Glow-worm Ultimate 40CF User Manual

Instructions for Use

Installation and Servicing

To be left with the user

40CF

G.C. No. 41 319 48

221785B.11.00

2143

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 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]

Hepworth Heating Ltd.,

Nottingham Road, Belper, Derbyshire. DE56 1JT

General/Sales enquiries:

Tel: [phone] Fax: [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 1.4.

CE Mark

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.

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.

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.

CONTENTS DESCRIPTION SECTION PAGE No.

INSTRUCTIONS

FOR USE

INSTALLATIONS

INSTRUCTIONS

Introduction 3
Lighting the Boiler 4

General Data 1 5
Flue & Ventilation 2 6
Water Systems 3 7
Installation 4 8
Electrical Connection 5 10
Commissioning 6 11
User Information 7 13

SERVICING

INSTRUCTIONS

221785B

Servicing and Replacement Parts 8 13
Fault Finding 9 17
Spare Parts 10 20

2

Instructions for Use

Introduction

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

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

Important Notice

This boiler is for use only on natural gas G20.

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 competent person in accordance
with the current issue of the above 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 the 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 control 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.

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.

The convection air openings on top of the boiler must never
obstructed.

Boiler 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.

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

Do not use an abrasive cleaner.

Boiler Electrical Supply

Warning. This boiler must be earthed.
The boiler must be connected to a 230V~50Hz supply, protected

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

BS7671.
Cables, PVC insulated type, to the current issue of BS6500

Table 16, 0.75mm
the boiler up.

6mm

WORKTOP

2

(24/0.20mm) only may be used to connect

260mm

Additional clearances may
be required for installation

108mm

6mm

100mm

915mm

TO
FLOOR

2166

Diagram 1

3

221785B

Instructions for Use

Connecting an Electrical Plug

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” or Green or the earth symbol

.

Safety Device

The boiler is fitted with a flue blockage safety device which will
shut it down if there is a problem with the chimney. 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 shown in diagram 2.

Shut down can occur during certain climate conditioned, 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.

Any problems found must be put right, by a competent person,
before the boiler is used again.

To Turn the Boiler On

Turn the electrical supply on to the boiler and check that any
remote controls are set to your requirements (refer to
manufacturer’s instructions supplied with these items).

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.

Slide to controls cover off and clear.
Identify the controls by reference to diagram 2.
Switch off the electrical supply to the boiler.
Check that the flue blockage safety device has not operated,

that is, the button is in. Refer to Safety Device instructions.

Turn thermostat knob “B” faulty anticlockwise to the “O” Off
position.

Push in control knob “D”, keep pushed in, push and release
piezo button “A” until the pilot lights.

Look through window “E”.
After the pilot burner lights keep the button pushed in for about

20 seconds. Check that the pilot is alight and stable, look
through window “E”. If the pilot burner fails to stay alight, wait
3 minutes before repeating the lighting operation.

The safety device may also need resetting, refer to the
instructions above.

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

Turn thermostat control knob “B” to a setting between “MIN” and
“MAX” and the main burner will light.

o

“MAX” is about 82
The above sequence must be carried out every time that the

burner is relit.
Check that all external controls are calling for heat.

C (180oF).

To Turn the Boiler Off

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

For longer periods, turn the thermostat knob fully clockwise to
“O” Off. Slide the gas control button “D” inward and release, see
diagram 2. Switch off the electrical supply to the boiler.

To relight, follow the full lighting sequence given above.

Protection Against Freezing

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

The serial number and GC number of the boiler can be found on
the data label.

221785B

A PIEZO UNIT BUTTON
B THERMOSTAT CONTROL KNOB
C GAS SERVICE COCK (SHOWN IN OFF POSITION)

E

A

DATA LABEL

D CONTROL BUTTON (GAS)
E VIEWING WINDOW
F FLUE BLOCKAGE SAFETY DEVICE

RESET BUTTON

FB

C

4

D

Diagram 2

8043

B

K

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

R

E

M

0020M

S

0020M

A

F

GAS CONNECTION RC

C

L

D

C

H

1

/2 (1/2 in. BSPT)

FLUE

GENERAL DIMENSIONS (all dimensions in mm)

MODEL

40CF

ABC D EF H K L M NR S

764 265 168 213 149 24.5 39 115 741 417 640 345 23

1 General Notes and Information

This boiler is for use on natural gas G20.
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.

This boiler is not suitable for use out of doors.

C

L

L

WATER CONNECTION RC1 (1in. BSPT)

N

Diagram 1.1

1.4 BSI Certification

The boiler is certificated to the current issue of BS6332 Part 1,
invoking the current issue of BS5258 Part 1 for performance
and safety. It is, therefore, important that no alteration is made
to the boiler 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 also infringe the current issue of the Statutory
Requirements.

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.

1.1 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, Local Water Company Byelaws, The

Building Standards (Scotland) Regulations (applicable in
Scotland), 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:

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

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

1.3 Range Rating

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

The respective Table 1 gives the ratings and settings.

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.

1.2 DATA

WEIGHT

(approx)

WATER
CONTENT

GAS
CONNECTION

WATER
CONNECTION

ELECTRICITY
SUPPLY

DATA
LABEL

On right hand side of electrical

45.0 kg
(99.0lb)

5.6 litres

(1.23 gal)

Rc 1/

2

Rc1

230V~50Hz, fused 3A

control box

5

221785B

1 General Data

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

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 should be through a common isolator fused at 3A,
maximum. This method of connection should be by a switched
spur box with a minimum contact separation of 3mm in both
poles. It should be clearly marked, showing its purpose,
preferably positioned close to the boiler.

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

Wiring to the boiler must be PVC insulated cable at least

0.75mm

2

(24/0.20mm) to the current issue of BS6500 Table 16.

1.7 Contents of Packaging

The boiler is delivered in one pack which contains:
Boiler with outer case and wall frame, side panels, burner,

combustion chamber shield, flueway baffle and loose items
pack.

The boiler must not be installed in a room used or intended to
be used as sleeping accommodation or a room containing a
bath or shower.

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

1.12 Boiler Clearances

Refer to diagram 4.4.
The 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.

1.13Heating 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.

1.8 Water System

The boiler shall only be used on an unrestricted open vented
system with the water supply taken from a feed and expansion
tank, having a head between 1m (3ft 3in) minimum and 27m
(90ft) maximum.

1.9 Draining Tap

A draining tap must be provided at the lowest point of the system
which will allow the entire system, the boiler and 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 Location

WARNING. Open flue boilers must not be installed in a private
garage.

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
interfered with or put out of action.

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

2.1 Flue Connection

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

TABLE 1

ULTIMATE 40CF RANGE RATING

RANGE RATING
NOMINAL

kW

HEAT INPUT
(GROSS)

NOMINAL

Btu/h

kW

HEAT
OUTPUT

BURNER

Btu/h
mbar

SETTING
PRESSURE

APPROX.

in.w.g

m3/h

GAS
RATE

ft3/h

INJECTOR
MARKING

COMPARTMENT AIR VENT TABLE 2.

ULTIMATE 40CF

COMPARTMENT
VENTILATION
REQUIREMENTS

FROM ROOM
OR SPACE

FROM
OUTSIDE

HIGH LEVEL LOW LEVEL
VENT AREA VENT AREA

140cm222in2278cm244in

70cm211in2139cm222in

Min.

11.69 15.36

39,900 52,400

8.79 11.72

30,000 40,000

8.1 14.2

3.3 5.7

1.13 1.47
40 52

BURNER :- FF2029

PILOT :- 7215

Max.

2

2

221785B

6