Glow-worm Ultimate 40BF User Manual

Instructions for Use

Installation and Servicing

To be left with the user

40BF

G.C. No. 41 319 52

221789B.11.00

3790

Balanced 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

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.

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 0208 247 9857

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

Nottingham Road, Belper, Derbyshire. DE56 1JT

Tel: [phone] Fax: [phone]

Hepworth Heating Ltd.,

General/Sales enquiries:

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 1.4.

CE Mark

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

Type test for purposes of Regulation 5 certified by: Notified body 0086.
Product/productioncertifiedby: Notified body 0086.
The CE mark on this appliance shows compliance with:

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

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

3. Directive 89/336/EEC on the approximation of the Laws of the Member States relating to electromagnetic compatibility.

INFORMATION FOR THE INSTALLER AND SERVICE ENGINEER.

Under Section 6 of The Health and Safety at Work Act 1974, we are required to provide information on substances hazardous to
health.

CERAMIC FIBRE/INSULATION PADS, GLASSYARN.

These can cause irritation to skin, eyes and the respiratory tract. If you have a history of skin complaint you may be susceptible to
irritation. High dust levels are usual only if the material is broken. Normal handling should not cause discomfort, but follow normal
good hygiene and wash your hands before eating, drinking or going to the lavatory. If you do suffer irritation of the eyes or severe
irritation to the skin seek medical attention.

CONTROL THERMOSTATS

These contain very small amounts of dichlorotrifluroethane 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.

CONTENTS DESCRIPTION SECTION PAGE No.

INSTRUCTIONS

FOR USE

INSTALLATION

INSTRUCTIONS

Introduction 3
Lighting the Boiler 4

General Data 1 5
Flue & Ventilation 2 7
Water Systems 3 9
Flue and Appliance Preparation 4 11
Boiler Installation 5 13
Commissioning 6 17
Instructions to User 7 18

SERVICING

INSTRUCTIONS

221789B

Servicing 8 19
Fault Finding 9 21
Replacement Parts 10 24
Spare Parts 11 27

2

Instructions for Use

Introduction

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

The Ultimate BF series are central heating boilers designed to
provide heating and indirect domestic hot water.

Important Notice

This boiler is for use only on G20 gas.

The Gas Safety (Installation and Use)
Regulations

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

Gas Leak or Fault

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

Maintenance

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

If this 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 any servicing be carried out by a competent
person.

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

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.

Cleaning

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

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

Do not use an abrasive cleaner.

Protection Against Freezing

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

100mm

6mm

500mm

65mm

6mm

Diagram 1

Data Label

The serial number and GC number of the boiler can be found on
the Data Label, see diagram 2.

Boiler Clearances

If fixtures are positioned close to the boiler space must be left as
shown in diagram 1. Enough space must also be left in front of
the boiler to allow for servicing.

Boilers Installed in a Compartment or
Cupboard

If the boiler is installed in a compartment or cupboard do not
obstruct any ventilation openings.

Do not use the compartment or cupboard for storage.

Boiler Electrical Supply

WARNING. This boiler must be earthed.
The boiler must only be connected to a 230V~50Hz supply

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

BS7671.
Wiring to the boiler must be PVC insulated type to the current

issue of BS6500 Table 16, not less than 0.75mm
The colours of 3 core flexible cable are:­Brown - live, Blue - neutral, Green and yellow - earth.
As the markings on your plug may not correspond with these

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

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

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

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

2

(24/0.20mm).

3864

.

3

221789B

Instructions for Use

To Light The Boiler

WARNING. If the pilot flame goes out, either intentionally or by
accident, no attempt should be made to relight it for at least
three minutes.

Identify the controls by reference to the diagram 2.
Switch off the electrical supply to the boiler.
Turn the control thermostat knob “B” fully anti-clockwise to the

“O”, Off position.
Push in control button “D”, keep pressed in and at the same time

operate the piezo button “A” until the pilot lights, look through
viewing window “E”. After the pilot lights keep the control button
“D” pushed in for 20 seconds. If the pilot fails to stay alight a
safety device prevents immediate relighting.

