Glow-worm Economy Plus C 40, economy plus c 50, economy plus c 30 Instructions For Use Installation And Servicing

Supplied By www.heating spares.co Tel. [phone]

Instructions for Use

Installation and Servicing

T o be left with the user

221461C.01.00

C

40

G.C. No. 41 319 38

Open Flue Boiler

BS 6332
BS 5258

This is a Cat I2H Appliance

Reference in these instructions to British Standards and Statutory

Regulations/Requirements apply only to the United Kingdom.

The instructions consist of three parts, User, Installation and Servicing Instructions, which includes the Guarantee Registration

For Ireland the rules in force must be used.

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.

2402

Guarantee Registration

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.

Attached to the center of these instructions is 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:

✔

All replacement parts

❏

✔

All labour charges

❏

All call-out charges

✔

❏

One Contact Local Service

REGISTER YOUR GLOW-WORM APPLIANCE

FOR 1ST YEAR GUARANTEE PROTECTION

CALL 0181 380 2555

Customer Services:
Tel: [phone]
Fax: [phone]

Nottingham Road, Belper, Derbyshire. DE56 1JT

Tel: [phone] Fax: [phone]

Hepworth Heating Ltd.,

General/Sales enquiries:

Supplied By www.heating spares.co Tel. [phone]

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 1.3.

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.

REFRACTORY CERAMIC FIBRE

This product uses insulation material containing Refractory Ceramic Fibre (RCF), which are man-made vitreous silicate fibres.
Excessive exposure to these materials may cause temporary irritation to eyes, skin and respiratory tract, consequently, it makes
sense to take care when handling these articles to ensure that the release of dust is kept to a minimum.

To ensure that the release of fibres from these RCF articles is kept to a minimum, during installation and servicing we recommend
that you use a HEPA filtered vacuum to remove any dust accumulated in and around the boiler before and after working on the boiler.
When replacing these articles we recommend that the replaced items are not broken up, but are sealed within heavy duty polythene
bags, clearly labelled as RCF waste. This is not classified as “hazardous waste” and may be disposed of at a tipping site licensed
for the disposal of industrial waste. Protective clothing is not required when handling these articles, but we recommend you follow
the normal hygiene rules of not smoking, eating or drinking in the work area and always wash your hands before eating or drinking.

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.

COMBUSTION PRODUCTS DISCHARGE SAFETY DEVICE

These contain very small amounts of ethylene glycol and methanol in the capillary. If broken, under normal circumstances the fluid
does not cause a problem, but in cases of skin or eye contact, wash with cold water. If ingested, drink plenty of water and seek medical
attention.

CONTENTS DESCRIPTION SECTION PAGE No.

INSTRUCTIONS

FOR USE

Introduction 3
Lighting the Boiler 4

General Data 1 5

INSTALLATION

INSTRUCTIONS

Flue and Ventilation 2 7
Water Systems 3 8
Installation 4 10
Electrical Wiring 5 11
Commissioning 6 12

SERVICING

INSTRUCTIONS

221461C

Servicing and Replacement Parts 7 14
Fault Finding 8 19
Spare Parts 9 24

2

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Instructions for Use

General Notes and Information

Please read these instructions and follow them carefully for the
safe and economical use of your boiler.

Important Notice

This boiler is for use only on G20 gas.
The convection air openings on the boiler must NEVER be

obstructed.

The Gas Safety (Installation and Use)
Regulations

In your interests 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.

Maintenance

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.

To obtain service, please call your installer, or Heatcall (Glow­worm’s own service organisation) using the telephone number
given on the controls tray.

If the appliance is installed in a rented property there is a duty of
care imposed on the owner of the property by the current issue
of the Gas Safety (Installation and Use) Regulations, Section 35.

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

Gas Leak or Fault

If a gas leak or fault exists or is suspected the boiler must be
turned off also the electrical supply. Advice/help should be
obtained from your installation/servicing company or the local
gas company.

Boiler Identification

The type of boiler and its output can be checked against the
details inside the controls cover.

Overheat Cutoff Device

The boiler is fitted with a safety device to prevent damage
through overheating. Should the boiler go out together with the
pilot for no apparent reason, allow the system to cool down, then
relight the boiler.

Should the problem persist, turn the boiler off and consult your
installation/servicing company.

Electrical Supply

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

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

BS7671.

