Glowworm 40 Operating manual

Hepworth Heating Ltd.,
Nottingham Road, Belper, Derbyshire. DE56 1JT
General/Sales enquiries:
Tel: [phone] Fax: [phone]
One Contact Local Service
Customer Services:
Tel: [phone]
Fax: [phone]
221834B.11.00
All replacement parts
All labour charges
All call-out charges
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.
In the center pages are to be found 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:
Guarantee Registration
This is a Cat II2H3P Appliance
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.
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.
Tobeleftwiththeuser
4040/S
❏
✔
❏
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❏
✔
Instructions for Use
Installation and Servicing
REGISTER YOUR GLOW-WORM APPLIANCE
FOR 1ST YEAR GUARANTEE PROTECTION
CALL 0208 247 9857
Energysaver
40
High Efficiency Boiler
G.C. No. 41 319 69
PAS010

2
221834B
Important Information
TESTING AND CERTIFICATION
Thisboileristestedandcertificatedforsafetyandperformance.
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
invalidatethecertification,boilerwarrantyandmayalsoinfringe
the current issue of the Statutory Requirements, see Section
1.2.
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.
TypetestforpurposesofRegulation5certifiedby:Notifiedbody
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.Directive89/336/EEContheapproximationoftheLaws
ofthe Member States relating to electromagnetic compatibility.
INFORMATION FOR THE INSTALLER AND
SERVICE ENGINEER.
UnderSection6ofTheHealthandSafetyatWorkAct1974,we
are required to provide information on substances hazardous
to health.
CERAMIC FIBRE/INSULATION PADS,
GLASSYARN.
Thesecancauseirritationtoskin,eyesandtherespiratorytract.
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,drinkingorgoingtothelavatory.Ifyoudosufferirritation
oftheeyesorsevereirritationtotheskinseekmedicalattention.
THERMOSTATS
Thesecontainverysmallamountsofxyleneinthesealedphial
and capillary. If broken, under normal circumstances the fluid
doesnotcauseaproblem,butincaseofskincontact,washwith
coldwater.Ifswalloweddrinkplentyofwaterand seekmedical
attention.
CUT OFF DEVICES
Cut off devices with copper phial/bulb only.
Bulb contains activated charcoal and very small amounts of
chloroddifludromethane in the sealed phial and capillary. If
broken under normal circumstances the fluid does not cause a
problem. If there is irritation to the eyes or skin then seek
medical attention.
FLUE SEALANT
This contains cyclohexylaminosilane.
Itmaycauseirritationofskinofsensitivepersons.Washcontact
area with soap and water, if irritation occurs, seek medical
advice.
It will cause irritation on contact with eyes. If so, wash eye with
largeamountsoffresh water foratleast15minutes. If irritation
occurs, seek medical advice.
If swallowed drink plenty of milk and seek medical advice.
Introduction 3
Lighting the Boiler 5
General Data 1 6
Water System 2 8
Boiler Location 3 11
Flue 4 12
Preparation 5 14
Water and Condensate Connections 6 16
Flue Installation 7 17
Gas Connection 8 20
Electrical Connection 9 20
Commissioning 10 22
User Information 11 23
Servicing 12 24
Fault Finding 13 26
Replacement Parts 14 33
Spare Parts 15 39
CONTENTS DESCRIPTION SECTION PAGE No.
INSTRUCTIONS
FOR USE
INSTALLATION
INSTRUCTIONS
SERVICING
INSTRUCTIONS

3221834B
0163M
m
a
x
m
i
n
0
t
e
m
p
Instructions for Use
Introduction
Pleasereadthese instructionsandfollowthem forthesafe and
economical use of your boiler.
This boiler is designed to provide central heating from a fully
pumpedopenventedorsealedwatersystemwithafullyindirect
cylinder.
The boiler is fully automatic in operation, having two user
controls, high/low control on the left and the control thermostat
on the right, see diagram 1.
The “high/low” control can set to “Low” during the summer
months.
Important Notice
This boiler is for use on natural gas (G20) as distributed in the
United Kingdom and Ireland, but may be converted for use on
L.P.G. Propane (G31) with the use of a conversion kit, i.e.
Energysaver 40, Kit No.444708.
If your boiler has been converted to use L.P.G. Propane the
following note applys:
Propane cylinders are under pressure and should never be
stored or used indoors residentially.
They should only be kept outside.
Under no circumstances should LPG Propane cylinders be
fitted or stored in basement areas or boiler house.
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 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/helpshould beobtainedfromyourinstallation/servicing
company or the local gas undertaking.
Maintenance/Servicing
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.
It is the Law that any servicing must be carried out by a
competent person.
To obtain service, please call your installer or Heatcall (Glow-
worm’s own service organisation) using the telephone number
given on the information plate, see diagram 2.
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
boilerLogbook. YoucancheckyourinstallerisCORGIregistered
by calling CORGI direct on :- 01256 372300.
GREEN
LIGHT
FOR HIGH
FLAME
GREEN
LIGHT
FOR LOW
FLAME
CONTROL
THERMOSTAT
KNOB
HIGH/LOW CONTROL KNOB
ORANGE DEMAND LIGHT Diagram 1
Diagram 2
RESET BUTTON
INSTRUCTION LABEL
7891

