Glowworm 40 GC 41 319 20 Versionshinweis

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COSHH

220677A.05.95

40GC No. 41 319 20 55GC No. 41 319 19

To be left with the user

Installation & Servicing Instructions

4746

Hepworth Heating Ltd.,

Nottingham Road, Belper, Derbyshire. DE56 1JT

General/Sales enquiries:

Tel: (01773) 824141 Fax: (01773) 820569

One Contact Total Service

Customer Services:

Tel: (01773) 828100

Fax: (01773) 828070

Fanned Flue Sealed System Boiler

Reference 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.

This is a Cat I 2H appliance

BS 6332

BS 5258

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220677A

1 General

3130

108

450

161

783

174

321

101

783

346 66

2.5

SAFETY

VALVE

DISCHARGE

All dimensions in millimetres

KEY:

22mm COMPRESSION

CENTRAL HEATING

(

in. BSPT)

GAS CONNECTION

STD FLUE TERMINAL = 63

LONG FLUE TERMINAL = 61

OVERALL DIMENSIONS Diagram 1.1

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,

The Electricity at Work Regulations, 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,

BS4814, BS5440 Part 1 and 2, BS5449, BS5546,

BS6700, BS6798, BS6891, BS7074 Part 1 and 2,

BS7478, BS7593, BS7671.

Manufacturer’s instructions must not be taken as

overriding statutory requirements.

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,

the warranty and could also infringe the current issue of

the Statutory Requirements.

The instructions consist of two parts, Installation and

Servicing and Instructions for Use. They are the

property of the user and must be handed to them on

completion of the installation.

1.1 Important Notices

This boiler is for use on natural gas (G20) as distributed

in the United Kingdom and Ireland and cannot be used

on any other 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.

This boiler is not suitable for use out of doors.

THIS BOILER IS FOR USE ONLY IN A SEALED

WATER SYSTEM.

It can be used to provide domestic hot water from a

vented or unvented domestic system.

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 the boiler MUST be carried out by a

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1 General

CE Mark

The CE mark on this appliance shows compliance with

Directive 90/396/EEC on the approximation of the Laws

of the Member States relating to appliances burning

gaseous fuels.

The CE mark on this appliance shows compliance with

Directive 73/23/EEC on the harmonization of the Laws

of the Member States relating to equipment designed for

use within certain voltage limits.

1.5 Range Rating

The boiler is range rated and is factory preset to

maximum, but may be adjusted to suit individual system

requirements, refer to Range Rating, Table 2.

1.6 Equipment

The boiler is supplied with an integral expansion vessel,

circulating pump, safety valve, pressure gauge, low

water pressure warning light, automatic bypass valve,

gas cock and valved water connections (with drain

points).

Data Label

The data label is positioned on the inner case cover.

Appliance Data refer to Table 1

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 and wiring shall be of the

approved type and comply with and be connected in

accordance with the requirements of 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. The method of connection

should be, preferably, by a fused double pole isolating

switch, provided it 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.

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 to the current to the of

BS6500 Table 16.

MODEL

DATA TABLE 1

LIFTING

WEIGHT

Rc 1/2(

in. BSPT)

GAS

CONNECTION

WATER

CONNECTION 22mm copper,

return at right, flow at left

135W, internal fuse F1A

ELECTRICITY

RATING

WATER

CONTENT

TOTAL

WEIGHT

240V~50Hz fused 3A

ELECTRICITY

SUPPLY

DATA LABEL On the inner case front

40 55

0.62 litre 0.62 litre

(0.136 gal) (0.136 gal)

33.3kg 33.3kg

(73.4lb) (73.4lb)

47.8kg 47.8kg

(105.4lb) (105.4lb)

RANGE RATING

NOMINAL

Btu/h

HEAT

INPUT

NOMINAL

Btu/h

HEAT

OUTPUT

BURNER

m bar

SETTING

PRESSURE

in.w.g

APPROX

GAS

RATE

TABLE 2.

Complheat 55

50,500 59,750 68,000

14.8 17.5 19.9

40,000 47,500 55,000

11.7 13.9 16.1

7.9 11.4 14.5

3.2 4.6 5.8

1.4 1.7 1.9

49.8 58.9 67.8

min mid max

RANGE RATING

NOMINAL

Btu/h

HEAT

INPUT

NOMINAL

Btu/h

HEAT

OUTPUT

BURNER

m bar

SETTING

PRESSURE

in.w.g

APPROX

GAS

RATE

TABLE 2.