Do not attempt to relight until the safety device has reset, that
is, for at least three minutes.

Switch on the electrical supply and check that all external
controls are calling for heat.

Turn the control thermostat knob “B” clockwise to any position
between “MIN” and “MAX” and the burner will light.

o

The maximum setting is about 82
The above sequence must be repeated every time that the

burner has to be relit.

C (180oF).

To Turn the Boiler Off

For short periods, turn the control thermostat knob “B” fully anti­clockwise to “O” Off. To relight, turn control thermostat knob
clockwise to any position between “MIN” and “MAX”.

For longer periods, turn the control thermostat knob “B” fully
anti-clockwise to “O” Off and slide multi-functional control
button “D” to the left, it will automatically reset. Switch off the
electrical supply to the boiler.

To relight, follow the full lighting sequence given above.

A PIEZO UNIT BUTTON
B THERMOSTAT CONTROL KNOB
C GAS SERVICE COCK

(shown in off position)

D CONTROL BUTTON (GAS)
E VIEWING WINDOW

8042

E

C

221789B

AB

DATA LABEL

D

4

Diagram 2

1 General Data

F

A

C

B

SS

NN

M

D

RETURN

FLOW

GRAVITY

SIDE ELEVATION

22mm COPPER PIPE
GAS CONNECTION RC

OVERALL DIMENSIONS (given in millmetres)

MODELS

40BF

ABCDEFLMNPR S

75 297 132 398 700 360 574 35 87 131 60 139

Important Notice

This boiler is for use only on G20 gas.
All dimensions are given in millimetres (except as noted).
This boiler can be used only on an open vented system, with

either gravity or pumped domestic hot water connections to the
indirect cylinder.

Wherever possible, all materials, appliances and components
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 boiler care should
be taken when handling sheet metal parts, to avoid any possibility
of personal injury.

1.1 Statutory Requirements

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

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

Building Regulations, The Building Standards (Scotland)
Regulations (applicable in Scotland), Local Water Company
Bye-laws, The Health and Safety at Work Act, Control of
Substances Hazardous to Health, The Electricity at Work
Regulations and any local regulations which may apply.

C

L

E

PUMPED

PUMPED

GRAVITY

FLOW

RETURN

P

FRONT ELEVATION

1

/2 (1/2 in. BSPT.)

Diagram 1.1

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

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

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

1.2 Data

See Table 1
The Seasonal Efficiency Domestic Boilers UK (SEDBUK)

is 72.1%.
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 Range Rating

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

Table 2 gives the ratings and settings.

1.4 B.S.I. Certification

This boiler is certificated to the current issue of British Standard
6332 Part 1, invoking the current issue of BS5258 Part 1 for
performance and safety. It is, therefore, important that no
alteration is made to this 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, warranty
and could also infringe the current issue of the Statutory
Requirements.

L

R

5

221789B

1 General Data

1.5 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 boiler.

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

1.6 Electrical Supply

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

comply with and be connected in accordance with 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 must be by a fused
double pole isolating switch, with a minimum contact separation
of 3mm on both poles. The switch should be readily accessible
and preferably adjacent to the appliance. It should supply the
appliance only and be easily identifiable as so doing.

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

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

2

(24/0.20mm).

1.7 Contents of Packaging

There are two packs, one contains the boiler, refer to Section 4.1
for contents.

The other pack contains the balanced flue terminal assembly,
wall duct and flue hood assembly.

Refer to Section 2.3 to check that the flue terminal assembly
supplied is suitable.

DATA TABLE 1.

TOTAL DRY

WEIGHT

(Including
Terminal)

LIFT WEIGHT

WATER
CONTENT

GAS
CONNECTION

WATER
CONNECTION

ELECTRICITY
SUPPLY

DATA LABEL

RANGE RATING

NOMINAL
HEAT
INPUT(GROSS)

NOMINAL
HEAT
OUTPUT

BURNER
SETTING
PRESSURE

APPROX
GAS
RATE

m bar

44.5kg
(98lb)

34kg
(75lb)

2.35Litre
(0.52gal)

1

/2 in.

