Glow-worm 56-3e Back Boiler User Manual
221725B.10.00
Installation & Servicing Instructions
To be left with the user
Glow-worm 56/3e
Back Boiler Unit
G.C. No. 44 047 04A
This Back Boiler Unit Is To Be Used Only With The Glow-worm Mk.3 Fire Front Range
6836
One Contact Local Service
This is a Cat I2H Appliance
Customer Services:
Tel: (01773) 828100
Fax: (01773) 828070
Nottingham Road, Belper, Derbyshire. DE56 1JT
Tel: (01773) 824141 Fax: (01773) 820569
Hepworth Heating Ltd.,
General/Sales enquiries:
1 General
1 General
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.
This boiler is NOT suitable for fitting to a precast flues.
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,
Bye-laws 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 Supplied in fittings pack
Electrical supply 230V~50Hz fused 3A
Weight, about 35kg
Water content 3.11Litres
Injector 3.6mm
Dimensions are given in millimetres (except as noted).
Data Label: Front, centre on base.
The Seasonal Efficiency Domestic Boilers UK (SEDBUK)
is 78.6%.
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.
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.
o
Wiring to the back boiler must be PVC (85
the current issue of BS6500 Table 16, not less than 0.75mm
(24/0.20mm).
C) insulated type to
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.
NOTE: For wider openings corner infills may be required when
fitting some fire fronts. The infills are for cosmetic reasons only,
see diagram 1.3.
Refer to Table 2 for dimensions of fire front fixing wall face
which must be true.
2
221725B
2
1 General
INSIDE DIAMETER
FIRE FIXING WALL FACE
C
L
E
T
G
FLUE
R
N
F
S
D
OF SOCKET FOR
125mm (5in)
NOMINAL DIAMETER
FLUE
P
B
H
C
L of Flue
WATER
CONNECTIONS
22mm COPPER PIPE
GAS CONNECTION
RC (1/2 in BSPT)
A
L
6837
C
M
SIDE ELEVATION
OVERALL DIMENSIONS
Dimension A B C D E F G H J K L M N P R S T
56/3e 550 400 338 337 245 130 3 146 177 174 60 457 65 530 80 50 490
RANGE RATING TABLE
Minimum Medium Maximum Maximum
RANGE RATING
Brown Ember 3 Miami 3
J
FRONT ELEVATION
Black Ash 3 Melody 3
Saxony 3
HEAT
INPUT
(NETT)
HEAT
OUTPUT
HOT
BURNER
PRESSURE
kW
Btu/h
kW
Btu/h
mbar
in.w.g
10.8 14.5 17.6 18.2
36,950 49,550 59,900 62,150
9.4 12.9 15.8 16.4
32,000 44,000 54,000 56,000
5.0 9.0 13.7 14.8
2.0 3.6 5.5 5.9
K
J
Diagram 1.1
INJECTOR
MARKING
3.6 Pt. No. 230208
3
221725B
1 General
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 1.4 and
1.5.
1.7 Sealed Water System
A kit and instructions, part number 459033, 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.
1.12 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.
TABLE 2
Dimensions
for minimum
FIRE TYPE
flat area
(no fixtures)
X Y X Y
Miami 3 BBU 642 698 750 836
Melody 3 BBU 642 698 750 836
Black Ash 3 BBU 700 660 840 890
Brown Ember 3 BBU 795 707 905 892
Saxony 3 BBU 700 625 840 860
ALL DIMENSIONS IN MM
Y
C
L
PREPARED
BASE
FRONT
OPENING
Dimensions
for fixture or
surround
protection
clearance
3013
X
1.11 Safety Valve
A safety valve need not be fitted to an open vented system.
TABLE 1
FIRE TYPE
Miami 3 BBU 37-047-04A 37-047-07A
Melody 3 BBU 37-047-06A
Black Ash 3 BBU 37-047-08
Brown Ember 3 BBU 37-047-02A
Saxony 3 BBU 37-047-09
G.C No.
Teak Mahogany
C
PREPARED
BOILER
BASE
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 BBU 350 406 to 460 560 to 590
*Brown Ember 3 BBU 350 406 to 580 560 to 590
Saxony 3 BBU 350 406 to 460 560 to 590
FRONT OPENING
A
B 405 min.
Diagram 1.2
6302
221725B
4
1 General
* CORNER IN-FILL
OPENING
(not required to be
full depth of opening)
405 mm. MIN.
Diagram 1.3
1.13 BSI Certification
FRONT
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.
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 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 for Regulation 5 certified by: Notified
body 0086.
Product/production certified by: Notified body 0086.
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.
6408
1 metre MIN
27 metres MAX
28mm
IMPORTANT
DIMENSION
NOT LESS
THAN 145mm
FLOW
DISTRIBUTOR
TUBE IN RETURN
CONNECTION
RETURN
INDIRECT
CYLINDER
22mm
CENTRAL
HEATING
RETURN
BOILER
22mm
CENTRAL
HEATING
FLOW
27 METRES
C
L
PUMPED HEATING &
GRAVITY DOMESTIC HOT
WATER (DIAGRAMMATIC)
Diagram 1.4
22mm MIN
OPEN VENT
MANUAL
AIR VENT
INDIRECT
CYLINDER
15mm
COLD
FEED
PUMP
150mm MAX
BOILER
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.)
C
L
HEATING
CIRCUIT
FULLY PUMPED SYSTEM
(DIAGRAMMATIC)
Diagram 1.5
6242
MAXIMUM
7218
5
221725B
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
Dimensions X, Y, and Z refer to
Fire Installation Instructions
PREPARED
BOILER
BASE
'X' mm MIN
HEARTH
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.
