Glowworm Economy Plus C 40 Operating manual

Supplied By www.heating spares.co Tel. [phone]
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]
221461C.01.00
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.
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:
Guarantee Registration
Open Flue Boiler
This is a Cat I2H Appliance
BS 6332
BS 5258
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.
Tobeleftwiththeuser
❏
✔
❏
✔
❏
✔
Instructions for Use
Installation and Servicing
G.C. No. 41 319 38
REGISTER YOUR GLOW-WORM APPLIANCE
FOR 1ST YEAR GUARANTEE PROTECTION
CALL 0181 380 2555
40
C
2402
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.

Supplied By www.heating spares.co Tel. [phone]
2
221461C
Important Information
Introduction 3
Lighting the Boiler 4
General Data 1 5
Flue and Ventilation 2 7
Water Systems 3 8
Installation 4 10
Electrical Wiring 5 11
Commissioning 6 12
Servicing and Replacement Parts 7 14
Fault Finding 8 19
Spare Parts 9 24
CONTENTS DESCRIPTION SECTION PAGE No.
INSTRUCTIONS
FOR USE
INSTALLATION
INSTRUCTIONS
SERVICING
INSTRUCTIONS
Testing and Certification
Thisboileristestedandcertificatedforsafetyandperformance. Itisthereforeimportantthatnoalterationismadetotheboiler,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 1.3.
CE Mark
This boiler meets the requirements of Statutory Instrument No. 3083 The boiler (Efficiency) Regulations, and therefore is deemed
tomeettherequirementsofDirective92/42/EEContheefficiencyrequirementsfornewhotwaterboilersfiredwithliquidorgaseous
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.
REFRACTORY CERAMIC FIBRE
This product uses insulation material containing Refractory Ceramic Fibre (RCF), which are man-made vitreous silicate fibres.
Excessive exposure to these materials may cause temporary irritation to eyes, skin and respiratory tract, consequently, it makes
sense to take care when handling these articles to ensure that the release of dust is kept to a minimum.
To ensure that the release of fibres from these RCF articles is kept to a minimum, during installation and servicing we recommend
thatyouuseaHEPAfilteredvacuumtoremoveanydustaccumulated inandaroundtheboilerbeforeandafterworkingontheboiler.
Whenreplacing these articleswe recommend thatthe replaced itemsare not brokenup, but aresealed within heavyduty polythene
bags, clearly labelled as RCF waste. This is not classified as “hazardous waste” and may be disposed of at a tipping site licensed
for the disposal of industrial waste. Protective clothing is not required when handling these articles, but we recommend you follow
the normal hygiene rules of not smoking, eating or drinking in the work area and always wash your hands before eating or drinking.
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
notcauseaproblem,but in caseofskincontact,washwithcold water. Ifswalloweddrinkplentyofwaterand seek medical attention.
COMBUSTION PRODUCTS DISCHARGE SAFETY DEVICE
These contain very small amounts of ethylene glycol and methanol in the capillary. If broken, under normal circumstances the fluid
doesnotcauseaproblem,butincasesofskinoreyecontact,washwithcoldwater.Ifingested,drinkplentyofwaterandseekmedical
attention.

