Instruction/ maintenance manual of the product 40 Glowworm Lighting
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Hepworth Heating Ltd., Nottingham Road, Belper, Derbyshire. DE56 1JT General/Sales enquiries: Tel: (01773) 824141 Fax: (01773) 820569 One Contact Local Service Customer Services: Tel: (01773) 828100 Fax: (01773) 828070 221834B.
2 221834B Impor tant Inf ormation 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.
3 221834B 0163M m a x m i n 0 t e m p Instructions for Use Introduction Please read these instructions and follow them for the safe and economical use of your boiler. This boiler is designed to provide central heating from a fully pumped open vented or sealed water system with a fully indirect cylinder.
4 221834B Instructions f or Use Boiler Clearances If fixtures are positioned close to the boiler, space must be left as shown in diagram 3. Enough space must also be left in front of the boiler to allow for servicing.
5 221834B Overheat Safety Cutoff If the cutoff operates on any other occasion than an electrical failure, press the reset button as stated in “ Electrical Supply Failure ” . If the boiler fails to relight contact your installation/servicing company.
6 221834B 1 General Important Notice This boiler is for use only on G20 gas, but may be converted for use on G31 gas (L.P.G.) with an available conversion kit.
7 221834B 1 General Rc 1 / 2 in. GAS CONNECTION WATER CONTENT WATER CONNECTION 28mm copper flow at right return at left LIFT WEIGHT 240V ~ 50H Z , fused 3A. ELECTRICITY SUPPLY 1.6 Litre (0.35 gal) 31.5 kg (69.5 lb) 48.0 kg (106 lb) TOTAL WEIGHT 40 DATA TABLE 1.
8 221834B Diagram 2.1 Diagram 2.2 Design Minimum Flow Rate Flow Rate 1.5 1.0 0.5 0 50 40 30 20 0 0 5 10 15 20 25 30 Flow rate ( litres/minute ) Water pressure loss (metres head of water) Water pressure loss (inches head of water) 10 60 01 2 3 4 56 Flow rate (gallons/minute) 35 40 70 78 2.
9 221834B Diagram 2.3 Diagram 2.4 FEED AND EXPANSION CISTERN CYLINDER FLOW RET. FLOW 150 mm MAX BOILER RET. PUMP 450mm MIN. HEIGHT 1150mm MIN. 22mm (MIN) VENT 15mm (MINIMUM) COLD FEED Open (vented) system. Recommended relationship between pump, cold feed and vent.
10 221834B Diagram 2.5 METHOD 1 METHOD 2 METHOD 3 SUPPLY STOP VALVE SUPPLY PIPE HOSE UNIONS SERVICING VALVE TEMPORARY HOSE HEATING SYSTEM HEATING SYSTEM TEMPORARY HOSE HOSE UNIONS SERVICING VALVE SUPP.
11 221834B Diagram 3.1 Ventilation From Outside Ventilation high level low level From Room cms in 2 cms in 2 Energysaver 40 123 19.1 123 19.1 PERMANENT SURFACE * 5 * 5 55 150 100 500 * INCREASE THIS D.
12 221834B S = "External wall face" to "boiler casing" Diagram 4.3 REAR FLUE LENGTHS Diagram 4.1 SIDE FLUE LENGTHS Diagram 4.2 0158M 2 ˚ 35mm 1metre SIDE FLUE FRONT VIEW Make sure.
13 221834B Diagram 4.4 0103M A A F G E A G G G B,C B,C F F K K K C G L L A DIRECTLY BELOW AN OPENABLE WINDOW, AIR VENT, OR ANY OTHER VENTILATION OPENING 300 B BELOW GUTTER, DRAIN/SOIL PIPE 75 C BELOW .
14 221834B Diagram 5.1 Diagram 5.2 Diagram 5.3 SECURING SCREW(4) INNER FITTING ➁ M5x10mm ➀ SELF TAPPER Note: Casing securing screws supplied in loose items pack. Fit in order of numerical sequence. No.10 x 3 / 4 INNER CASE 6289 6290 6288 5 Preparation BASE TRAY WALL TEMPLATE TOP CARTON WRAP BOILER MOUNTING BRACKET INSTRUCTIONS TOP FITTING 5.