Complheat 40

38,200 44,000 49450

11.2 12.9 14.5

30,000 35,000 40,000

8.8 10.3 11.7

7.6 10.3 13.3

3.1 4.1 5.3

1.0 1.2 1.4

37.7 43.4 49.3

min mid max

INJECTOR

SIZE 3.1mm 3.6mm

220377B

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2 Water System

Diagram 2.2

WATER SYSTEM

DIAGRAMATIC LAYOUT

2.1 General Notes

The installation of the boiler must comply with the

requirements of the current issue of BS6798.

2.2 Safety Valve

The safety valve, preset at 3bar, is an integral part of the

boiler and cannot be adjusted.

2.3 Pressure gauge

A pressure gauge is incorporated into the boiler to

indicate the system pressure.

2.4 Circulating Pump

The circulating pump is integral with the boiler.

The remaining conveying capacity of the pump is shown

in diagram 2.1.

2.5 Expansion Vessel

The boiler has an integral expansion vessel with a

capacity of 8Litres (1.76 gallons), with a charge pressure

of 0.75bar.

The maximum heating system water content using the

fitted expansion vessel ranges from 119litres with a cold

fill pressure of 0.7bar, to 98litres with a cold fill pressure

of 1.05bar. If, due to a high static head, the cold fill

pressure is higher, then the expansion vessel pre-fill

pressure must be increased, and the maximum system

volume decreased, see the current issue of BS7074

Part 1.

Further information can be obtained from the British Gas

Publication “British Gas Specification for Domestic Wet

Central Heating Systems” and the current issue of

BS4814, BS5449 and BS7074 Part 1 and 2.

2.6 Flow Rate

A valve must be incorporated in the main flow or return

of the system, valve “A” shown in the flow diagram 2.2.

This valve must be lockable and be positioned so that

inadvertent closure or unauthorised interference is not

possible. The design differential is 11oC (20oF) with the

boiler thermostat set at “MAX” which is about 82oC

(180oF). The pump adjuster should always be left at

maximum (3).

2.7 Bypass

An automatic bypass valve is incorporated in the boiler

pipework it is preset and must not be adjusted.

Diagram 2.1

3131

3 LITRES

MAKE-UP

BOTTLE

(if required)

NON-RETURN

VALVE

AUTO

AIR

VENT

'A'

ADDITIONAL

EXPANSION

VESSEL

(if required)

DRAIN

COCK

BOILER

RETURN

FLOW CONTROL

VALVE

FILLING

POINT

HEATING

CIRCUIT

REMAINING CONVEYING

CAPACITY OF PUMP

WATER FLOW RATE

AT 110C (200F) DIFFERENTIAL

UNIT 40 55

litre/min. 15.3 21.0

gal/min. 3.4 4.6

3.0

2.4

1.8

1.2

0510 15 20 25 30

Flow rate (litres/minute)

Available pump head (Ft)

0.6

3.6

01.1 2.2 3.3 4.4 5.5 6.6

Flow rate (gallons/minute)

Available pump head (m)

Nominal flow rate

for 11

C differential

3131/B

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2 Water Systems

Diagram 2.3

FILLING SEALED

WATER SYSTEMS

2.8 Water Make Up

Provision should be made for replacing water lost from

the system using a make up bottle mounted in a position

higher than the top point of the system, connected

through a non-return valve to the return side of the

heating circuit, see diagram 2.2.

Alternatively, provision for make up can be made using

a filling loop.

2.9 Filling Sealed Water Systems

Provision for filling the system at a low level must be

made.

Three methods of filling are shown in diagram 2.3.

There must be no permanent connection to the mains

water supply, even through a non-return valve.

2.10 Corrosion 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 in the system, contact a

manufacturer for their recommendations.

2.11 Existing Systems

When fitting the boiler into an existing system, special

care should be taken to drain the entire system, including

radiators, then thoroughly cleaning out before fitting the

boiler whether or not adding an inhibitor.

2.12 Draining Tap

A draining tap must be provided at the lowest points of

the system, which will allow the entire system to be

drained. An additional draining tap MUST be fitted

close to the boiler.

Draining taps must be to the current issue of BS2879.

The flow and return isolating valves on the boiler are

fitted with drain points for heat exchanger draining.

2.13 Domestic Hot Water System

General

The domestic hot water service must be in accordance

with the current issue of BS5546, refer also to the

current issue of BS6700.

