221834B.11.00 Instructions for Use Installation and Servicing 4040/S To b e l e f t w i t h t h e u s e r Energysaver 40 G.C. No. 41 319 69 High Efficiency Boiler PAS010 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.
Important Information TESTING AND CERTIFICATION CERAMIC FIBRE/INSULATION PADS, GLASSYARN. 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. 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.
GREEN LIGHT FOR HIGH FLAME HIGH/LOW CONTROL KNOB CONTROL THERMOSTAT KNOB 0163M Instructions for Use min GREEN LIGHT FOR LOW FLAME 0 ma x te m p ORANGE DEMAND LIGHT Diagram 1 Introduction Maintenance/Servicing Please read these instructions and follow them for the safe and economical use of your boiler. 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.
Instructions for 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. 150 *5 Boilers Installed in a Compartment or Cupboard If the boiler is installed in a cupboard or compartment do not obstruct any ventilation openings. 5 Do not use the cupboard or compartment for storage. 5 Regularly make sure that the air vent openings are clear of obstructions.
Instructions for Use Overheat Safety Cutoff To Turn the Boiler Off If the cutoff operates on any other occasion than an electrical failure, press the reset button as stated in “Electrical Supply Failure”. For short periods, turn thermostat control knob anti-clockwise until “O” is against the setting point. To relight the main burner, turn the thermostat knob clockwise to any setting between ”MIN” and “MAX”. If the boiler fails to relight contact your installation/servicing company.
0156M 1 General 460 FLUE TERMINAL DETAIL 360 50 102 124 63 119 65 Ensure flue slopes 2˚ down towards the boiler i.e. 35mm fall per metre of flue length (2˚) 42 CONDENSATE DRAIN 640 WATER CONNECTIONS 710 GAS CONNECTION 32 25 70 300 CAPPED OFF 32 DRAIN CONNECTION Diagram 1.1 Important Notice BS5440 Part 1 and 2, BS5449, BS5546, BS6700, BS6798, BS6891 and BS7074 Part 1 and 2, BS7478, BS7593, BS7671. This boiler is for use only on G20 gas, but may be converted for use on G31 gas (L.P.G.
1 General 1.5 Gas Supply DATA TABLE 1. 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 a suitable leak detection fluid, purge in accordance with the above standard. 1.6 Electrical Supply WARNING. This boiler must be earthed.
2 Water System 4042 Note. The boiler has 28mm copper connections, which can be reduced to 22mm for the Energysaver 40, provided the system resistance does not exceed the chosen pump duty. BOILER DRAIN POINT 2.1 Draining Tap The boiler is provided with a draining point at the lower left hand side of the burner manifold, to be used for draining the boiler, see diagram 2.1.
2.10 Safety Valve Open (vented) system. Recommended relationship between pump, cold feed and vent. 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. 450mm MIN. HEIGHT The drain from the safety valve must be routed clear of any electrical fittings and positioned so that any discharge can be seen.
2 Water Sytem 2.12 Pressure Gauge METHOD 1 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. COMBINED CHECK VALVE AND VACUUM BREAKER TEMPORARY HOSE 0051M HEATING SYSTEM 2.13 Domestic Hot Water Cylinder SINGLE FEED INDIRECT CYLINDERS ARE NOT SUITABLE. The hot water cylinder must be of the indirect coil type. It must be suitable for working at a gauge pressure of 0.
3 Boiler Location 0157M 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.
4 Flue 6860 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. 'R' The air and flue duct connect to the top of the boiler using an elbow which can be positioned to the side or rear.
4 Flue 0103M 4.1 Terminal Position The minimum acceptable spacings from the terminal to obstructions and ventilation openings are as shown in diagram 4.4. C A The boiler must be installed so that the terminal is exposed to the external air. B,C B,C G A It is important that the position of the terminal allows the free passage of air across it at all times. F G Note.
5 Preparation 5.1 Unpacking: diagram 5.1 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.
5 Preparation 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. 0248M 5.3 Flue Hole Cutting 115 Minimum hole 125 up to 300mm wall 135 up to 680mm wall This will allow for the 35mm per metre (2o) fall towards the boiler. Note: If required, an optional Wall Liner Kit, part No.900862, is available, complete with fixing instructions. 56.5mm MIN 124mm 'H'= 0.035x 5.
BOILER TOP FIXING POINTS TEMPLATE 4043 S 0170 5 Preparation AIR PRESSURE TUBES RED TUBE 7dia. CLEAR TUBES NO. 12x2in. 3/16dia. PLUG 7dia. NO. 12x2in. 3/16dia. PLUG 5mm MOUNTING BRACKET FIXING POINT(S) SECURING SCREWS (3) BOILER MOUNTING BRACKET ELECTRICAL CONNECTIONS Diagram 5.7 5.