4
221834B
Instructions for Use
Boiler Clearances
If fixtures are positioned close to the boiler, space must be left
asshownin diagram 3. Enoughspacemust also beleftinfront
of the boiler to allow for servicing.
Boilers Installed in a Compartment or
Cupboard
If the boiler is installed in a cupboard or compartment do not
obstruct any ventilation openings.
Do not use the cupboard or compartment for storage.
Regularly make sure that the air vent openings are clear of
obstructions.
Cleaning
WARNING. Thisappliancecontainsmetalparts(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
severeweatherconditionswerecommendthatthewholeofthe
system, including the boiler, be drained off to avoid the risk of
freezingup. Makesurethat,iffitted,theimmersionheaterinthe
cylinder is switched off.
If you have a sealed water system contact your installation/
servicing company as draining, refilling and pressurising must
be carried out by a competent person.
Boiler Electrical Supply
WARNING. The boiler must be earthed.
The boiler must only be connected to a 240V~50Hz supply,
protected by a 3A fuse.
All wiring must be in accordance with the current issue of
BS7671.
The colours of three 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 “R” or “Red”.
The wire coloured green and yellow must be connected to the
terminal marked “E”, “Green” or the earth symbol .
Electrical Supply Failure
Failure of the electrical supply will cause the burner to go out.
Shouldthishappen,operationoftheboilerwillnormallyresume
after the electrical supply is restored.
Iftheburnerdoesnotrelightafteranelectricalsupplyfailurethe
overheat device may need resetting, press the reset button on
the underside of the boiler, see diagram 2.
PERMANENT
SURFACE
*5
*5
55
1
5
0
100
500
*INCREASE THIS DIMENSION TO
25mm FROM COMBUSTIBLE MATERIAL
CLEARANCE OPPOSITE TO FLUE EXIT
MUST BE ADEQUATE FOR THE
INTERNAL INSTALLATION
5
*5
Diagram 3

5221834B
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.
To Turn the Boiler On
Sealed Water Systems.
CAUTION Asealedwatersystemmustbefilledandpressurised
by a competent person.
Only light the boiler when you are sure that the system and
boiler have been filled and pressurised.
Thepressuregauge should showatleast0.7bar, anything less
thanthisfigurecouldindicatealeakandyouMUSTcontactyour
installation/servicing company.
If there is any doubt about the boiler and system being full of
water consult your installation/servicing company.
All Systems
Turn the electrical supply on to the boiler and check that any
remote controls are set to your requirements (refer to
manufacturer’s instructions for these items).
On demand, the orange light will come on.
Turn the left hand switch to “high”flame.
Turn the control thermostat knob, at the right, clockwise to any
position between “MIN”and “MAX., see diagram 1. The
maximum setting is about 82oC (180oF).
The boiler will not light between “O”and “MIN”.
The boiler lighting operation is now automatic as follows:
The fan operates, followed by an ignition spark until the burner
lightsonlowflameafterashortperioditwillgotohighflameand
the green light will come on.
The burner will remain alight until switched off by the control
thermostat or other remote control.
Ifthecontrolthermostatisturned“Off”,byhand,waitatleast30
seconds before turning on again.
When the boiler thermostat is satisfied the burner and green
light will go out.
When the system controls are satisfied the burner, orange and
green lights will go out.
The automatic lighting sequence will operate again when heat
is required.
The “high/low”switch should be set to “high”for winter use, but
when domestic hot water only is required in the summer it can
be turned to “low”.
If no light comes on you should contact your installation/
servicing company, to check the controls, although the system
may be working.
To Turn the Boiler Off
For short periods, turn thermostat control knob anti-clockwise
until“O”isagainst the settingpoint. To relightthe mainburner,
turnthethermostatknobclockwisetoanysettingbetween ”MIN”
and “MAX”.
For longer periods, turn the thermostat control knob anti-
clockwiseuntil“O”isagainstthesettingpointandswitch offthe
electrical supply to the boiler.
To relight follow the sequence given above.
Note: If the burner goes out for any reason, wait 30 seconds
before relighting.
Condensation Pluming
Like all condensing boilers this appliance will produce a plume
of condensation from the flue terminal in cool weather. This is
due to the high efficiency and hence low flue gas temperature
of the boiler.
Instructions for Use

