Glow-worm 56-2 Back Boiler User Manual
221781A.07.00
Installation and Servicing Instructions
To be left with the user
Glow-worm 56/2 Back Boiler Unit
GC No 44 315 40
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.
One Contact Local Service
This is a Cat I
Customer Services:
Tel: (01773) 828100
Fax: (01773) 828070
BS 6332
Appliance
2H
Hepworth Heating Ltd.,
Nottingham Road, Belper, Derbyshire. DE56 1JT
General/Sales enquiries:
Tel: (01773) 824141 Fax: (01773) 820569
BS 5258
1 General
FLUE
F
C
L
GAS CONNECTION
Rc 1/2 (1/2 in. BSPT)
WATER CONNECTION Rc1
(1in. BSPT) ON RIGHT-HAND
SIDE OR LEFT-HAND SIDE
C
L
FLUE
C
M
L
N
Q
(R.H. SHOWN)
INSIDE DIAMETER OF
A
H
SOCKET FOR 125mm (5in)
NOMINAL DIAMETER FLUE
J
D
P
E
B
G
K
GENERAL DIMENSIONS
All dimensions are in
millemetres
Diagram 1.1
Dimension A B C D E F G H J K L M N P Q
'56/2' 345min 238min 88min
BACK BOILER 547 357 146 185 56 212 382 168 350 460
370max 263max
154 192 113max
6070
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.
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.
1.2 Data
Gas connection Rc1/2 (1/2inBSPT)
Water connection Rc1 (1inBSPT)
Electrical supply 230V~50Hz fused 3A
Weight, about 47.4kg (104.5lb)
Water content 6.28Litres (1.38gall)
Injector 3.7mm
Dimensions are given in millimetres (except as noted).
Data Label: Bottom left of control tray.
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.
221781A
2
1 General
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 0.75mm
(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
NOMINAL
kW
HEAT INPUT
(GROSS)
NOMINAL
Btu/h
kW
HEAT
OUTPUT
BURNER
Btu/h
mbar
SETTING
PRESSURE
in.w.g
INJECTOR
MARKING
T a b l e 1
FIRE TYPE
Miami 3 BBU 37-047-04A 37-047-07A
Melody 3 BBU 37-047-06A
2
Black Ash 3 37-047-08
Saxony 3 37-047-09
Brown Ember 3 37-047-02
T a b l e 2
FIRE
TYPE
Minimum Medium Maximum
18.5 20.2 21.9
63,200 69,000 74,800
13.8 15.2 16.5
47,100 51,950 56,450
9.8 11.7 13.7
3.94 4.70 5.5
3.7 203001
G.C No.
Teak Mahogany
Dimensions
for
minimum
flat area
(no fixtures)
Dimensions
for fixture or
surround
protection
clearance
XY XY
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
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.
PREPARED
BASE
3
FRONT
OPENING
X
221781A
C
L
BOILER
1 General
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
B.S. 5546
22mm
VENT
INDIRECT
CYLINDER
28mm
PUMP
C
L
HEATING
CIRCUIT
BOILER
DRAIN COCK
PUMPED HEATING & GRAVITY
DOMESTIC HOT WATER
(DIAGRAMMATIC)
15mm
COLD
FEED
27 metres
MAX
Diagram 1.3
1587
* CORNER IN-FILL
B
(not required to be full
depth of opening)
PREPARED
C
BOILER
BASE
A
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
C
L
C
L
405mm
Diagram 1.2
3012/A
22mm MIN
OPEN VENT
MANUAL
AIR VENT
INDIRECT
CYLINDER
1 metre MIN
27 metres MAX
15mm
COLD
FEED
PUMP
150mm
MAX
HEATING
CIRCUIT
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
1588
221781A
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.
_________________________________________
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.
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.
The builder’s opening, with lintel must have minimum dimensions
as shown in diagram 1.2 and 2.3.
FIRE FIXING
WALL FACE
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 WALL FACE
PREPARED BASE
TOP OF HEARTH
350mm
MIN.
MUST NOT BE ABOVE
PREPARED BASE
13mm MIN NONCOMBUSTIBLE
MATERIAL
50mm
MIN.