Supplied By www.heating spares.co Tel. [phone]
3221461C
Instructions for Use
General Notes and Information
Please read these instructions and follow them carefully for the
safe and economical use of your boiler.
Important Notice
This boiler is for use only on G20 gas.
The convection air openings on the boiler must NEVER be
obstructed.
The Gas Safety (Installation and Use)
Regulations
Inyour interests and that ofgassafety it is the Lawthat ALL gas
appliances are installed by a competent person in accordance
with the current issue of the above regulations.
Maintenance
Toensurethecontinuedefficientandsafeoperationoftheboiler
it is recommended that it is checked and serviced at regular
intervals. The frequency of servicing will depend upon the
particular installation and usage, but in general once a year
should be enough.
To obtain service, please call your installer, or Heatcall (Glow-
worm’s own service organisation) using the telephone number
given on the controls tray.
Iftheappliance is installed in arentedproperty there is a duty of
care imposed on the owner of the property by the current issue
oftheGasSafety(InstallationandUse)Regulations,Section35.
Itis the Law thatservicing is carried outby a competent person.
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.
Gas Leak or Fault
If a gas leak or fault exists or is suspected the boiler must be
turned off also the electrical supply. Advice/help should be
obtained from your installation/servicing company or the local
gas company.
Protection Against Freezing
If the boiler is to be out of use for any long period of time during
severeweather conditions werecommend that the whole of the
system, including the boiler be drained off to avoid the risk of
freezing up. If an immersion heater is fitted in the domestic hot
water cylinder make sure that it is switched off.
If you have a sealed water system you should contact your
installer/servicing company as a sealed water system should
onlybedrained,refilledandpressurisedbyacompetentperson.
Boiler Clearance
The boiler must be positioned so that at least the minimum
operationalandservicingclearancesareprovided,seediagram
1.
Iffixturesarepositionedclosetotheboiler they should be made
removable for access to pipework.
Enough space must be left in front of the boiler for servicing.
Boiler in a Compartment
If the boiler is fitted in a compartment or cupboard, purpose built
ventilation must be provided and kept clear.
Do not use the enclosed space for storage.
Boiler Identification
The type of boiler and its output can be checked against the
details inside the controls cover.
Overheat Cutoff Device
The boiler is fitted with a safety device to prevent damage
throughoverheating. Shouldthe boiler go out togetherwiththe
pilotfornoapparentreason,allowthesystemtocooldown,then
relight the boiler.
Should the problem persist, turn the boiler off and consult your
installation/servicing company.
Electrical Supply
WARNING. The boiler must be earthed.
The boiler must only be connected to a 240V~50Hz supply,
protected by a 3A fuse, maximum.
All wiring must be in accordance with the current issue of
BS7671.
Heat resistant cable having a conductor size of 0.75mm2, (24/
0.20mm) to BS6500 Table 16 must be used.
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”, Green or the earth symbol .
AL.H. and R.H. side of casing 25
BTop of casing 75
CBottom of casing 150
DFront of boiler (from a
permanent surface 305
OPEN FLUE BOILERS
Minimum Clearances from
Walss, Ceiling, Floor, etc.
Diagram 1
MINIMUM
CLEARANCES
A
B
2390
A
C

Supplied By www.heating spares.co Tel. [phone]
4
221461C
Instructions for Use
Safety Device
Thisapplianceisfittedwithaflueblockage safety device which
will shut down the appliance in the event of abnormal flue
conditions.ThisdeviceisNOTasubstituteforanindependently
mounted Carbon Monoxide detector.
Thesafetydevice isreset,afterthreeminutesbypushinginthe
button “ F ” shown in diagram 3.
Note: The pilot will stay alight but the device must be reset.
Shut down can occur during certain climate conditions, 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.
Lighting the Boiler
CAUTION
Ifthepilotflamegoesout,eitherintentionallyorbyaccident,no
attempt should be made to relight for at least three minutes.
Slide the controls cover off and clear, see diagram 2.
Makesurethattheelectrical supply totheboilerisswitchedoff.
Identify the controls by referring to diagram 3.
Turn the control thermostat knob “A” fully anticlockwise to the
“OFF” position.
Pushandholdingascontrolknob“B”. Pushandreleaseigniter
button “C” until the pilot burner lights, look through window “D”.
When the pilot is alight keep gas control knob “B” pushed in for
about 15 seconds and then release.
Ifthepilotdoesnotlightorfailstostayalight,waitthreeminutes
and repeat the lighting operation, only this time keep knob “B”
pushed on for a little longer.
The flue blockage safety device may also need resetting, refer
to safety device instructions.
Make sure that the pilot is alight and stable.
Switch on the electrical supply to the boiler.
Check that all external controls are calling for heat.
Turn control thermostat knob “A” fully clockwise to “MAX” and
themainburnerwilllightfullyinaboutthreetofiveseconds,look
through window “D”.
Ifthemainburnerdoesnotlight,theflueblockagesafetydevice
may need resetting, refer to Safety Device instructions.
Adjustthecontrolthermostatknobtothedesiredsettingbetween
“MIN” and “MAX”. “MAX” is about 82oC (180oF).
Replace controls cover.
To Turn the Boiler Off
Forshortperiods,turncontrolthermostatknob“A”anticlockwise
until “O” is against the setting point. The pilot will stay alight, to
relightthemainburnerturncontrolthermostatknob“A”clockwise
to the desired setting between “MIN” and “MAX”.
For longer periods, turn the control thermostat knob “A”
anticlockwise until “O” is against the setting point. Slide gas
controlknob“B”toleftandrelease,thecontrolwillautomatically
reset. Switch off the electrical supply.
To relight, follow the full lighting procedure given above.
Cleaning
WARNING. Thisappliancecontainsmetalparts(components)
and care should be taken when handling and cleaning, with
particular regard to edges.
Clean the casing by wiping it over occasionally with a wet cloth
or dry polishing duster.
Do not use abrasive cleaners.
Diagram 2
CONTROLS
COVER
2391
BOILER
CONTROLS Diagram 3
A
D
C
MODEL AND
SERIAL
NUMBER
PLATE
F
A. CONTROL THERMOSTAT KNOB
B. GAS CONTROL KNOB
C. IGNITER BUTTON
D. VIEWING WINDOW
F. FLUE BLOCKAGE SAFETY DEVICE
RESET BUTTON
B
5354