6
221834B
1 General
Important Notice
ThisboilerisforuseonlyonG20gas,but maybeconvertedfor
use on G31 gas (L.P.G.) with an available conversion kit.
Energysaver 40, Kit No. 444708
The boiler is delivered in one pack.
Wherever possible, all materials 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 must have fully pumped circuits, but is suitable for
use with open vented or sealed water systems.
This boiler is not suitable for outdoor locations.
1.1 Sheet Metal Parts
WARNING. When installing or servicing the boiler care should
betakenwhenhandlingsheetmetalpartstoavoidanypossibility
of personal injury.
1.2 Statutory Requirements
TheinstallationoftheboilerMUSTbecarriedoutbyacompetent
person in accordance with the relevant requirements of the
current issue of:
Manufacturer’s instructions, supplied.
TheGasSafety(InstallationandUse)Regulations,TheBuilding
Regulations, The Building Standards (Scotland) Regulations
(applicable in Scotland), local Water Company Bylaws, The
HealthandSafetyatWorkAct,ControlofSubstancesHazardous
toHealth, TheElectricityatWorkRegulationsandanyapplicable
local regulations.
Detailedrecommendationsarecontainedinthecurrentissueof
thefollowingBritishStandardsandCodesofPractice,BS4814,
0156M
WATER CONNECTIONS
CONDENSATE DRAIN
GAS CONNECTION
460
50
360
Ensure flue slopes 2
˚
down
towards the boiler
i.e. 35mm fall per metre
of flue length (2
˚
)
124
42
30070
32
FLUE
TERMINAL
DETAIL
102
63
65
119
640
25
710
32 DRAIN
CONNECTION
CAPPED OFF
Diagram 1.1
BS5440 Part 1 and 2, BS5449, BS5546, BS6700, BS6798,
BS6891and BS7074 Part 1 and 2, BS7478, BS7593, BS7671.
WealsosuggestthatyouhavetohandacopyoftheBritishGas
publication, “Guidance Notes for the Installation of Domestic
Condensing Boilers”.
Manufacturer’snotesmustnotbe taken as overriding statutory
obligations.
BSI Certification
This boiler certificated to the current issue of P.A.S. 010 for
performance and safety.
It is 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.,
couldinvalidatethewarrantyandcouldalsoinfringethecurrent
issue of the Statutory Requirements.
1.3 Range Rating
The boiler is range rated and is factory preset to maximum, but
maybeadjustedtosuitindividualsystemrequirements,referto
Table 2.
1.4 General Data
The data label is positioned on the inner case, visible when the
outer case is removed.
All dimensions on diagrams are given in millimetres (except as
noted).
The Seasonal Efficiency Domestic Boilers UK (SEDBUK) is
86.7%.
ThevalueisusedintheUKGovernment’sStandardAssessment
Procedure (SAP) for energy rating of dwellings. The test data
from which it has been calculated have been certified by B.S.I.