Rc

4 x 22mm copper pipes from

top of case

230V~50Hz, fused 3A.

Bottom right hand side of case

TABLE 2.

min medium max

kW

Btu/h

kW

Btu/h

11.13 12.90 14.65

37,980 44,000 50,000

8.79 10.26 11.72

30,000 35,000 40,000

8.1 10.8 13.6

in.w.g

m3/h

ft3/h

3.3 4.3 5.5

1.07 1.25 1.42
38 44 50

1.8 Water System

This boiler shall only be used on an unrestricted open vented
system with the water supply taken from a feed and expansion
cistern having a head of 27m (90ft) maximum.

This boiler must not be connected to a sealed water system.

1.9 Drain
System

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

Draining taps should be to the current issue of BS2879.

Boiler

A draining point is fitted at the bottom right hand side of the heat
exchanger. Cover controls to avoid water damage. If required
remove the combustion chamber front cover to improve access.

BURNER INJECTOR MARKING: 205708

PILOT INJECTOR MARKING: 7215

1.10 Safety Valve

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

1.11 Location

This boiler is not suitable for outdoor installation.
This boiler may be installed in any room, although particular

attention is drawn to the requirements of the current issue of
BS7671 with respect to the installation of a boiler in a room
containing a bath or shower. Any electrical switch or boiler
control utilising mains electricity should be placed so that it
cannot be touched by a person using the bath or shower.
The electrical provisions of the Building Standards (Scotland)
Regulations apply to such installations in Scotland.

The boiler must be mounted on a flat wall which is sufficiently
robust to take its total weight.

221789B

6

1 General Data

500mm

Additional clearance may be

required for installation

65mm

100mm

6mm

6mm

FRONT VIEW

TOP VIEW

1.12 Boiler Clearances

Refer to diagram 1.2.
This boiler must be positioned so that at least the minimum

operational and servicing clearances are provided.
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.

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.

3792

2 Flue and Ventilation

Note: Detailed recommendations for flues are given in the
current issue of BS5440 Part 1.

2.1 Terminal Position

The minimum acceptable siting dimensions for the terminal
from obstructions, other terminals and ventilation openings are
shown in diagram 2.1.

The terminal must be exposed to the external air, the position
allowing free passage of air across it at all times.

Car ports or similar extensions of a roof only, or a roof and one
wall, require special consideration with respect to any openings,
doors, vents or windows under the roof. Care is required to
protect the roof if it is made of plastic sheeting. If the car port
consists of a roof and two or more walls, seek advice from the
local gas company before installing the boiler.

If the terminal is fitted within 600mm below plastic guttering or
painted soffit an aluminium shield 1500mm long should be fitted
immediately beneath the guttering or eaves. If the terminal is
fitted within 450mm below painted eaves or a painted gutter, an
aluminium shield 750mm long should be fitted immediately
beneath the guttering or eaves.

2.2 Terminal Guard

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

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

Diagram 1.2

A suitable guard, reference Type “F”, can be bought from:-

Tower Flue Components Ltd
Morley Road
Tonbridge
Kent. TN9 1RA

2.3 Wall Thickness

Check the thickness of the wall.
Flues available are:­Standard Pack:- 40BF Part No.446202
Extension Pack:- Part No.424680 plus
Standard Pack as above for 410 to 625mm (16 to 25in)
Note: If the wall thickness is less than 280mm the wall duct and

flue ducts can be cut down, to a minimum length of 100mm.

2.4 Room Ventilation

The boiler is room sealed and does not require the room or
space containing it to have permanent air vents.

7

221789B

2 Flue and Ventilation

2.5 Boilers in a Compartment

Where the installation of the boiler will be in an unusual position,
special requirements are needed, the current issue of BS6798
gives detailed guidance on these requirements.

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 requirements for 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 3.

2.6 Timber Frame Building

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.