1589
N.B. *Minimum dimension.
This dimension refers to
minimum clearance after
carpet or any floor
covering has been fitted.
PREPARED BASE
350mm
MIN.
TOP OF
CARPET,FLOOR
COVERING OR
COMBUSTIBLE
HEARTH
COMBUSTIBLE HEARTH / WALL
MOUNTED INSTALLATIONS
FIRE FIXING
WALL FACE
*165mm
FLUE PIPE
N.B. *This dimension can
be increased up to 190mm
if builders opening depth
is at least 375mm deep.
MIN. 48mm
MAX. 73mm
*75mm
Diagram 2.2
1591 1590
INSTALLATION WITH
HEARTH (NON-COMBUSTIBLE)
Diagram 2.1
LINTEL DIMENSION
5
Diagram 2.3
221781A
3 Flue and Ventilation
3.1 General
The general recommendations of the current issue of BS5440
Part 1 should be followed.
In all cases the flue should be lined, preferably with a flexible
liner.
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.
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.
The end of the liner at the chimney top must be adequately
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.
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.
1592
SEALING AND
CLAMPING
PLATE
AIR SPACE
SEALING
PLATE
600mm
3.2 Existing Chimney
An existing brick chimney must be thoroughly swept and all
debris cleared away before lining.
Remove any register plates, dampers and the like. Alternatively
it may be locked in the open position.
A flexible flue liner is preferred but a rigid 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.
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
better insulation, reducing the possibility of condensation, see
diagram 3.1.
Check the flue system efficiency before installing the back
boiler.
3.3 New Chimney
A newly built chimney can be lined with a moisture resistant
lining, such as salt glazed pipe, of an appropriate diameter as
specified in the Building Regulations
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.
If a flue and false chimney breast are to be constructed all
openings for pipework to upper floors etc., must be sealed. The
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
boiler, it must conform to the requirements of the current issue
of BS5440 Part 1 and BS5871.
The flue should, preferably, end above ridge height but at least
above the eaves of a pitched roof. Use a certificated terminal.
BACK
BOILER
UNIT
EXISTING FLUE FITTED WITH
APPROVED LINING
FLEXIBLE
LINER
BACK BOILER
FLEXIBLE LINER
CONNECTION
Diagram 3.1
1593
RIGID
FLUE
LINER
APPROVED
SEAL
Diagram 3.2
221781A
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:
2
(15in2)
97cm
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.
4 Installation
4.1 Preparation
Remove draught diverter, flueway baffle and fittings pack from
carton.
Remove back boiler body assembly from carton.
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.
HEAT
EXCHANGER
SECURING
SCREWS (2)
5188
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.
95mm
28mm
238
PUMPED HEATING WITH GRAVITY HOT
WATER PRE-PIPING
168mm
COMBUSTION
CHAMBER
SECURING
SCREWS (2)
22mm
380mm
MAX.
Diagram 4.1
1595
30mm
MIN.
40mm
MIN.
Diagram 4.2
7
221781A
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.
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.
4.8 Alternative Back Boiler Fixing
Position the back boiler as described in Section 4.7 paragraphs
1 to 3.
Carefully disconnect the electrical plug from the gas valve and
undo the four screws securing the combustion chamber
extension and remove, see diagram 4.8.
Mark position of fixing holes on each side of the floor protection
plate, see diagram 4.9. Remove back boiler from the opening.
Drill two holes to accept the plugs and fixings provided.
'Y'
VIEW ON
ARROWS
'Y'
FIRE
FIXING
LIMIT
MARKS
INSTALLATION
CENTRE LINE
'A'
56
45
FIRE
FIXING
WALL
FACE
LIMIT
MARKS
NOTCH
Diagram 4.4
VIEW ON
ARROWS
'A'
FIXING
HOLE(S)
7mm Drill
INSTALLATION
CENTRE LINE
'A'
LIMIT
MARKS
8014
22mm
238
PUMPED HEATING
& HOT WATER PRE-PIPING
221781A
95mm
22mm
380mm
MAX.
30mm
MIN.
Diagram 4.3
FLUE BAFFLE
FLUEWAY
FRONT OF
5190
BACK BOILER
Diagram 4.5
8
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