Glow-worm 45-2 Back Boiler User Manual

221780A.07.00

Installation and Servicing Instructions

To be left with the user

Glow-worm 45/2 Back Boiler Unit

GC No 44 315 39

For use with specially designed Glow-worm fire fronts only

8010

References 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.

						BS 6332
			This is a Cat I	Appliance		BS 5258
			2H
				Hepworth Heating Ltd.,
			Customer Services:
				Nottingham Road, Belper, Derbyshire. DE56 1JT
			Tel: [phone]
				General/Sales enquiries:
One Contact Local Service Fax: [phone]
				Tel: [phone] Fax: [phone]

1 General

C

C

6070

L

L

FLUE

M

FLUE

GAS CONNECTION

C

Rc 1/

(1/ in. BSPT)

2

2

L

WATER CONNECTION Rc1

N

Q

F

(1in. BSPT) ON RIGHT-HAND

SIDE OR LEFT-HAND SIDE

(R.H. SHOWN)

INSIDE DIAMETER OF

A

H

SOCKET FOR 125mm (5in)

NOMINAL DIAMETER FLUE

J

D

G

GENERAL DIMENSIONS

P

E

All dimensions are in

millemetres

B

K

Diagram 1.1

Dimension

A

B

C

D

E

F

G

H

J

K

L

M

N

P

Q

'45/2'

345min 238min

130min

45/2

BACKBOILERBOILER

547

357

146

185

56

170

340

168

350

418

370max

263max

154

192 155max

The instructions consist of three parts, Installation and Servicing Instructions for the Back Boiler Unit, Installation and Servicing Instructions for the Fire Front and Instructions for Use, 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.

This boiler is for use only with a specially designed Glow-worm Gas Fire Front, see Table 1.

The boiler is delivered in one pack which contains all the parts necessary for the installation.

If installing the back boiler unit and fire front at the same time please read both sets of instructions before starting.

1 General Notes and Information

IMPORTANT NOTICE

The back boiler is fitted with a safety device which will shut it down if there is a lack of oxygen. If the back boiler shuts down frequently for no apparent reason the first things to be checked are the chimney and air inlets into the room. Any problems found must be put right, by a competent person, before the back boiler is used again.

This back boiler is for use only on G20 gas.

Wherever possible, all materials, appliances 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.

Sheet Metal Parts

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

1.1 Statutory Requirements

The installation of this back boiler unit must be carried out by a competent person in accordance with the current issue and relevant requirements of:

Manufacturer’s instructions, supplied.

The Gas Safety (Installation and Use) Regulations, The Building Regulations, The Building Standards (Scotland) Regulations (applicable in Scotland), Local Gas Undertaking, Byelaws of the Local Water Company, The Health and Safety at Work Act, Control of Substances Hazardous to Health, The Electricity at Work Regulations and any applicable local regulations.

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

BS6891, BS5449, BS5546, BS6700, BS5871, BS5440 Part 1 and 2, BS6798, BS1251, BS7478, BS7593, BS7671.

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

221780A

2

1 General

1.2 Data

Gas connection	Rc1/	2	(1/ inBSPT)
			2
Water connection	Rc1 (1inBSPT)
Electrical supply	230V~50Hz fused 3A
Weight, about	42.5kg (93.7lb)
Water content	5.6Litres (1.23gall)
Injector	3.3mm

Dimensions are given in millimetres (except as noted).

Data Label: Bottom left of control tray.

1.3 Gas Supply

The gas installation shall 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 back boiler.

On completion test the gas installation using the pressure drop method and suitable leak detection fluid, purge in accordance with the current issue of BS6891.

1.4 Electrical Supply

WARNING. This back boiler must be earthed.

All system components shall be of an approved type and shall be connected in accordance with the current issue of BS7671 and any applicable local regulations.

Connection of the back boiler and system controls to the mains supply should be through a double pole isolating switch, fused 3A having a minimum contact separation of 3mm in both poles.

Alternatively, a fused 3A 3 pin plug and unswitched socket outlet to the current issue of BS1363 may be used.

Wiring to the back boiler must be PVC (85oC) insulated type to the current issue of BS6500 Table 16, not less than 0.75mm2 (24/0.20mm).