7221834B
1 General
Rc 1/2in.
GAS
CONNECTION
WATER
CONTENT
WATER
CONNECTION 28mm copper flow
at right return at left
LIFT
WEIGHT
240V ~ 50HZ, 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.
MODEL
RANGE RATING
NOMINAL kW
HEAT INPUT
(GROSS) Btu/h
NOMINAL kW
HEAT
OUTPUT Btu/h
10.16 10.16 11.86 13.55
34,680 34,680 40,462 46,240
8.79 8.79 10.26 11.72
30,000 30,000 35,000 40,000
9.40 9.40 10.97 12.53
32,100 32,100 37,400 42,800
NOMINAL kW
HEAT
OUTPUT Btu/h
CONDENSING
BURNER m bar
SETTING (HOT)
PRESSURE in.w.g
9.7 9.7 12.7 16.6
3.88 3.88 5.1 6.64
0.96 0.96 1.1 1.3
34 34 39.9 45.5
APPROX m3h
GAS
RATE ft3h
LOW MIN MID MAX
TABLE 2. Energysaver 40
BURNER INJECTOR MARKING: 40N
1.5 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
toprovideasteadyinletworkingpressureof20mbar(8inwg)at
the boiler.
Oncompletion,testthegasinstallationforsoundnessusingthe
pressuredropmethodandasuitableleakdetectionfluid,purge
in accordance with the above standard.
1.6 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 the requirements of
thecurrentissueofBS7671andanyapplicablelocalregulations.
Connection of the boiler and system controls to the mains
supply must be through a common isolator and must be fused
3Amaximum. Thismethodofconnectionshouldbe,preferably,
by a double pole isolating switch, provided it has a minimum
contact separation of 3mm on both poles. This should be
readily accessible and preferably adjacent to the appliance. It
shouldsupplytheapplianceonlyandbeeasilyidentifiableasso
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.
1.7 Condensate
The boiler condensate should, if possible, be discharged into
thehouseholdinternal draining system,thatis,sinkor washing
machine drain. If this is not practicable, discharge can be
external, into the household drainage system or a purpose
designed soakaway
Theboilerisfittedwithasafetydevicetopreventtheboilerfrom
working if the condensate pipe gets blocked by either ice or
debris.
It is, therefore, recommended that any external condensate
drain pipe is insulated to prevent it freezing up.
Alternatively,alargerdiameterpipecanbeusedandinsulated.
The condensate drain pipe should be checked during any
servicing and any debris found removed.
Refer to the British Gas publication “Guidance Note for the
Installation of Domestic Condensing Boilers”for further
information.
1.8 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-Conservationoffuelandpower,1995edition-Appendix
G, table 4b.
1.9 Anti-theft Kits
Anti-theft kits are available for these appliances, contact
Hepworth Heating Ltd. for further information.

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
0510 15 20 25 30
Flow rate
(
litres/minute
)
Water pressure loss
(metres head of water)
Water pressure loss
(inches head of water)
10
60
0123456
Flow rate (gallons/minute)
35 40
70
78
2.0
0164M
TABLE 3
BOILER
DRAIN
POINT
Energysaver 40 15.5L/min 11L/m
4042
2 Water System
Note.
The boiler has 28mm copper connections, which can be
reducedto22mmfortheEnergysaver 40,providedthe system
resistance does not exceed the chosen pump duty.
2.1 Draining Tap
Theboilerisprovidedwithadrainingpointatthelowerlefthand
side of the burner manifold, to be used for draining the boiler,
see diagram 2.1.
A draining tap must be provided at the lowest points of the
systemwhichwillallowtheentiresystemandhotwatercylinder
to be drained.
Draining taps shall be to the current issue of BS2879.
2.2 Safety Valve
A safety valve need not be fitted to an open vented system.
2.3 Pump
The pump should be fitted in the flow pipe from the boiler and
have isolating valves each side, integral if possible.
A variable duty pump should be set to give a temperature
difference of 11oC (20oF) between the flow and return, with the
thermostat set at “MAX”, which is about 82oC (180oF), to give
a design flow rate as shown in Table 3.
See chart for pressure drop of the boiler, diagram 2.2.
High resistance microbore systems may require a higher duty
pump.
2.4 Bypass
A BYPASS MUST BE FITTED, see diagram 2.3 for a suitable
position.
Theflowratethroughtheboilermustnotbeallowedtofallbelow
that given in Table 3.
Where the water system can allow the boiler and pump to
operate on bypass only, the bypass must be placed at least
1.5m away from the boiler.
2.5 Inhibitor
Attention is drawn to the current issue of BS5449 and BS7593
on the use of inhibitors in central heating systems.
Ifaninhibitoristobeused,contactaninhibitormanufacturerfor
their recommendations as to the best product to use.
Note: This boiler has a totally copper water system and does
not require a special inhibitor normally associated with other
types of high efficiency (“condensing”) boilers.
If an existing system is to be reused take special care to drain
the entire system, including the radiators, then thoroughly
cleaning out before fitting the boiler whether or not adding an
inhibitor.
2.6 Open (Vented) Water System
The boiler must be supplied from an unrestricted water supply
takenfromafeedandexpansioncisternsituatedatamaximum
height of 27metres (90ft) above the boiler.
The cold feed must be 15mm minimum size.
The vent must rise continuously and be unrestricted.
It is important that the relative positions of the pump, cold feed
and open vent are as shown in diagram 2.3.
2.7 Domestic Hot Water Cylinder
Thedomestichotwatercylindermustbeofthedoublefeedfully
indirect type. Not the single feed self priming type.
2.8 Domestic Hot Water System - Unvented
Whereastorage system willnothavea vent toatmospherethe
installationmustcomplywiththeBuildingRegulationsandlocal
Water Company bylaws, see also the current issue of BS5546
and BS6700.
If fitting to an existing system the local authority should be
informed.
2.9 Sealed Water Systems
Theinstallationmustcomplywiththeappropriaterequirements
ofthecurrentissueofBS4814,BS5449, BS6759, BS6798 and
BS7074 Part 1 and 2.
See diagram 2.4 for a suggested layout.