Supplied By www.heating spares.co Tel. [phone]
5221461C
1 General Data
1.1 Important Notice
This boiler is for use only on natural gas G20.
The boiler is delivered in one pack.
Wherever possible, all materials, appliances and components
to be used shall comply with the requirements of applicable
British Standards.
Where no British Standards exist, 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 fitting out of doors.
The boiler must not be installed in a bedroom, bed sitting room
or a room containing a bath or shower.
Open flue boilers must not be installed in private garages.
1.2 Sheet Metal Parts
WARNING. When installing or servicing the boiler care should
betakenwhenhandlingsheetmetalpartstoavoidanypossibility
of personal injury.
1.3 Statutory Requirements
Theinstallationofthisboilermustbecarriedoutbyacompetent
person in accordance with the relevant requirements of the
current issue of:
Manufacture’s instructions, supplied.
TheGasSafety(InstallationandUse)Regulations,TheBuilding
Regulations, The Building Standards (Scotland) Regulations
(applicable in Scotland), local Water Company Byelaws, The
HealthandSafetyatWorkAct,ControlofSubstancesHazardous
to Health, The Electricity at Work Regulations and any local
applicable regulations.
Detailed recommendation are contained in the current issue of
the following British Standards and Codes of Practice:
BS4814, BS5400 Part and 2, BS5449, BS5446, BS6700,
BS6798, BS6891, BS7074 Part and 2, BS7478, BS7593,
BS7671.
Manufacturers’ instructions must not be taken as overriding
statutory requirements.
1.4 Data
Weight of boiler: 40C - 20.1kg (44.3lb)
Water content: 40C - 0.50Litre (0.11gal)
Gas connection: Rc1/2
Water connection: 22mm copper flow at right
Electrical supply: 240V - 50Hz fused at 3A
Data label: Bottom of inner case door.
Injector: 40C - Cat 98 - 1150
The Seasonal Efficiency Domestic Boilers UK (SEDBUK)
is 71.9%.
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.
1.5 Range Rating
The boiler is range rated and may be adjusted to suit individual
system requirements.
The respective Table 1 gives the ratings and settings.
,
,
,
,










INSIDE DIAMETER
OF SPIGOT FOR
100 mm (4in) NOMINAL
DIAMETER FLUE
242
115
DIA.
RETURN FLOW
WATER
CONNECTIONS
11
GAS CONNECTION 40
36
600
360
FLUE
C
L86
43
WATER
CONNECTIONS
490
GAS
CONNECTION
110
225
98
300
*
*
Diagram 1.1
OVERALL DIMENSIONS (given in millimetres)
2409