1.5 Site Requirements

Refer to diagram 1.1 for dimensions appropriate to the back boiler.

For all types of installation a standard sized builder’s opening is required, see diagram 1.2.

It is important that the opening is cleared of debris and mortar.

It is recommended that the access hole for pipework into the fireplace or builder’s opening is either at the left hand or right hand side of the chimney breast. If access is required at both sides then it may be necessary to prepare some of the connections before fitting the back boiler into the builder’s opening.

The prepared base for the back boiler must be level.

Refer to Table 2 for dimensions of fire front fixing wall face which must be true.

1.6 Water System - Open Vented

This back boiler can be used on an unrestricted open vented system with the water supply taken from a feed and expansion cistern, having a head between 1m (3ft3in) minimum and 27m (90ft) maximum.

Diagrammatic layouts of systems are shown in diagram 1.3 and 1.4.

RANGE RATING TABLE

RANGE RATING Minimum Medium Maximum

NOMINAL	kW			12.9		15.4		17.8
HEAT INPUT
(GROSS)	Btu/h		44,100			52,500		60,900
NOMINAL	kW			9.5		11.7		13.7
HEAT
OUTPUT	Btu/h		32,450			39,800		46,750
BURNER	mbar			8		11.4		15.2
SETTING
PRESSURE	in.w.g			3.21		4.54		6.10
INJECTOR				3.3			FF2022
MARKING
T a b l e	1				G.C No.
FIRE TYPE				Teak			Mahogany
Miami 3 BBU			37-047-04A				37-047-07A
Melody 3 BBU					37-047-06A
Black Ash 3				37-047-08
Saxony 3				37-047-09
Brown Ember 3				37-047-02
T a b l e	2		Dimensions				Dimensions
			for				for fixture or
FIRE			minimum				surround
			flat area				protection
TYPE			(no	fixtures)			clearance
			X		Y		X	Y
Miami 3 BBU			642		698		750	836
Melody 3 BBU			642		698		750	836
Black Ash 3			700		660		840	890
Brown Ember 3			795		707		905	892
Saxony 3			700		625		840	860
ALL DIMENSIONS IN MM								3013

Y

C

L

PREPARED

BASE FRONT

OPENING X

3

221780A

Diagram 1.3

1588

1 General

1.7 Sealed Water System

A kit and instructions, part number 426520, is available to enable the back boiler to be used on a sealed water system.

Please give the serial number of the back boiler when ordering the kit.

1.8 Hot Water Cylinder

The back boiler is suitable for open vented systems using an indirect cylinder (including single feed self priming type). The indirect cylinder must be fitted to the manufacturer’s recommendations and the system must conform to the requirements of the current issue of BS5546 and BS6700.

It is recommended that the indirect cylinder be fitted with some form of temperature control.

1.9 Frost Protection

If the position of the back boiler is such that it may be vulnerable to freezing it should be protected as specified in the current issue of BS5422.

It is also recommended that a frost protection thermostat is fitted.

1.10 Draining Tap

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

Draining taps shall be to the current issue of BS2879.

1.11 Safety Valve

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

1.12 Back Boiler Location

This back boiler MUST NOT be installed in a private garage or in a room containing a bath or shower or in a room used or intended to be used as sleeping accommodation.

1.13 BSI Certification

This appliance is certificated to the current issue of BS6332 Part 1 invoking the current issue of BS5258 Part 8 for safety and performance. It is, therefore, important that no alteration is made to it without permission, in writing, from Hepworth Heating Ltd.

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

Refer to	1587
B.S. 5546	22mm
	VENT

15mm

COLD INDIRECT FEED CYLINDER

27 metres MAX

		28mm
	HEATING CIRCUIT	PUMP
		BOILERCL
		DRAIN COCK

PUMPED HEATING & GRAVITY DOMESTIC HOT WATER (DIAGRAMMATIC)

* CORNER IN-FILL (not required to be full depth of opening)