15 221834B Diagram 5.5 Diagram 5.4 WALL THICKNESS 115 DIAMETER 125 DIAMETER 135 DIAMETER 2 ˚ See template for centre line positions 75 300 680 REAR FLUE 0249M 0248M "x" 2 ˚ SIDE FLUE 'H'= 0.035x 124mm 56.5mm MIN 115 Minimum hole 125 up to 300mm wall 135 up to 680mm wall 5 Preparation 5.
16 221834B OLIVE FLOW RETURN 28mm O.D. COPPER TUBING WATER CONNECTIONS FLUE GAS SAMPLE POINT UNION NUT 4037 6 W ater and Condensate Connections It is, therefore, recommended that any external condensate drain pipe is insulated to prevent it freezing up.
17 221834B Diagram 7.1.A FAN BRACKET FAN BRACKET SECURING SCREW (2) FAN SECURING SCREW (3) 4444 7 Flue Installation 7.1 Rear Flue Mark and cut the air duct terminal assembly, see diagram 7.1 and the flue duct, diagram 7.2 to the lengths required, cutting square and removing any burrs.
18 221834B Diagram 7.3 Diagram 7.4 Diagram 7.5 "N" "N" minus 42mm "N" AIR DUCT/TERMINAL AND FLUE DUCT ASSEMBLY SEAL WITH TAPE SUPPLIED 3mm DRILL SIZE FLUE ELBOW ASSEMBLY .
19 221834B Diagram 7.8 Diagram 7.9 ✽ STD FLUE TERMINAL = 63 ✽ LONG FLUE TERMINAL = 61 ✽ FLUE TERMINAL FLUE DUCT "Q" "Q" minus 25mm FOAM SEAL 6867 6868 7 Flue Installation Diagram 7.7 FOAM SEAL 10mm "Q" 6866 Diagram 7.
20 221834B 9 Electrical Connection Diagram 9.1 PULL SLIGHTLY FORWARD AND UP LOCATING SLOTS SECURING SCREW (2) CONTROL BOX 4051 8 Gas Connection Diagram 8.
21 221834B ✽ Diagram 9.2 ✽ RED LINK SL TO 1 REMOTE CONTROLS SL PL PN 1 L N MAINS SUPPLY CABLE PUMP CABLE PUMP AND REMOTE CONTROLS GROMMET MAINS SUPPLY CABLE GROMMET CHASSIS EARTH POST 4052 9 Electrical Connection 9.1 Pump and External Controls Connection The pump must be connected directly to the control box, as shown in diagram 9.
22 221834B Diagram 10.2 HIGH SETTING ADJUSTMENT (BRASS NUT) LOWER SETTING ADJUSTMENT (INNER SCREW) 9023 m a x m i n 0 t e m p Diagram 10.1 GREEN LIGHT FOR HIGH FLAME HIGH/LOW CONTROL KNOB CONTROL THER.
23 221834B 10 Commissioning this is quite normal and it will disappear after a short period of time. Refit the electrical controls box. 10.5 Heating System Check that all remote controls are calling for heat. Allow the system to reach maximum temperature and examine for water leaks.
24 221834B Diagram 12.3 FLUE HOOD FLUE HOOD SECURING SCREW (2) 4055 S ELECTRICAL CONNECTIONS SECURING SCREWS (3) AIR PRESSURE TUBES RED TUBE CLEAR TUBES 4043 S 12 Servicing Diagram 12.
25 221834B Diagram 12.4 Diagram 12.6 Diagram 12.5 CONDENSATE TRAY PRIMARY HEAT EXCHANGER BURNER VIEWING WINDOW SECURING SCREW (2) SECONDARY HEAT EXCHANGER BAFFLE 4056 4057 4058 12 Servicing Brush from back to front NOT left to right. Do not use a brush with metallic bristles.
26 221834B 13.1 Electrical Important. On completion of the Service/Fault Finding task which has required the breaking and remaking of the electrical connections the earth continuity, polarity, short circuit and resistance to earth checks must be repeated using a suitable multimeter.
27 221834B PUMP OVERRUN OPERATION The control thermostat has a pump overrun facility built into it, when the control thermostat is set at maximum only, the pump overrun will keep the pump running to allow the boiler to cool down after which it will stop, providing the remote controls are NOT calling for heat.
28 221834B Diagram 13.1 Before detailed checking of electrical components ensure that remote controls are calling for heat. Check that the gas supply is free of obstructions and purged of air. Check the overheat thermostat and fluehood thermostat have not operated.