2

Heat resistant cable having a conductor size of 0.75mm

0.20mm) to BS6500 Table 16 must be used.
The colours of three core flexible cable are, Brown - live, Blue -

neutral, Green and yellow - earth.
As the marking on your plug may not correspond with these

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

marked “L” or “Red”.
The wire coloured blue must be connected to the terminal

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

terminal marked “E”, Green or the earth symbol

MINIMUM
CLEARANCES

B

, (24/

.

2390

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. If an immersion heater is fitted in the domestic hot
water cylinder make sure that it is switched off.

If you have a sealed water system you should contact your
installer/servicing company as a sealed water system should
only be drained, refilled and pressurised by a competent person.

Boiler Clearance

The boiler must be positioned so that at least the minimum
operational and servicing clearances are provided, see diagram

1.
If fixtures are positioned close to the boiler they should be made

removable for access to pipework.
Enough space must be left in front of the boiler for servicing.

Boiler in a Compartment

If the boiler is fitted in a compartment or cupboard, purpose built
ventilation must be provided and kept clear.

Do not use the enclosed space for storage.

A

C

OPEN FLUE BOILERS
Minimum Clearances from
Walss, Ceiling, Floor, etc.

A L.H. and R.H. side of casing 25
B Top of casing 75
C Bottom of casing 150
D Front of boiler (from a

permanent surface 305

3

A

Diagram 1

221461C

Supplied By www.heating spares.co Tel. [phone]

Instructions for Use

Safety Device

This appliance is fitted with a flue blockage safety device which
will shut down the appliance in the event of abnormal flue
conditions. This device is NOT a substitute for an independently
mounted Carbon Monoxide detector.

The safety device is reset, after three minutes by pushing in the
button “ F ” shown in diagram 3.

Note: The pilot will stay alight but the device must be reset.
Shut down can occur during certain climate conditions, but if it

recurs the chimney flue and air inlet into the room must be
checked and any problems found corrected by a competent
person, before the boiler is used again.

Lighting the Boiler

CAUTION
If the pilot flame goes out, either intentionally or by accident, no

attempt should be made to relight for at least three minutes.
Slide the controls cover off and clear, see diagram 2.
Make sure that the electrical supply to the boiler is switched off.
Identify the controls by referring to diagram 3.
Turn the control thermostat knob “A” fully anticlockwise to the

“OFF” position.
Push and hold in gas control knob “B”. Push and release igniter

button “C” until the pilot burner lights, look through window “D”.
When the pilot is alight keep gas control knob “B” pushed in for
about 15 seconds and then release.

If the pilot does not light or fails to stay alight, wait three minutes
and repeat the lighting operation, only this time keep knob “B”
pushed on for a little longer.

The flue blockage safety device may also need resetting, refer
to safety device instructions.

Make sure that the pilot is alight and stable.
Switch on the electrical supply to the boiler.
Check that all external controls are calling for heat.
Turn control thermostat knob “A” fully clockwise to “MAX” and

the main burner will light fully in about three to five seconds, look
through window “D”.

If the main burner does not light, the flue blockage safety device
may need resetting, refer to Safety Device instructions.

Adjust the control thermostat knob to the desired setting between
“MIN” and “MAX”. “MAX” is about 82

Replace controls cover.

o

C (180oF).

To Turn the Boiler Off

For short periods, turn control thermostat knob “A” anticlockwise
until “O” is against the setting point. The pilot will stay alight, to
relight the main burner turn control thermostat knob “A” clockwise
to the desired setting between “MIN” and “MAX”.

For longer periods, turn the control thermostat knob “A”
anticlockwise until “O” is against the setting point. Slide gas
control knob “B” to left and release, the control will automatically
reset. Switch off the electrical supply.

To relight, follow the full lighting procedure given above.

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 by wiping it over occasionally with a wet cloth
or dry polishing duster.

Do not use abrasive cleaners.

CONTROLS
COVER

Diagram 2

2391

A. CONTROL THERMOSTAT KNOB

D

B. GAS CONTROL KNOB
C. IGNITER BUTTON
D. VIEWING WINDOW
F. FLUE BLOCKAGE SAFETY DEVICE

A

C

RESET BUTTON

BOILER
CONTROLS

221461C

F

4

5354

B

MODEL AND
SERIAL
NUMBER
PLATE

Diagram 3

Supplied By www.heating spares.co Tel. [phone]

1 General Data

242

*

RETURN FLOW

115
DIA.

WATER

CONNECTIONS

GAS CONNECTION

360

36

*

INSIDE DIAMETER
OF SPIGOT FOR
100 mm (4in) NOMINAL
DIAMETER FLUE

11

600

40

WATER
CONNECTIONS

490

GAS
CONNECTION

110

225

FLUE

C

L

2409

86
43

98

OVERALL DIMENSIONS (given in millimetres)

1.1 Important Notice

This boiler is for use only on natural gas G20.
The boiler is delivered in one pack.
Wherever possible, all materials, appliances and components

to be used shall comply with the requirements of applicable
British Standards.