9221834B
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.
15mm (MINIMUM)
BY-PASS WITH
LOCKSHIELD VALVE
HEATING
4357A
2 Water System
2.10 Safety Valve
A safety valve must be fitted to a sealed 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.
2.11 Expansion Vessel
A diaphragm type expansion vessel, conforming to the current
issue of BS4814 (see also BS7074 Part 1 and 2) must be
connected at a point close to the inlet side of the circulating
pump, see the diagrammatic layout, diagram 2.4 unless laid
down differently by the manufacturer.
The expansion vessel volume depends on the total water
systemvolumeand theinitialsystemdesign pressure. Forany
system an accurate calculation of vessel size is given in the
current issue of BS7074 Part 1.
Example: For an initial system design pressure of 0.7bar, the
minimum total vessel volume required is 0.063xTotal System
volume.
Note: A higher initial design pressure requires a larger volume
expansion vessel.
Guidance on vessel sizing is also given in the current issue of
BS5449 and BS7074 Part 1.
Thechargepressuremustnotbelessthanthestaticheadofthe
system, that is, the height of the highest point of the system
above the expansion vessel.
The water content of the boiler is given in the Data Table 1.
5609
3 LITRES (0.66 gals)
MAKE-UP BOTTLE
(if required)
NON-RETURN
VALVE
AUTO
AIR
VENT
FLOW
DRAIN
COCK BOILER
SAFETY
VALVE
(Make-up
alternatives) EXPANSION
VESSEL
PRESSURE
GAUGE
CIRCULATING
PUMP
FILLING POINT
AIR
RELEASE
POINT
HEATING CIRCUIT
40/50-15mm (min)
60-15mm (min)
BY-PASS WITH
LOCKSHIELD
VALVE
RETURN
15mm (min)

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
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
0051
M
2 Water Sytem
2.12 Pressure Gauge
A pressure gauge with a set pointer and covering at least 0 to
4bar (0 to 60lb/in2) shall be fitted permanently to the system is
a position where it can be seen when filling the system.
2.13 Domestic Hot Water Cylinder
SINGLEFEEDINDIRECTCYLINDERSARENOTSUITABLE.
The hot water cylinder must be of the indirect coil type. It must
be suitable for working at a gauge pressure of 0.35bar above
the safety valve setting.
2.14 Water Makeup
Provision should be made for replacing water loss from the
system using a make up bottle or filling loop mounted in a
position higher than the top point of the system, connected
through a non-return valve to the return side of either the
heating circuit or the hot water cylinder.
Alternatively, provision for make up can be made using a filling
loop.
2.15 Filling a Sealed Water System
Provisionforfillingthesystematlowlevelmustbemade. Three
methodsareshownindiagram2.5. Theremustbenopermanent
connection to the mains water supply, even through a non-
return valve.

11 221834B
Diagram 3.1
Ventilation
From Outside
Ventilation high level low level
From Room cms in2cms in2
Energysaver 40 123 19.1 123 19.1
PERMANENT
SURFACE
*
5
*
5
55
150
100
500
*
INCREASE THIS DIMENSION TO
25mm FROM COMBUSTIBLE MATERIAL
CLEARANCE OPPOSITE TO FLUE EXIT
MUST BE ADEQUATE FOR THE
INTERNAL INSTALLATION
0157M
5
*
5
TABLE 4
3 Boiler Location
NOTE:
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 total weight, see Data Table 1.
3.1 Boiler Clearances
The boiler must be positioned so that at least the minimum
operational and servicing clearances are as shown in diagram
3.1.
Additional clearances may be required around the boiler for
installation purposes, dependent upon site conditions.
3.2 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
documentIGE/UP/7/1998. Ifindoubtseekadvicefromthelocal
gas undertaking or Hepworth Heating Ltd.
3.3 Room Ventilation
Theboilerisroom sealed, sowheninstalledina room orspace
a permanent air vent is not required.
3.4 Cupboard or Compartment Ventilation
Where the boiler is fitted in a cupboard or compartment,
permanenthighandlowlevelventilationmustbeprovided. The
ventilation areas required are given in Table 4.
Wheretheinstallationoftheboilerwillbeinanunusuallocation,
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.
The doorway opening should be of sufficient size to allow for
easy removal of the boiler.
Energysaver 40 62 9.6 62 9.6