2.14 Domestic Hot Water Cylinder

SINGLE FEED INDIRECT CYLINDERS ARE NOT

SUITABLE AND SHOULD NOT BE USED.

The domestic hot water cylinder must be of the indirect

coil type. It must be suitable for a working at a gauge

pressure of 0.35bar above the safety valve setting.

2.15 Domestic Hot Water System -

Unvented

Where a storage system will not have a vent to

atmosphere the installation must comply with Building

Regulations and local Water Company bye-laws, see

also the current issue of BS6700.

If fitting into an existing system the local authority must

be informed.

2819

METHOD 1

METHOD 2

METHOD 3

SUPPLY STOP

VALVE

SUPPLY

PIPE

HOSE

UNIONS SERVICING

VALVE

TEMPORARY

HOSE

HEATING

SYSTEM

HEATING

SYSTEM

TEMPORARY

HOSE

UNIONS SERVICING

VALVE

SUPPLY

PIPE

SUPPLY STOP

VALVE

DOUBLE CHECK

VALVE ASSEMBLY

HEATING

SYSTEM

SERVICING

VALVE

SUPPLY

STOP VALVE

SUPPLY

PIPE

HOSE

UNIONS DOUBLE CHECK

VALVE ASSEMBLY

OVERFLOW

CISTERN

COMBINED

CHECK VALVE

AND VACUUM

BREAKER

PRESSURE

REDUCING

VALVE

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3 Boiler Location

MINIMUM CLEARANCES Diagram 3.1

3.1 General

The 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 using mains

electricity should be so situated that it cannot be touched

by a person using the bath or shower.

The electrical provisions of the Building Standards

(Scotland) Regulations are applicable to such

installations in Scotland.

The boiler must be mounted on a flat wall which is

sufficiently robust to take its complete weight, see

Appliance Data, Table 1.

The boiler may be fitted to a wall made of combustible

material. See diagram 3.1.

3.2 Boiler Clearances

The boiler should be positioned so that at least the

minimum operational and servicing clearances are

provided, see diagram 3.1.

3.3 Timber Frame Buildings

If the boiler is to be installed in a timber frame building,

it should be fitted in accordance with the British Gas

Publication “Guide for Gas Installation in Timber

Framed Housing” reference DM2. If in doubt, seek

advice from the local gas undertaking or Hepworth

Heating Ltd.

3.4 Room Vent

The boiler is room sealed, so when installed in a room or

space, a permanent air vent is not required.

3.5 Cupboard or Compartment Vent

Where the boiler is fitted in a cupboard or compartment,

permanent high and low level ventilation must be

provided.

The vent areas required are given in Table 3.

Where the installation of the boiler will be in an unusual

location, special procedures are necessary, refer to the

current issue of BS6798 for guidance.

Make sure that the cupboard or compartment air vents

are positioned to be clear of obstructions at all times.

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, refer to the current issue of

BS6798 for guidance.

The doorway opening should be of sufficient size to

allow easy removal of the boiler.

TABLE 3. COMPARTMENT AIR VENTS

VENTILATION

REQUIREMENTS HIGH LEVEL LOW LEVEL

VENT AREA VENT AREA

cm2in2cm2in2

VENTILATION

FROM

ROOM

OR SPACE

MODEL

VENTILATION

FROM

OUTSIDE

132 20 132 20

181 28 181 28

66 10 66 10

91 14 91 14

MINIMUM CLEARANCES FROM WALLS, CEILING,

FLOOR, CUPBOARD, WORKTOPS AND

INFLAMMABLE MATERIALS

❋ WHERE EXTERNAL ACCESS TO

THE FLUE IS NOT PRACTICAL THEN

CLEARANCE MUST BE ADEQUATE TO

PERMIT INSTALLATION OF THE FLUE

3133

150

800*

186

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SIDE FLUE Diagram 4.2

REAR FLUE Diagram 4.1

The flue must be installed in accordance with the current

issue of BS5440 Part 1.

The air and flue ducting connect to the top of the boiler

using an elbow which can be positioned to the left or

right hand side or the rear.

The rear and side flue assemblies are designed for

internal installation, but if necessary, due to insufficient

clearances (boiler/flue terminal location) they can be

installed from the outside.

For a wall thickness up to 300mm the flue can be fully

installed from the inside.

For wall thickness of over 300mm the external cut hole

will need to be made good from the outside.

The standard flue will provide the flue length range as

shown in diagram 4.1 and 4.2.

