Air Pressure Switch: diagram 14.7.

Remove the air pressure tubes and electrical connections. Remove the two securing screws to release the air pressure

switch. When fitting the replacement make sure that all the air pressure

tubes and electrical connections are made as shown.

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 Parts

14.7 Multifunctional Control: diagram 8.1.

Disconnect the screws and electrical plugs at the multifunctional control.

Support the multifunctional control and remove the four screws from the flanged connection, undo the union at the gas service cock and remove the support bracket securing screw.

Remove the multifunctional control by easing the flange and service cock apart.

Remove the union half and refit to the replacement multifunctional valve.

Use a little jointing compound on the external thread only, to ensure gas soundness.

Make sure that the new “O” ring is in place in the flanged connection is replaced.

It will be necessary to purge the pipework and multifunctional control before relighting and checking the pressure, refer to “Commissioning”.

14.8 Fan

Refer to Section 12.1 “Heat Exchanger Cleaning”. Make sure that the earth connection is remade onto the

replacement fan. The polarity of the electrical connections is not important.

14.9 Injector

Refer to Servicing Section 12.3. Fit new injector as shown. Note: The replacement injector is supplied complete with the

gas supply pipe manifold.

14.10 Heat Exchanger: diagram 14.8

Note: To carryout the following operations it will be found more convenient if the whole of the heat exchanger and burner are removed as a unit.

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.

Release union connections and the six securing screws, then remove the complete assembly.

Heat Exchanger: Secondary - diagram 14.9

Disconnect the union connector. Remove and fit the flexible hose to the replacement.

221834B

Diagram 14.9

UNION CONNECTION

PRIMARY HEAT EXCHANGER

UNION CONNECTION

BURNER

SECONDARY HEAT EXCHANGER

UNION CONNECTION

14 Replacement of Parts

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 whole of the heat exchanger and burner are removed as a unit.

Release the flexible tube from the condense drain trap, this is a push-fit.

Release union connections and the six securing screws, then remove the complete assembly.

Remove the insulation as Section 14.14 and retain for use in the replacement part.

Disconnect the two union connections. Fit the insulation.

Diagram 14.10

Diagram 14.11

INSULATION

SECURING SCREW (2)

REAR INSULATION

COMBUSTION CHAMBER FRONT PANEL

PILOT VIEWING WINDOW

Diagram 14.12

SIDE INSULATION

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 Parts

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.

14.14 Insulation - Sides - diagram 14.12

Remove the spark electrode refer to Section 12.4. Remove the insulation by sliding it out.

14.15 Condensate Sensor: diagram 14.13

Refer to the relevant parts of Section 14.2 to remove the screw.

14.16 Viewing Window Glass: diagram 14.14

Remove the two screws to release the frame and glass. When replacing take care not to damage the gasket.

14.17 Inner Case Cover Seal

When removing seal make sure that all the old adhesive is removed.

When fitting the new seal make sure that it fits correctly and has not buckled.

14.18 Fascia and Lights Assembly

Release the control box as Section 9. Refer to the relevant parts of Section 14.5 to remove the fascia

and lights bracket.

221834B

Part No.

Key No.

Description

GC Part No.

15 Spare Parts

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 manifold assembly - 40 - Nat 278 048

9 202231 Fuse

10 208302 Sight glass 312 419

208093 Gasket - sight glass - not shown 312 420

11 800840 Ignition lead E00335

12 202211 Control board (PCB) 379 239

13 800876 Fan

14 202625 Electrode 278 096

15 202210 Interconnection board 379 238

16 212121 'O' Ring 136 785

15 Spare Parts

When ordering spare parts, please quote the appliance name and serial number, to be found on the data label, visible when the outer casing is removed.

If ordering from the British Gas also quote the GC number of the part.

221834B

Because of our constant endeavour for improvement details may vary slightly from those in the instructions.

Diagram 15.1

15 Spare Parts

6291

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

Specifications and Main Features

Frequently Asked Questions

User Manual