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 flue slopes
2
˚
down
towards the boiler
that is 35mm fall per metre
of flue length (2
˚
)
Make sure flue slopes
2
˚
down towards
the boiler
that is 35mm fall
per metre
of flue
length (2
˚
)
300mm
2
˚
10.5mm
REAR FLUE
SIDE VIEW
R = Wall Thickness
STD Flue pack 80mm to 331mm
4 Flue
NOTE:
The flue must be installed in accordance with the current issue
of BS5440 Part 1.
Important. The flue must be installed with a fall of 35mm per
metre (2o) towards the boiler, see diagram 4.1.
It is of no advantage to exceed this angle (2o) indeed sealing of
the fan to flue elbow may become more difficult as the angle is
increased.
The air and flue duct connect to the top of the boiler using an
elbow which can be positioned to the side or 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.
Fora wallthicknessover300mmtheexternalcut holewillneed
to be made good from the outside.
The standard flue is able to provide the duct lengths as shown
in diagram 4.2 for a rear flue and diagram 4.3 for a side flue.
If a longer flue duct is required, do not extend the ductings. A
1, 2 or 3metre long flue system and terminal can be supplied.
STD Flue pack 75mm to 442mm
3m Flue pack 75mm to 2933mm
2m Flue pack 75mm to 1953mm
3m Flue pack 80mm to 2821mm
2m Flue pack 80mm to 1841mm
1m Flue pack 75mm to 953mm
1m Flue pack 80mm to 841mm
'R'
'S'
6861 6860

13 221834B
Diagram 4.4
0103M
A
A
FGEA
G
G
G
B,C B,C
FF
K
K
K
C
G
LL
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
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
K VERTICAL FROM A TERMINAL 1500
L HORIZONTALLY FROM A TERMINAL 300
MINIMUM SITING DIMENSIONS
FOR FANNED FLUE
TERMINALS POSITION
MINIMUM
SPACING
in mm
H,I
4 Flue
4.1 Terminal Position
The minimum acceptable spacings from the terminal to
obstructionsand ventilation openings are as shown in diagram
4.4.
The boiler must be installed so that the terminal is exposed to
the external air.
It is important that the position of the terminal allows the free
passage of air across it at all times.
Note. The flue will produce a plume of condensation in cold
weather,sospecialcaremustbetakeninsitingtheflueterminal
so as not to cause a nuisance to adjacent property.
Where the terminal is fitted within 600mm (24in) below plastic
guttering an aluminium shield 1500mm (5ft) long should be
fittedtotheundersideandimmediatelybeneaththegutteringor
eaves.
Wheretheterminalisfittedwithin450mm(18in)beloweavesor
painted guttering an aluminium shield 750mm (2ft6in) long
should be fitted to the underside and 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
aminimumof50mmclearancefromanypartoftheterminaland
be central over the terminal, see diagram 4.4.
A suitable terminal guard can be obtained from:
Tower Flue Components Ltd.,
Morley Road,
Tonbridge,
Kent.
TN9 1RA
their reference, CGD K3 BL
0161M
* It may be necessary to increase this dimension to prevent
staining of adjacent walls depending on weather conditions.