COMPARTMENT AIR VENT TABLE

COMPARTMENT
VENTILATION
REQUIREMENTS

HIGH LEVEL LOW LEVEL

VENT AREA VENT AREA

VENTILATION
FROM ROOM

132cm220in2132cm220in

OR SPACE
FROM

OUTSIDE

A

A

F

G

65cm2 10in2 65cm2 10in

B,C

G

A

E

G

F

G

B,C

K

2

2

3815A

C

K

L

L

F

K

G

Under Car Port etc.

J

H,I

MINIMUM SITING DIMENSIONS FORBALANCED FLUE
TERMINALS

POSITION SPACING (mm)

A DIRECTLY BELOW AN OPENABLE

WINDOW, AIR VENT, OR ANY OTHER

VENTILATION OPENING 300
B BELOW GUTTER, DRIAN/SOIL PIPE 300
C BELOW EAVES 300
D BELOW A BALCONY OR CAR PORT 600
E FROM VERTICAL DRAIN PIPES AND

SOIL PIPES 75
F FROM INTERNAL OR EXTERNAL

CORNERS 250
G ABOVE ADJACENT GROUND OR

BALCONY LEVEL 300
H FROM A SURFACE FACING THE

TERMINAL 600
I FACING TERMINALS 600
J FROM OPENING (DOOR/WINDOW) IN

CAR PORT INTO DWELLING 1200
K VERTICAL FROM A TERMINAL 1500
L HORIZONTALLY FROM A TERMINAL 300

K

MINIMUM

Diagram 2.1

D

F

221789B

8

3 Water Systems

The installation of the boiler must comply with the requirements
of the current issue of BS6798.

3.1 Frost Protection

If the position of the boiler is such that it may be vulnerable to
freezing it should be protected as specified in the current issue
of BS5422. It is recommended that a frost protection thermostat
be fitted.

3.2 Pump

The pump, with integral valves, should be fitted in the heating
flow pipework from the boiler, it should be set to produce a
temperature difference of 11oC (20oF), between the flow and
return, with the control thermostat set at “MAX”, which is about
82oC (180oF).

The resistance through the boiler can be found from diagram 3.1.
High resistance microbore systems may require a higher duty

pump.

3.3 Bypass - Fully Pumped Water System

A bypass is usually unnecessary on systems using a 3 port
diverter valve since one port will remain in the open position at
all times. This allows satisfactory operation of the pump
overrun.

However if thermostatic radiator valves are fitted to all radiators
or two port valves are used a bypass is required.

The bypass connection must be at least 2 metres away from the
boiler.

The flow through the boiler must not be allowed to fall such that
there is a temperature difference greater than 20
flow and return.

o

C between the

OPEN VENTED FULLY PUMPED WATER SYSTEM
RECOMMENDED RELATIONSHIP BETWEEN
PUMP COLD FEED AND VENT

22mm VENT
450mm
MIN.
HEIGHT

FEED AND
EXPANSION
CISTERN

1150mm
MIN.

There must always
be a cold water path
to the return
connection
of the boiler.

BOILER

(MIN.)

15mm (MINIMUM)
COLD FEED

RETURN

PUMP

150mm
MAX.

IF REQUIRED
15mm (MINIMUM)
BY-PASS WITH
LOCKSHIELD VALVE

FLOW

CYLINDER

RET.

Diagram 3.2

6455

FLOW

HEATING

3.4 Water System

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

and open vent are as shown in diagram 3.2.
The unrestricted open vent from the boiler must rise continuously

to discharge over the feed and expansion cistern.

1000

750

500

(mm head of water)

Water pressure loss

PRESSURE LOSS OF BOILER

250

0

51015

0

20 25

30

Flow rate (litres/minute)

Diagram 3.1 Diagram 3.3

3794

28mm
PIPE

COMPRESSION

4632

JOINT

1m MIN.
27m MAX.

FLOW (GRAVITY)

RETURN

22mm
PIPE

28mm

VIEWED
FROM
FRONT

FLOW

28mm
PIPE

RETURN (GRAVITY)

22mm
PIPE

Note: When cutting leave
sufficient length for fittings

22mm VENT
15mm COLD FEED
INDIRECT CYLINDER

(Shown with
recommended
thermostat and valve)

HEATING
SYSTEM

PUMP

REFER TO BS5546

9

221789B