The builder’s opening, with lintel must have minimum
dimensions as shown in diagram 1.2 and 2.3.
FIRE FIXING
5423
350mm
MIN.
WALL FACE
N.B. *Minimum dimension.
This dimension refers to
minimum clearance after
carpet or any floor
covering has been fitted.
PREPARED BASE
TOP OF CARPET,
FLOOR COVERING
OR
COMBUSTIBLE
HEARTH
1590
'Y' mm
165mm
MAX
350mm
MIN
'Z' mm
FIRE FIXING
WALL FACE
PREPARED BASE
TOPS OF HEARTH
MUST NOT BE
ABOVE PREPARED
BASE
13mm MIN
NON-COMBUSTIBLE
MATERIAL
Diagram 2.1
50mm
MIN
COMBUSTIBLE HEARTH / WALL
MOUNTED INSTALLATIONS
350mm MIN
FIRE FIXING
WALL FACE
FLUE
PIPE
*165mm
MAX
*NOTE
This dimension can
be increased up to
190mm if builder’s
opening depth is at
least 375mm deep
*75mm
Diagram 2.2
6838
Diagram 2.3
221725B
6
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.
SEALING AND
CLAMPING
PLATE
AIR
SPACE
150mm (6in) plug of Mineral Wool or similar
SEALING
PLATE
600mm
6197
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.
BACK
BOILER
UNIT
Existing Flue Fitted with
Approved Lining
FLEXIBLE
LINER
Diagram 3.1
RIGID
FLUE
LINER
APPROVED
SEAL
7194
BACK BOILER
Diagram 3.2
7
221725B
3 Flue and Ventilation
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.
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
(13.5in2)
87cm
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 minimizes
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.
221725B
8
4 Installation
4.1 Preparation
Remove draught diverter assembly, flueway baffles and fittings
pack from carton.
Check contents of fittings pack against packed list.
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 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 two heat exchanger connections are supplied in the fittings
pack and MUST be used, see diagram 4.1.
NOTE: Take care when soldering the copper connections not
to damage the sealing washers.
4.3 Pumped Heating with Gravity Domestic
Hot Water
NOTE: The draught diverter assembly and capillaries are
shown to aid plumbing, but would not be fitted at this stage.
All pipework must comply with the current issue of BS5546.
The domestic hot water flow and return pipes must be 28mm.
Refer to diagrams 1.3 and 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 so that the gravity
circuits exit on the same side as the boiler connections.
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 4.2. Turn heat exchanger, refit the four
screws.
It is recommended that pumped heating connections are prepiped as in diagram 4.4.
Note: The diagram 4.4 shows two methods “A” and “B” of
plumbing the flow pipe.
The central heating return must have the injector fitted on both
methods “A” and “B”, see diagram 4.4 for fitting the injector.
22mm COPPER PIPE
SUPPLIED WITH
APPLIANCE (Do not cut)
SEALING
WASHERS
HEAT
EXCHANGER
SECURING
SCREWS (4)
INJECTOR
UNEQUAL
TEE PIECE
22mm
COPPER
PIPE
SUPPLIED
WITH
APPLIANCE
(Do not cut)
COMBUSTION
CHAMBER
6254
Diagram 4.1
6839
Diagram 4.2
4.4 Pumped Heating and Hot Water
NOTE: The draught diverter assembly and capillaries are
shown to aid plumbing, but would not be fitted at this stage.
Refer to diagram 1.5 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 boiler connections.
It is recommended that the pumped return is pre-piped 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 6.
22mm COPPER PIPE
SUPPLIED WITH
APPLIANCE (Do not cut)
Pumped Heating and Hot Water
9
22mm
RETURN
22mm
FLOW
22mm COPPER
PIPE SUPPLIED
WITH APPLIANCE
(Do not cut)
Diagram 4.3
221725B
6840
4 Installation
FITTING THE
INJECTOR
6842
145 mm
MINIMUM
22mm
COPPER PIPE
SUPPLIED
WITH
APPLIANCE
(Do not cut)
METHOD A
28mm DOMESTIC HOT
WATER FLOW
(Must rise to allow air to
escape from the system)
22mm COPPER
PIPE SUPPLIED
WITH APPLIANCE
(Do not cut)
6843
22mm COPPER PIPE
SUPPLIED WITH
APPLIANCE (Do not cut)
22mm
22mm CENTRAL
HEATING RETURN
28mm
22mm CENTRAL
HEATING FLOW
(Must run down
to allow air in
system to
escape)
145 mm
MINIMUM
22mm
CENTRAL
HEATING
RETURN
INJECTOR
(Supplied)
UNEQUAL TEE
(supplied)
22mm COPPER
PIPE SUPPLIED
WITH APPLIANCE
(Do not cut)
22mm COPPER
PIPE SUPPLIED
WITH APPLIANCE
(Do not cut)
28mm
DOMESTIC
HOT WATER
FLOW
22mm
CENTRAL
HEATING
RETURN
6841
28mm
DOMESTIC
HOT
WATER
RETURN
145 mm
MINIMUM
221725B
28mm
COPPER
PIPE
28mm DOMESTIC
HOT WATER
RETURN
22mm COPPER PIPE
SUPPLIED WITH
APPLIANCE
(Do not cut)
10
METHOD B
22mm CENTRAL
HEATING FLOW
Note: If the tee piece is
fitted away from the
boiler, the central
heating flow pipe must
be increased to 28mm
as shown.
Diagram 4.4
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