14
221834B
Diagram 5.1
Diagram 5.2
Diagram 5.3
SECURING
SCREW(4)
INNER
FITTING
➁M5x10mm
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
5.1 Unpacking: diagram 5.1
Open top carton, remove top fitting, wall template, loose items
fittings pack and boiler mounting bracket.
Remove carton wrap and spacing pieces
Liftoffwhiteoutercasefront. Removeprotectivepackingpiece.
Remove the cover of the inner case, see diagram 5.3.
5.2 Rear and Side Flue Application
Having selected the location and flue application, with due
regard to the terminal position:
Take the template and temporarily position it on the wall see
diagram 5.4, making sure that the minimum clearances are
maintained.
For a rear flue, mark the position of the flue as diagram 5.4.
LOOSE ITEMS PACK
CONTROLS
FITTING
For a side flue, extend the centre line horizontally (taking into
account the required fall towards the boiler) left or right to the
corner of the adjacent surface where the flue is required to exit
to the outside. Alternatively, the increase in the centre height
over a distance “X”is given by H = 0.35X. Mark the position of
the centre of the flue as in diagram 5.4.

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
5.3 Flue Hole Cutting
Having marked out the flue centre cut a hole for the flue see
diagram 5.5 for minimum core drill size for various wall
thicknesses.
Thiswillallowforthe35mmpermetre(2o)falltowardstheboiler.
Note: If required, an optional Wall Liner Kit, part No.900862, is
available, complete with fixing instructions.
5.4 Wall Mounting Bracket
Repositionthetemplate,makingsureofdimensionalalignment
with the flue centre lines
Mark the boiler securing screws and mounting plate position,
see diagram 5.6.
Drill holes and plug, fit the securing screws allowing sufficient
clearance to accept the keyhole fixing brackets and secure the
boiler mounting bracket to the wall.

16
221834B
OLIVE
FLOW
RETURN
28mm O.D.
COPPER
TUBING
WATER CONNECTIONS
FLUE GAS
SAMPLE
POINT
UNION NUT
4037
6 Water and Condensate Connections
It is, therefore, recommended that any external condensate
drain pipe is insulated to prevent it freezing up.
Alternatively,alarger diameter pipecanbeused andinsulated.
The condensate drain pipe should be checked during any
servicing and any debris found removed.
Refer to the British Gas publication “Guidance Notes for the
Installation of Domestic Condensing Boiler”for advice on the
disposal of boiler condensate.
Diagram 6.1
0170
Diagram 5.7
4043 S
CLEAR
TUBES
ELECTRICAL
CONNECTIONS
SECURING
SCREWS (3)
RED TUBE
Diagram 5.6
TEMPLATE BOILER TOP
FIXING POINTS
7dia.
7dia.
3/16dia. PLUG
NO.
12x2in.
NO.
12x2in.
BOILER MOUNTING
BRACKET
5mm MOUNTING
BRACKET
FIXING
POINT(S)
3/16dia. PLUG
5 Preparation
6 Water Connections
Makethewater connection totheheatingsystem,see diagram
6.1.
The boiler has compression connections with nuts and olives
supplied loose in the fittings pack, to accept 28mm outside
diameter copper tubing to BS2871.
The 28mm connections can be reduced to 22mm for the
Energysaver 40, provided the system resistance does not
exceed the chosen pump duty.
The right hand connection is the flow from the boiler.
6.1 Condensate Connection
The condensate drain connection is at the bottom right of the
boiler.
The drain ends in a spigot which is suitable for push fit 22mm
(3/4in) plastic overflow pipe, for example, Hepworth Polypipe,
Uponor, Osma, Orcaster. If using Marley, Terain or Hunter
tubing,whichisslightlylarger,usethesiliconesealantprovided
in the fittings pack to make a leak proof joint to the drain
connection on the boiler.
The condensate discharge pipe should have a fall of 21/2o.
Itisnotnecessarytoprovideairbreaks,ortrapsinthedischarge
pipe since the boiler has an integral 50mm trap and siphon.
Theboilerisfittedwithasafetydevicetopreventtheboilerfrom
working if the condensate pipe gets blocked by either ice or
debris.
AIR
PRESSURE
TUBES
5.5 Boiler Preparation
Lift the boiler into position above the boiler mounting bracket,
lowering the boiler into position at the same time locating the
key hole slots of the boiler on to the securing screws, when
located secure the screws, see diagram 5.6.