PREPARED

BOILER

BASE

A

B	3012/A

C

C

C L

L

405mm

100mm

	A		B		C
Miami 3 BBU	350	405	to 580	560	to 590
Melody 3 BBU	350	405	to 580	560	to 590
Black Ash 3	350	406	to 460	560	to 590
*Brown Ember 3	350	510	to 580	560	to 590
Saxony 3	350	406	to 460	560	to 590
FRONT OPENING				Diagram 1.2

22mm MIN

OPEN VENT MANUAL AIR VENT

INDIRECT

CYLINDER

	1 metre MIN	15mm
		COLD
	27 metres MAX
		FEED

	PUMP
BOILERCL	150mm	HEATING
		CIRCUIT
	MAX

DRAIN COCK

The COLD FEED PIPE may be connected to the flow pipe, adjacent to the open vent pipe as shown . (THERE MUST ALWAYS BE A COLD WATER PATH TO THE RETURN CONNECTION Of THE BOILER.)

FULLY PUMPED SYSTEM
(DIAGRAMMATIC)	Diagram 1.4

221780A

4

1 General

CE Mark

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 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.

_________________________________________

This boiler is exempt from the general requirements of the Boiler (Efficiency) Regulations (1993) and Directive 92/42/EEC by reason of its conformity to Schedule 3.I.7 of those Regulations and Article 4.3 of that Directive.

_________________________________________

1.14 Inhibitor

Attention is drawn to the current issue of BS5499 and BS7593 on the use of inhibitors in central heating systems.

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

If using in an existing system 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 Types of Installation

2.1 With Non-combustible Hearth

The back boiler must be installed level with the hearth or above it, see diagram 2.1.

For minimum dimensions of a hearth see diagram 2.1.

2.2 Combustible Hearth

If the hearth is existing and made of a combustible material the back boiler must be installed to the dimensions in diagram 2.2.

2.3 With Surround

The combined thickness of the surround and lintel must be checked, to make sure that the back boiler can be positioned within the opening to allow easy connection of the flue into the back boiler flue socket, see diagram 2.3.

The surround requires a minimum opening for access as shown in diagram 1.2.

2.4 Wall Mounted - that is - Without Surround or Hearth

If there is to be any combustible material beneath the fire front, for example, carpet then the base of the builder’s opening must not be less than 75mm above the floor covering as shown in diagram 2.2.

	FIRE FIXING	1589
	WALL FACE
	PREPARED BASE
	TOP OF HEARTH
	MUST NOT BE ABOVE
350mm	PREPARED BASE
MIN.	13mm MIN NON-
	COMBUSTIBLE
	MATERIAL
	50mm
	MIN.

INSTALLATION WITH HEARTH	Diagram 2.1
(NON-COMBUSTIBLE)

The builder’s opening, with lintel must have minimum dimensions as shown in diagram 1.2 and 2.3.

			FIRE FIXING		1590
			WALL FACE
			N.B. *Minimum dimension.
			This dimension refers to
			minimum clearance after
			carpet or any floor
			covering has been fitted.
			PREPARED BASE
	350mm		TOP OF
	MIN.
			CARPET,FLOOR
			COVERING OR
			COMBUSTIBLE
			HEARTH
			*75mm
	COMBUSTIBLE HEARTH / WALL
	MOUNTED INSTALLATIONS			Diagram 2.2
	PIPE		FIRE FIXING		1591
	FLUE		WALL FACE
		*165mm	N.B. *This dimension can
			be increased up to 190mm
			if builders opening depth
			is at least 375mm deep.
			MIN. 90mm
			MAX. 115mm