Supplied By www.heating spares.co Tel. [phone]
6
221461C
1 General Data
1.6 B.S.I. Certification
This boiler is certificated to the current issue of BS6332 Part 1,
invoking the current issue of BS5258 Part for performance and
safety. It is, therefore, important that no alteration is made to
boiler without permission, in writing, from Hepworth Heating
Ltd.
Any alteration that is not approved by Hepworth Heating Ltd.,
couldinvalidatetheB.S.I.,certificationoftheboiler,thewarranty
and could also infringe the current issue of the Statutory
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
toprovideasteadyinletworkingpressureof20mbar(8inwg)at
the boiler.
Oncompletion,testthegasinstallationforsoundnessusingthe
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 shall be of the approved type and be
wired and connected in accordance with requirements 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
3Amaximum. Thismethod of connection should be byafused
double pole isolating switch, which has a minimum contact
separationof3mmonbothpoles. This switchshouldbereadily
accessible and preferably adjacent to the appliance. It should
supplytheapplianceonlyandbeeasilyidentifiableassodoing.
Wiring to the boiler must be insulated PVC flexible type to the
current issue of BS6500 Table 16, not less than 0.75mm2(24/
0.20mm).
1.9 Draining Tap
A draining tap must be provided at the lowest points of the
system which will allow the entire system, boiler and domestic
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 Clearances
Theboilerpositionshouldbesuchthattheclearancesshownin
diagram 1.2 are achieved.
Additional clearances may be required for installation.
Iffixtures are positioned next to the boilerthey should be made
removable for access to pipework.
Sufficient clearance must be left in front of the boiler for
servicing.
The casing side grilles must be kept clear at all times.
The boiler must be mounted on a flat wall which is sufficiently
robust to take its weight.
AL.H. and R.H. side of casing 25
BTop of casing 75
CBottom of casing 150
DFront of boiler (from a
permanent surface) 305
Minimum Clearances
from Walls, Ceiling,
Floor, Cupboard, Worktops etc.
Diagram 1.2
BOILER FIXING DIMENSIONS
AND MINIMUM CLEARANCES
B
518
232 200 200 C
A
46
300
Boiler
Outline Minimum
clearance
limit
0003M
1.12 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.
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-Conservationoffuelandpower,1995edition-Appendix
G, table 4b.

Supplied By www.heating spares.co Tel. [phone]
7221461C
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
interferred with or put out of action.
The safety device must only be replaced with the Glow-worm
parts.
2 Flue Connection
Theintegraldraughtdiverterontheboilermakesthecombustion
performance independent of the conditions in the secondary
flue,butincommonwithotherfuelsanefficientflueisnecessary
to ensure a trouble free installation.
The flue outlet on the boiler is designed to take flue pipes to
BS567. If a flue pipe to BS715 is to be used an adapter must
be fitted to the boiler flue socket.
The flue must be in accordance with the current issue of
BS5440 Part 1.
Give maximum possible vertical rise from the boiler, at least a
minimum of 600mm, before any offset or bend. The use of 90o
bends is not recommended.
An existing flue must be lined and end, at least above ridge
height, with a certificated terminal.
Achimneypreviouslyusedforsolidfuelmustbesweptandany
damper or register plate left in the locked open position or
removed.
2.1 Boilers in a Compartment
Wheretheinstallationoftheboilerwillbeinanunusuallocation,
specialproceduresarenecessary,thecurrentissueofBS6798
gives detailed guidance on this aspect.
A compartment used to enclose the boiler must be designed
and constructed specifically for this purpose.
Anexistingcupboard or compartment modified for thepurpose
may be used. Details of essential features of 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 “A”.
2.2 Boiler Installed in a Room or Space
Apurposedesignedventilationopeningmustbeprovidedonan
outside wall of the premises, refer to the current issue of
BS5440 Part 2 for further information.
The opening may be either, directly into the room or space
containing the boiler or into an adjacent room or space which
hasaninternalpermanentairventofthesamesizeastheroom
containing the boiler.
DONOTventilatethroughaprivategarage,bedroom,bedsitting
room or a room containing a bath or shower.
Air vents through a cavity wall must be ducted.
Whentheboiler is installed in a spacealreadycontainingafuel
burning appliance account must be taken of the TOTAL air
requirement.
2.3 Extract Fans
Ifanextractfanisfittedinthepremisesthereisapossibilitythat
if adequate air openings are not provided spillage of products
from the boiler may occur.
When openings are fitted in accordance with the
recommendationsofthecurrentissueofBS5440Part1andthis
Section,extractfansshouldnotcausespillage,butwheresuch
an installation is found spillage tests as the current issue of
BS5440 Part 1 must be carried out.
The necessary action should then be taken.
See also Section 6.6.
Range Rating
Nominal kW
Heat
Input (GROSS) Btu/h
11.14 12.90 14.65
38,000 44,000 50,000
min medium max
Burner m bar
Setting
Pressure in.w.g
Nominal kW
Heat
Output Btu/h
8.80 10.26 11.70
30,000 35,000 40,000
7.8 10.4 13.1
3.1 4.2 5.3
Table 1 ECONOMY PLUS 40C
Burner Injector Marking: 1.25
Burner Injector Size: 1.25 X 7
Pilot Injector Marking: 7218
TABLE "A" COMPARTMENT AIR VENTS
ECONOMY PLUS 40C
High Level
Vent Area Low Level Vent Area
Ventilation
Requirements
Air from room or
internal space 132cm2264cm2
Air direct from
outside 66cm2132cm2
ECONOMY PLUS 40C
TABLE "B" ROOM/SPACE AIR VENTS
Effective area
of vent 35cm2