If a longer flue is required, do not extend the ducting. A

1, 2 or 3metre flue system must be used and can be

supplied. This will provide the flue length range as

shown in diagram 4.1 and 4.2.

A "Flue Bend Kit" and "Vertical Flue Kit" can be

supplied.

4 Flue

STANDARD FLUE TERMINAL ILLUSTRATED

3134

'R'

3135

Rear Flue Lengths

S='External wall face’to‘boiler mounting frame’

Side Flue Lengths

Flue. STD 80mm to 547mm

1m 80mm to 857mm

2m 80mm to 1857mm

3m 80mm to 2852mm

Flue. STD 75mm to 598mm

1m 75mm to 913mm

2m 75mm to 1913mm

3m 75mm to 2908mm

R= Wall Thickness

'S'

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4 Flue

Diagram 4.3

4.1 Terminal Position

The minimum acceptable siting dimensions for the

terminal from obstructions, other terminals and

ventilation openings are shown in diagram 4.3.

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 comprises 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 and 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.

4.2 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.

A suitable guard as shown, reference type K3, can be

obtained from:

Tower Flue Components Ltd.,

Morley Road,

Tonbridge,

Kent.

TN9 1RA

FGEA

B,C B,C

UNDER CAR PORT etc.

H,I

2816

A DIRECTLY BELOW AN OPENABLE

WINDOW, AIR VENT, OR ANY OTHER

VENTILATION OPENING 300

B BELOW GUTTER, DRAIN/SOIL PIPE 75

C BELOW EAVES 200

D BELOW A BALCONY OR CAR PORT 200

E FROM VERTICAL DRAIN PIPES AND

SOIL PIPES 75

F FROM INTERNAL OR EXTERNAL

CORNERS 300

G ABOVE ADJACENT GROUND OR

BALCONY LEVEL 300

H FROM A SURFACE FACING THE

TERMINAL 600

I FACING TERMINALS 1200

J FROM OPENING (DOOR/WINDOW) IN

CAR PORT INTO DWELLING 1200

K VERTICAL FROM A TERMINAL 1500

L HORIZONTALLY FROM A TERMINAL 300

MINIMUM SITING DIMENSIONS

FOR FANNED FLUE

TERMINALS POSITION

0161M

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5 Preparation

OUTER CASE Diagram 5.1

Diagram 5.3GAS SERVICE COCK / WATER ISOLATING VALVES

INNER CASE COVER Diagram 5.2

5.1 Unpacking

Remove the top carton from the boiler.

To remove the outer case, slide the information plate up

to access and remove the single securing screw, see

diagram 5.1, unhook the case at the top and lift it off.

Remove the cover of the inner case, secured with four

screws, see diagram 5.2.

Disconnect the gas service cock union and the front

unions of the isolation valves, see diagram 5.3.

Slacken but do not remove the retaining strap screws of

the gas service cock and the isolating valves.

3137

31383139

OUTER CASE SECURING SCREW

INFORMATION

PLATE

INNER CASE

COVER

RETAINING

STRAP

GAS SERVICE

COCK UNION

FLOW

WATER

ISOLATING

VALVE

UNION

RETAINING

STRAP RETAINING

STRAP

RETURN

WATER

ISOLATING

VALVE

UNION

SECURING

SCREW (4)

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220677A

5 Preparation

Diagram 5.4

SIDE FLUE Diagram 6.2

BOILER FIXING POINTS Diagram 6.1

BOILER

MOUNTING FRAME

6 Installing the Flue

Remove the two boiler securing screws, see diagram 5.4

then separate the boiler from the mounting frame, by

pulling the location studs/clips apart then unhook it at

the top.

6.2 Marking

The boiler mounting frame is the same width as the

boiler but the flue connection protrudes above. Place the

boiler mounting frame on the wall in the required

position, maintaining minimum clearances,

see diagram 3.1.

3140

173 173

115 Dia. FLUE

CENTRE

LINES

CORNER

(LEFT FLUE)

CORNER

(RIGHT FLUE)

3142

3143

FLUE

TEMPLATE

BOILER

MOUNTING FRAME

FIXING POINTS

480

629

149

78 FLUE

CENTRE LINE

115 Diameter

Top of

Boiler

MINIMUM

CLEARANCE

300

BOILER

MOUNTING FRAME LOCATION

STUD(S) and CLIP(S)

6.1

With due regard to boiler location, clearances and

having determined the flue application, length and

terminal position carry on as follows:

BOILER

SECURING SCREW (2)

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