LINTEL DIMENSION

Diagram 2.3

5

221780A

	3	Flue and Ventilation
	3.1 General			1592
	The general recommendations of the current issue of BS5440
	Part 1 should be followed.			SEALING AND
	In all cases the flue should be lined, preferably with a flexible			CLAMPING
	liner.			PLATE
	It is essential that the flue has an equivalent height of at least
	2.5m (8.2ft) measured from the flue connection on the appliance.
	The first 600mm, at least, above the draught diverter must be
	vertical.		AIR SPACE
	The flue socket is designed to take flue pipe to BS567. If flue
	pipe conforming to a different standard is used a suitable
	adapter must be fitted and secured to the flue socket. A flexible
	flue liner may be used, with connection to the back boiler flue
	socket made with a short vertical piece of flexible liner, see
	diagram 3.2.
	The existing flue may not be completely sound. To prevent any
	possibility of leakage, additional sealing MUST be carried out
	between the base of the chimney and the flue liner.		SEALING
	The end of the liner at the chimney top must be adequately		PLATE
	sealed and clamped, using proprietary fittings suitable for the
	flue liner used, see diagram 3.1.
	The flue should, preferably, end above ridge height but at least
	above the eaves of a pitched roof. Use a certificated terminal.			600mm
	If the flue is to pass through or near any combustible material it
	should be installed in accordance with the current issue of
	BS5440 Part 1. If in doubt seek advice from the local gas
	undertaking or Hepworth Heating Ltd.
	3.2 Existing Chimney
	An existing brick chimney must be thoroughly swept and all
	debris cleared away before lining.		BACK
	Remove any register plates, dampers and the like. Alternatively
			BOILER
	it may be locked in the open position.
	A flexible flue liner is preferred but a rigid liner may be used, with		UNIT
	connection to the back boiler flue socket made with a short
	vertical piece of flexible liner, see diagram 3.2.
	Any air supply that enters the builder’s opening other than by the
	front opening, that is underdraught openings and the like, must
	be completely sealed off.
	The sealing plate also prevents debris falling and gives the flue		EXISTING FLUE FITTED WITH
	better insulation, reducing the possibility of condensation, see		APPROVED LINING	Diagram 3.1
	diagram 3.1.
	Check the flue system efficiency before installing the back			1593
	boiler.
	3.3 New Chimney
	A newly built chimney can be lined with a moisture resistant			RIGID
				FLUE
	lining, such as salt glazed pipe, of an appropriate diameter as
	specified in the Building Regulations			LINER
	In the case of a salt glazed lined flue, it is recommended that a
	short vertical length of flue pipe, preferable flexible metallic be
	used, fixed and sealed to the back boiler flue socket, made good
	with approved packing and parged with fire cement, see diagram
	3.2.			APPROVED
	If a flue and false chimney breast are to be constructed all		FLEXIBLE
				SEAL
	openings for pipework to upper floors etc., must be sealed. The		LINER
	only opening for the back boiler must be at the front, being of the
	dimensions as shown in diagram 1.2.

	If a specially built compartment is constructed for the back	BACK BOILER
	boiler, it must conform to the requirements of the current issue
	of BS5440 Part 1 and BS5871.	FLEXIBLE LINER
	The flue should, preferably, end above ridge height but at least
		CONNECTION	Diagram 3.2
	above the eaves of a pitched roof. Use a certificated terminal.

221780A

6

3 Flue and Ventilation

3.4 Ventilation - Back Boiler and Fire Front

It is important that the room in which the back boiler unit is installed has adequate air inlets to ensure correct operation as specified in the current issue of BS5440 Part 2.

Ventilation requirement for this back boiler is:

75cm2 (12in2)

This ventilation area takes into account the total requirement of the back boiler unit and any of the specially designed gas fire fronts.

The ventilation openings may communicate direct with outside air or with an internal room or space (such as a hall) which itself is provided with a permanent air vent of the same effective area. The permanent air vent should be in a position which minimises nuisance to occupants due to draughts.

This vent must NOT be placed in the builder’s opening.

If the appliance is to be installed in a room already containing another fuel burning unit, the air supply required for this other unit MUST be added to the figure above.

Any air vent taken through a cavity wall must be ducted.

3.5 Extract Fans

If an extract fan is fitted in the premises, there is a possibility that if adequate air inlet openings are not provided spillage of the products of combustion could occur.

When openings are fitted in accordance with the recommendations of the current issue of BS5440 Part 2, extract fans should not cause spillage.

Where such a fan installation is found, a clearance of products test must be conducted as described in the fire front Installation Instructions.

This test must be carried out with the back boiler fitted with its fire front.

See also Section 6.3 of these instructions.

4 Installation

4.1 Preparation

Remove draught diverter, flueway baffle and fittings pack from carton.

Remove back boiler body assembly from carton.

4.2 Water Connections

IT IS EXTREMELY IMPORTANT THAT NO SERVICE PIPES ARE ROUTED IN FRONT OF THE BACK BOILER.