Supplied By www.heating spares.co Tel. [phone]
8
221461C
Notes:
PUMP
Thepumpwithintegralvalves,ifpossible,shouldbefittedinthe
flowpipeworkfromtheboiler,toproduceatemperaturedifference
across the boiler of 11oC (20oF).
See diagram 3.1 for pressure loss across the boiler.
High resistance microbore systems may require a higher duty
pump.
BYPASS
A bypass must be fitted, see diagram 3.2.
The flow through the boiler must not be allowed to fall below:
40C - 10.5L/min (2.3gall/min)
whilst the burner is alight.
3.1 Open (Vented) Water System
For an open (vented) water system the boiler must be supplied
from an unrestricted water supply taken from a cold feed and
expansioncistern situatedatamaximumheightof27.5 metres
(90ft) above the boiler.
The cold feed supply must be 15mm minimum size.
It is important that the relative position of the pump, cold feed
and open vent are as shown in diagram 3.2.
3.2 Domestic Hot Water Cylinder
Thedomestichotwatercylindermustbeofthedoublefeed,fully
indirect type. Single feed, self priming cylinders are not
recommended.
3.3 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, contact a manufacturer for their
recommendations for the best product to use.
When installing a boiler in an existing system, whether or not
using an inhibitor, take special care to drain the entire system,
including the radiators, then thoroughly cleaning out before
fitting the boiler and adding the inhibitor.
3.4 Sealed Water Systems
Theinstallationshouldcomplywiththeappropriaterequirements
ofthecurrent issue of BS4814, BS5449,BS6759,BS6798 and
BS7074 Part 1 and 2.
See diagram 3.3 for a diagrammatic layout.
3.5 Safety Valve
A safety valve must be fitted to a sealed water 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.
Diagram 3.1
PRESSURE LOSS OF BOILER
Diagram 3.2
Open (vented) system.
Recommended
relationship between
pump, cold feed and
vent.
22 mm (MIN) VENT
FEED AND
EXPANSION
CISTERN
15mm (MINIMUM)
COLD FEED
15mm (MINIMUM)
BY-PASS WITH
LOCKSHIELD VALVE
450mm
MIN.
HEIGHT
1150mm
MIN.
150
mm
MIN.
BOILER
PUMP
150mm
MAX
FLOW
RET.
ALTERNATIVE
PREFERRED
RET.
CYLINDER
FLOW
HEATING
0392
3 Water Systems
GALLONS/MINUTE
LITRES/MINUTE
FUELSAVER 40C
WATER PRESSURE LOSS
(m head of water)
WATER PRESSURE LOSS
(in head of water)
0124
35
0510 15 20 25
55
50
45
40
35
30
25
20
15
10
5
0
1.4
1.2
1.0
0.8
0.6
0.4
0.2
0
6927