29 221834B Has boiler been operating for 10 seconds yet ? Does gas ignite ? 2 YES NO YES Isolate supply NO Replace PCB Examine electrode and leads. Repair/replace as necessary Reconnect supply Is APS .
30 221834B Diagram 13.1 Does the burner remain alight ? Isolate supply Check continuity between 4 and 1 on High/Low switch. Switch ok ? Replace High/Low switch NO YES 2 Replace gas valve YES NO NO YES NO NO Turn High/Low switch to “ High ” .
31 221834B 13 Fault Finding Diagram 13.2 b 1 2 3 4 5 6 7 8 9 10 KEY: b - BLUE bk - BLACK br - BROWN g/y - GREEN/ YELLOW g - GREY SL PL PN 1 L N FAN AIR PRESSURE SWITCH EARTH POST MAINS 240VAC 50Hz PUMP SUPPLY EARTH POST CHASSIS EARTH CONDENSE CUT-OFF SPARK ELECTRODE OVERHEAT CUT-OFF BOILER CONTROL THERMOSTAT 2 AMP FUSE CONTROL P.
32 221834B Diagram 13.3 13 F ault Finding 554 8 I.C. P.C.B. CONNECTIONS: ie STAT (Pin No. from bottom) PLASTIC OVERHEAT CONTROL THERMOSTAT FAN NO C NC MAIN TERMINAL STRIP CONNECTIONS CONTROL THERMOSTA.
33 221834B Diagram 13.4 Diagram 13.5 4067 S INSTRUCTION LABEL RESET BUTTON 7891 FLUE HOOD OVERHEAT THERMOSTAT RESET BUTTON 13 F ault Finding Notes: Replacement of parts must be carried out by a competent person.
34 221834B Diagram 14.3 SUPPORT POST (4) IGNITION LEAD ELECTRICAL PLUG (5) I.C.B TERMINAL STRIP CONTROL P.C.B. SUPPORT POST (2) ELECTRICAL PLUG 4065 14 Replacement of P ar ts 14.3 Printed Circuit Boards (PCBs): diagram 14.3 Release the control box as Section 9.
35 221834B Diagram 14.4 CONTROL THERMOSTAT SECURING SCREW (2) OVERHEAT CUT OFF LOCKNUT RETAINING PIN OVERHEAT CUT OFF PHIAL CONTROL THERMOSTAT PHIAL 4078 14 Replacement of P ar ts Diagram 14.
36 221834B Diagram 14.8 CONDENSATE TUBE UNION CONNECTIONS SECURING SCREWS (6) INJECTOR MANIFOLD SPARK ELECTRODE Diagram 14.6 Diagram 14.7 SECURING SCREW (2) SECURING SCREW (4) LIGHTS BRACKET LOCKNUT H.
37 221834B Diagram 14.9 UNION CONNECTION PRIMARY HEAT EXCHANGER UNION CONNECTION BURNER SECONDARY HEAT EXCHANGER UNION CONNECTION 14 Replacement of P ar ts Heat Exchanger - Primary - diagram 14.10 Disconnect the three union connections. 14.11 Burner: diagram 14.
38 221834B Diagram 14.13 Diagram 14.14 VIEWING WINDOW/INNER CASE FRAME VIEWING WINDOW/COMBUSTION CHAMBER FRONT PANEL FRAME GLASS GASKET CONDENSATE SENSOR SCREW SECURING SCREW (2) GLASS GASKET SECURING SCREW (2) 14 Replacement of P ar ts 14.12 Insulation - Rear - diagram 14.
39 221834B Part No. Key No. Description GC Part No. 15 Spare P ar ts 1 230530 Multifunctional control 2 800476 Thermostat - control 278 094 3 800477 Thermostat - over heat cutoff 278 095 4 800466 Over.
40 221834B Because of our constant endeavour for improvement details may vary slightly from those in the instructions. Diagram 15.1 5 12 8 10 3 14 13 6 9 15 Spare P arts 7 15 6291 4 11 16 1 3 2.
An important point after buying a device Glowworm Lighting 40 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Glowworm Lighting 40 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Glowworm Lighting 40 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Glowworm Lighting 40 you will learn all the available features of the product, as well as information on its operation. The information that you get Glowworm Lighting 40 will certainly help you make a decision on the purchase.
If you already are a holder of Glowworm Lighting 40, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Glowworm Lighting 40.
However, one of the most important roles played by the user manual is to help in solving problems with Glowworm Lighting 40. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Glowworm Lighting 40 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