If the builder’s opening was previously used for solid fuel all pipework within should be protected with PVC tape or equal. Pipework passing through walls of the opening should be sleeved and made good.

The four heat exchanger connections are tapped Rc1 and are all on one side of the heat exchanger, see diagram 1.1.

4.3 Pumped Heating with Gravity Domestic Hot Water

All pipework must comply with the current issue of BS5546.

The domestic hot water flow and return pipes must be 28mm.

The domestic return must be into the connection directly below the domestic flow connection.

Refer to diagram 1.3 for a diagrammatic layout.

If it is necessary to route pipework from both sides of the builder’s opening, it is recommended that the heat exchanger is positioned on the combustion chamber so that the gravity circuits exit on the same side as the back boiler connections.

It is recommended that pumped heating connections are prepiped as in diagram 4.2.

If the heat exchanger connections are opposite hand to that required, the heat exchanger can be turned, as follows, remove the four screws securing the heat exchanger to combustion chamber, see diagram 4.1. Turn heat exchanger, refit the four screws.

HEAT	5188
EXCHANGER

SECURING

SCREWS (2)

COMBUSTION

CHAMBER

SECURING

SCREWS (2)

Diagram 4.1

		1595
95mm
		30mm
28mm	22mm	MIN.
	168mm
196		40mm
	380mm	MIN.
	MAX.
PUMPED HEATING - WITH GRAVITY HOT
WATER PRE-PIPING		Diagram 4.2
7		221780A

4 Installation

4.4 Pumped Heating and Hot Water

The pumped flow connection must be diametrically opposite to the pumped return connection.

Refer to diagram 1.4 for a diagrammatic layout.

If it is necessary to route pipework from both sides of the builder’s opening it is recommended that the heat exchanger is positioned on the combustion chamber such that the flow pipe exits on the same side as the back boiler connections.

It is recommended that the pumped return is prepiped as in diagram 4.3.

If the heat exchanger connections are opposite hand to that required, turn in the same manner as described in Section 4.3 paragraph 7.

4.5 Pump

Isolating valves, integral if possible, must be fitted each side of the pump.

4.6 Gas Supply

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

See diagram 1.1 for position of gas connection.

It is recommended that the gas supply enters the builder’s opening on the right hand side.

If the gas supply enters from the left hand side it will be necessary to route the pipe behind the combustion chamber before final fixing, see diagram 4.2 and 4.3.

4.7 Positioning the Back Boiler

To position the back boiler lift by the casting and place centrally in the builder’s opening. The installation centre line is marked on the combustion chamber extension and by a notch on the front edge of the floor protection plate.

The back boiler must be positioned so that a line across the opening of the fire fixing wall face falls between the appropriate front and rear limiting marks, see diagram 4.4.

The easiest method of aligning the back boiler is to use a straight edge across the top of the combustion chamber extension. It is important that the back boiler is square to the fire front fixing wall face.

Check that the back boiler is level. If packing is required to adjust the level of the back boiler, use metal shims and pack under the full width of the base.

22mm
95mm		30mm
22mm		MIN.
196
	380mm
	MAX.
PUMPED HEATING
& HOT WATER PRE-PIPING		Diagram 4.3
221780A		8

Mark through the fixing holes each side of the combustion chamber, see diagram 4.4. Remove the back boiler. Drill two holes to accept the plugs and fixings provided.

If access to the fixing holes shown in diagram 4.4 is difficult, use the alternative method described in Section 4.8 otherwise proceed as Section 4.9.

VIEW ON	VIEW ON		8014
ARROWS	ARROWS
'A'	'Y'
FIXING	FIRE
HOLE(S)	FIXING	56
	LIMIT
	MARKS 45
	INSTALLATION
	CENTRE LINE
7mm Drill
INSTALLATION
CENTRE LINE
		FIRE
		FIXING
		WALL
		FACE
'Y'	'A'
		LIMIT
'A'		MARKS
LIMIT	NOTCH
MARKS
		Diagram 4.4
FLUE BAFFLE		6045

FLUEWAY

BAFFLES

	FLUEWAY	FRONT OF
		BACK BOILER

Diagram 4.5