Supplied By www.heating spares.co Tel. [phone]
9221461C
3 Water Systems
3.6 Expansion Vessel
A diaphragm type expansion vessel, conforming to the current
issue of BS4814 (see also the current issue of BS7074 Part 1
and2)must beconnectedata pointclosetothe inletsideofthe
circulating pump, see diagram 3.3, unless laid down differently
by the manufacturer.
The expansion vessel volume depends on the total water
systemvolumeand theinitialsystemdesign pressure. For any
system an accurate calculation of vessel volume 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.
Guidance is also given in the current issue of BS5449.
Thechargepressuremustnotbelessthanthestaticheadofthe
system, that is, the height of the highest point of the system
above the expansion vessel.
The water capacity of the boiler is given in Section 1.
3.7 Pressure Gauge
A pressure gauge with a set pointer and covering at least the
range of 0 to 4 bar (0 to 60lb/in2) shall be permanently fitted to
the system in a position where it can be seen when filling the
system.
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
15mm (min)
BY-PASS WITH
LOCKSHIELD
VALVE
RETURN
SEALED WATER SYSTEM DIAGRAMMATIC LAYOUT
EXPANSION VESSEL SYSTEM
EXPANSION VESSEL
PRESSURE (BAR)
A = SYSTEM VOLUME Diagram 3.4
INTIAL SYSTEM
PRESSURE (BAR)
EXPANSION VESSEL
VOLUME (LITRES)
INTIAL SYSTEM
PRESSURE (BAR)
EXPANSION VESSEL
VOLUME (LITRES)
EXPANSION VESSEL
PRESSURE (BAR) 0.5
1.0
A X 0.075 A X 0.126
A X 0.098 A X 0.171
0.5 1.0
1.0 1.5
Diagram 3.3
5812

Supplied By www.heating spares.co Tel. [phone]
10
221461C
3 Water Systems
Diagram 3.5
FILLING SEALED
WATER SYSTEMS
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
3132
3.8 Domestic Hot Water Cylinder
SINGLEFEEDINDIRECTCYLINDERSARENOTSUITABLE.
Thedomestichotwatercylindermustbeoftheindirectcoiltype.
It must be suitable for working at a gauge pressure of 0.35bar
above the safety valve setting.
3.9 Water Make-up
Provision should be made for the replacing the water loss from
thesystemusingamake up bottlemountedinapositionhigher
than the top point of the system, connected through a non-
return valve to the return side of either the heating circuit of the
domestic hot water cylinder.
Alternatively, provision for make up can be made by using a
filling loop.
3.10 Filling a Sealed Water System
Provisionforfillingthesystematlowlevelmustbemade. Three
methodsareshownindiagram3.5. Theremustbenopermanent
connection to the mains water supply, even through a non-
return valve.
4.1 Appliance Preparation
Remove the controls cover by pulling it forwards and off, see
diagram 4.1.
Remove the boiler from the carton and lay it on its back.
The side grilles are packed in the bottom of the carton.
Remove the outer case by undoing the screws at the bottom
and unhooking at the top, see diagram 4.1.
Remove the two screws and attach the side grilles by hooking
over the top of the side panel and secure, see diagram 4.1.
4.2 Appliance Fitting
Refer to diagram 1.2 for fixing screw positions and minimum
clearances.
Mark position of the three fixing screws.
Drill and plug the holes, suitable for No10x2in woodscrews.
Fit the screws, leave about 6mm proud.
Hook the boiler on to the lower screw and keyhole slots at the
top, tighten all screws.
Connect the system pipework to the boiler.
Fixthefluetothe flue hoodinaccordancewithnormalpractice.
4 Installation