Where no British Standards exist, 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 fitting out of doors.
The boiler must not be installed in a bedroom, bed sitting room

or a room containing a bath or shower.
Open flue boilers must not be installed in private garages.

1.2 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.

1.3 Statutory Requirements

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

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

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

300

Detailed recommendation are contained in the current issue of
the following British Standards and Codes of Practice:

BS4814, BS5400 Part and 2, BS5449, BS5446, BS6700,
BS6798, BS6891, BS7074 Part and 2, BS7478, BS7593,
BS7671.

Manufacturers’ instructions must not be taken as overriding
statutory requirements.

Diagram 1.1

1.4 Data

Weight of boiler: 40C - 20.1kg (44.3lb)
Water content: 40C - 0.50Litre (0.11gal)
Gas connection: Rc1/
Water connection: 22mm copper flow at right
Electrical supply: 240V - 50Hz fused at 3A
Data label: Bottom of inner case door.
Injector: 40C - Cat 98 - 1150

The Seasonal Efficiency Domestic Boilers UK (SEDBUK)
is 71.9%.

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.

2

1.5 Range Rating

The boiler is range rated and may be adjusted to suit individual
system requirements.

The respective Table 1 gives the ratings and settings.

5

221461C

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1 General Data

1.6 B.S.I. Certification

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

Any alteration that is not approved by Hepworth Heating Ltd.,
could invalidate the B.S.I., certification of the boiler, the warranty
and could also infringe the current issue of the Statutory

1.7 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 suitable leak detection fluid, purge
in accordance with the current issue of BS6891.

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

Wiring to the boiler must be insulated PVC flexible type to the
current issue of BS6500 Table 16, not less than 0.75mm

0.20mm).

2

(24/

1.12 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.

1.13 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.

B

0003M

1.9 Draining Tap

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

Draining taps shall be to the current issue of BS2879.

1.10 Safety Valve

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

1.11 Clearances

The boiler position should be such that the clearances shown in
diagram 1.2 are achieved.

Additional clearances may be required for installation.
If fixtures are positioned next to the boiler they should be made

removable for access to pipework.
Sufficient clearance must be left in front of the boiler for

servicing.
The casing side grilles must be kept clear at all times.
The boiler must be mounted on a flat wall which is sufficiently

robust to take its weight.

300

518

232

Minimum Clearances
from Walls, Ceiling,
Floor, Cupboard, Worktops etc.

Boiler
Outline

46

200 200

A L.H. and R.H. side of casing 25
B Top of casing 75
C Bottom of casing 150
D Front of boiler (from a

permanent surface) 305

BOILER FIXING DIMENSIONS
AND MINIMUM CLEARANCES

Minimum
clearance
limit

A

C

Diagram 1.2

221461C

6

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2 Flue and Ventilation

Important note

The boiler is fitted with a Flue Blockage Safety Device, which
will shut down the boiler if there is an unacceptable spillage of
products at the draught diverter.

This safety device MUST NOT under any circumstances be
interferred with or put out of action.

The safety device must only be replaced with the Glow-worm
parts.

2 Flue Connection

The integral draught diverter on the boiler makes the combustion
performance independent of the conditions in the secondary
flue, but in common with other fuels an efficient flue is necessary
to ensure a trouble free installation.

The flue outlet on the boiler is designed to take flue pipes to
BS567. If a flue pipe to BS715 is to be used an adapter must
be fitted to the boiler flue socket.

The flue must be in accordance with the current issue of
BS5440 Part 1.

Give maximum possible vertical rise from the boiler, at least a
minimum of 600mm, before any offset or bend. The use of 90
bends is not recommended.

An existing flue must be lined and end, at least above ridge
height, with a certificated terminal.

A chimney previously used for solid fuel must be swept and any
damper or register plate left in the locked open position or
removed.

2.1 Boilers in a Compartment

Where the installation of the boiler will be in an unusual location,
special procedures are necessary, the current issue of BS6798
gives detailed guidance on this aspect.

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

An existing cupboard or compartment modified for the purpose
may be used. Details of essential features of cupboard or
compartment design are given in the current issue of BS6798.

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

Where the boiler is fitted in a cupboard or compartment,
permanent high and low level ventilation must be provided.