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.
Refer to diagram 7.3, mark through the holes in the flue elbow
assemblyanddrilltheductasshown,makingsureofthecorrect
alignment of the “Top”.
7.2 Side Flue
Mark and cut the air duct terminal assembly, see diagram 7.4
and flue duct, diagram 7.5 to the lengths required, cutting
square and removing any burrs.
Refer to diagram 7.3 mark through the holes in the flue elbow
assembly and drill the flue duct as shown, making sure of the
correct alignment of the “Top”.
7.3 Internal Flue Assembly
Ifaccess totheoutsidewallisnotpractical,theflue systemcan
be installed from inside. Use of the optional wall liner kit
recommended.
Apply sealant to the flue duct, locate into the air duct terminal,
see diagram 7.6.
Apply sealant to the flue elbow spigot and then locate the flue
and air duct terminal assembly to the flue elbow as shown in
diagram 7.3, making sure of the alignment of the “Top”.
Securetheairduct/terminalassemblytotheflueelbowandflue
duct assembly with the two self tapping screws supplied in the
loose items pack and then seal with the tape provided.
Place the flue assembly into the flue hole. Make sure that the
flue terminal is correctly positioned and projecting the correct
distance from the outside wall face, see diagram 7.9.
7.4 External Flue Installation
Locate the air duct/terminal assembly into the flue elbow
assembly as shown in diagram 7.3, making sure of correct
terminal alignment of the “TOP”.
Mark the position of the air duct terminal assembly securing
holes and drill two 2.8mm diameter holes through the air duct/
terminal assembly.
Apply sealant to the flue duct and locate into air duct terminal,
see diagram 7.6.
From outside, place the air duct/terminal assembly and flue
duct into the flue hole. Make sure that the flue terminal is
correctly positioned and projecting the correct distance from
the outside wall face, see diagram 7.9.
Apply sealant to the flue elbow spigot and then locate the flue
andairductterminal assembly as shown in diagram 7.3, make
sure of the correct alignment of the “Top”.
Secure the air duct terminal to the flue elbow with the two self
tappingscrewssupplied in thelooseitems pack, thensealwith
the tape provided.
7.5 Flue Elbow
Fit the flue elbow gasket, from the fittings pack, to the casing
top.
The two fan bracket securing screws should be loosened, but
notremoved,beforeslackeningthethreefansecuring screws.
Afterlocatingtheflueelbowintotheoutletofthefan,securethe
flue elbow onto the top panel with the four M4x14 screws
provided.
Then push fan upward, making sure that the flue elbow spigot
engages inside the fan outlet and compresses the gasket. Diagram 7.1
"Q"
STANDARD FLUE
TERMINAL
LONG FLUE
TERMINAL
"Q" plus 67mm
6862
Complete assembly by fully tightening the two fan bracket
securing screws.
Finally tighten the three fan securing screws.
Fit the inner case door.

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
SEALANT AIR DUCT/
TERMINAL AND
FLUE DUCT
ASSEMBLY
BOILER
CENTRE
LINE
BOILER
CENTRE
LINE
"N" minus 57mm
STANDARD FLUE
TERMINAL
LONG FLUE
TERMINAL
6864
4079
6885
7 Flue Installation
Diagram 7.2
"Q" plus 82mm
FLUE DUCT
"Q"
FLUE DUCT
6863

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 7.6
FLUE DUCT
SEALANT
AIR DUCT/
TERMINAL
ASSEMBLY FLUE DUCT
4080
7.6 Wall Liner
If a wall liner is used, fit self adhesive seal as follows :
For wall thicknesses up to 300mm fit the self adhesive seal to
the air duct, see diagram 7.7, make sure the joint is on top.
For wall thicknesses over 300mm see diagram 7.8.

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 8.1
PLUGS
BURNER
PRESSURE
TEST POINT SECURING
SCREW
GAS SERVICE
COCK (SHOWN
OFF)
SECURING
SCREWS
(4)
SOLENOID
SECURING SCREW SUPPORT BRACKET
SECURING SCREW
9022
UNION
CONNECTOR
Make the gas connection to the gas service cock, see diagram 8.1
WARNING: This boiler must be earthed.
Remove the screws as diagram 9.1.
Pullthecontrolboxforwardstoreleasefromtherearslot,allow
to pivot and place into position as shown in diagram 9.1.
Using PVC insulated cable to the current issue of BS6500
Table16,andofasuitablelength,threadthe cablethroughthe
small cable clamp and connect to the appropriate terminals,
see diagram 9.2.
Standardcolours are,brown-live(L),blue- neutral(N),green/
yellow - earth (E) .
Themainscable outerinsulationmustnot becutbackexternal
to the cable clamp.
Whenmakingconnections,makesurethattheearthconductor
ismadeofagreaterlengththanthecurrentcarryingconductors,
sothatifthecableisstrained the earth conductor would be the
last to become disconnected.
It is essential that the polarity is correct.
MULTI-FUNCTIONAL
CONTROL
SECURING
SCREW