The minimum ventilation areas required are given in Table “A”.

2.2 Boiler Installed in a Room or Space

A purpose designed ventilation opening must be provided on an
outside wall of the premises, refer to the current issue of
BS5440 Part 2 for further information.

The opening may be either, directly into the room or space
containing the boiler or into an adjacent room or space which
has an internal permanent air vent of the same size as the room
containing the boiler.

DO NOT ventilate through a private garage, bedroom, bedsitting
room or a room containing a bath or shower.

Air vents through a cavity wall must be ducted.
When the boiler is installed in a space already containing a fuel

burning appliance account must be taken of the TOTAL air
requirement.

2.3 Extract Fans

If an extract fan is fitted in the premises there is a possibility that
if adequate air openings are not provided spillage of products
from the boiler may occur.

When openings are fitted in accordance with the
recommendations of the current issue of BS5440 Part 1 and this
Section, extract fans should not cause spillage, but where such
an installation is found spillage tests as the current issue of
BS5440 Part 1 must be carried out.

The necessary action should then be taken.
See also Section 6.6.

o

TABLE "A" COMPARTMENT AIR VENTS

ECONOMY PLUS 40C

Ventilation
Requirements

Air from room or
internal space

Air direct from
outside

TABLE "B" ROOM/SPACE AIR VENTS

ECONOMY PLUS 40C

Effective area
of vent

Table 1 ECONOMY PLUS 40C

Range Rating
Nominal kW

Heat
Input (GROSS)

Btu/h

Nominal kW
Heat
Output

Btu/h

Burner m bar
Setting
Pressure

in.w.g

Burner Injector Marking: 1.25
Burner Injector Size: 1.25 X 7
Pilot Injector Marking: 7218

High Level

Vent Area

132cm

66cm

2

2

35cm

Low Level
Vent Area

264cm

132cm

2

min medium max

11.14 12.90 14.65

38,000 44,000 50,000

8.80 10.26 11.70

30,000 35,000 40,000

7.8 10.4 13.1

3.1 4.2 5.3

2

2

7

221461C

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3 Water Systems

GALLONS/MINUTE

LITRES/MINUTE

FUELSAVER 40C

WATER PRESSURE LOSS

(m head of water)

WATER PRESSURE LOSS

(in head of water)

0

1

24

35

0

5

10

15 20 25

55
50
45
40
35
30
25
20
15
10
5
0

1.4

1.2

1.0

0.8

0.6

0.4

0.2
0

6927

Notes:
PUMP
The pump with integral valves, if possible, should be fitted in the

flow pipework from the boiler, to produce a temperature difference
across the boiler of 11

See diagram 3.1 for pressure loss across the boiler.
High resistance microbore systems may require a higher duty

pump.
BYPASS
A bypass
The flow through the boiler must not be allowed to fall below:
40C - 10.5L/min (2.3gall/min)
whilst the burner is alight.

must be fitted, see diagram 3.2.

3.1 Open (Vented) Water System

For an open (vented) water system the boiler must be supplied
from an unrestricted water supply taken from a cold feed and
expansion cistern situated at a maximum height of 27.5 metres
(90ft) above the boiler.

The cold feed supply must be 15mm minimum size.
It is important that the relative position of the pump, cold feed

and open vent are as shown in diagram 3.2.

3.2 Domestic Hot Water Cylinder

The domestic hot water cylinder must be of the double feed, fully
indirect type. Single feed, self priming cylinders are not
recommended.

3.3 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 a manufacturer for their
recommendations for the best product to use.

When installing a boiler in an existing system, whether or not
using an inhibitor, take special care to drain the entire system,
including the radiators, then thoroughly cleaning out before
fitting the boiler and adding the inhibitor.

3.4 Sealed Water Systems

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

See diagram 3.3 for a diagrammatic layout.

3.5 Safety Valve

A safety valve must be fitted to a sealed water 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.

221461C

o

C (20oF).

PRESSURE LOSS OF BOILER

8

450mm
MIN.
HEIGHT

1150mm
MIN.

150
mm
MIN.

BOILER

Open (vented) system.
Recommended
relationship between
pump, cold feed and
vent.

22 mm (MIN) VENT

FEED AND
EXPANSION
CISTERN

15mm (MINIMUM)
COLD FEED

15mm (MINIMUM)
BY-PASS WITH
LOCKSHIELD VALVE

ALTERNATIVE

PREFERRED

PUMP

150mm
MAX

Diagram 3.1

RET.

CYLINDER

Diagram 3.2

0392

FLOW

RET.

HEATING

FLOW