7 Flue Installation Complete assembly by fully tightening the two fan bracket securing screws. 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. Finally tighten the three fan securing screws. FAN BRACKET SECURING SCREW (2) 4444 Fit the inner case door. Refer to diagram 7.
6863 6864 7 Flue Installation FLUE DUCT LONG FLUE TERMINAL STANDARD FLUE TERMINAL "Q" plus 82mm "N" minus 57mm FLUE DUCT BOILER CENTRE LINE "N" "Q" Diagram 7.2 4079 6885 Diagram 7.4 3mm DRILL SIZE SEAL WITH TAPE SUPPLIED AIR DUCT/TERMINAL AND FLUE DUCT ASSEMBLY "N" minus 42mm BOILER CENTRE LINE FLUE ELBOW ASSEMBLY "N" SEALANT AIR DUCT/ TERMINAL AND FLUE DUCT ASSEMBLY Diagram 7.5 Diagram 7.
6867 FLUE DUCT 4080 7 Flue Installation FOAM SEAL SEALANT "Q" minus 25mm "Q" AIR DUCT/ TERMINAL ASSEMBLY FLUE DUCT Diagram 7.6 6868 6866 Diagram 7.8 ✽ STD FLUE TERMINAL = 63 ✽ LONG FLUE TERMINAL = 61 FOAM SEAL ✽ FLUE TERMINAL 10mm FLUE DUCT Diagram 7.9 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.
8 Gas Connection SOLENOID SECURING SCREW MULTI-FUNCTIONAL CONTROL SUPPORT BRACKET SECURING SCREW 9022 Make the gas connection to the gas service cock, see diagram 8.1 GAS SERVICE COCK (SHOWN OFF) SECURING SCREWS (4) BURNER PRESSURE TEST POINT SECURING SCREW SECURING SCREW PLUGS UNION CONNECTOR Diagram 8.1 9 Electrical Connection WARNING: This boiler must be earthed. 4051 Remove the screws as diagram 9.1.
9 Electrical Connection 4052 9.1 Pump and External Controls Connection MAINS SUPPLY CABLE GROMMET The pump must be connected directly to the control box, as shown in diagram 9.2. Any external controls must only be connected to interrupt the Red Link between terminals 1 and SL. Thread the cable(s) through the large cable clamp in the side of the control box. 9.2 Testing - Electrical Checks to ensure electrical safety should be carried out by a competent person.
10 Commissioning Please ensure the “Benchmark” logbook is completed and left with the user. If the main burner pressure requires adjustment, see diagram 10.2. The brass nut, controls the main (high) burner pressure. 10.1 Preliminaries-All Systems The centre, plastic posidrive screw controls the “Low” burner pressure. Commissioning should be carried out by a competent person in accordance with current issue of BS6798.
10 Commissioning this is quite normal and it will disappear after a short period of time. 10.7 Operational Checks Adjust the control thermostat and any system controls to their required settings and set “high/low” switch to “high”. Refit the electrical controls box. Do not attempt to adjust the thermostat calibration screw. 10.
12 Servicing 4054 Notes To ensure the continued efficient and safe operation of the boiler 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. SECURING SCREW(2) It is the Law that any servicing is carried out by a competent person. Note. For obtaining a products of combustion reading use the connection on top of the boiler, see diagram 6.1.
12 Servicing Brush from back to front NOT left to right. 12.6 Operational Checks Do not use a brush with metallic bristles. After completing a service, before fitting the casing, check the inner case seal to ensure that it is in good condition, renew if necessary. Remove the paper and any debris. 12.2 Burner Clean the fins of the burner with a suitable soft brush, any debris can be allowed to fall into the mixing chamber. Do not use a brush with metallic bristles.
4059 SECURING SCREW (2) INJECTOR MANIFOLD SILICONE SLEEVING 4061 12 Servicing SECURING SCREW (3) IGNITION AND SENSING LEAD SECURING SCREW (2) SPARK ELECTRODE GASKET 4060 Diagram 12.7 SECURING SCREW (3) SPARK GAP 3mm to 4mm CONDENSE DRAIN TRAP Diagram 12.9 CAP WASTE OUTLET Diagram 12.8 13 Fault Finding 13.1 Electrical Important.
13 Fault Finding 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.
13 Fault Finding 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. Isolate the electrical supply and physically check ALL cables, connections and the printed circuit board (PCB) fuse. Check the air tubes to air pressure switch.
13 Fault Finding PM5 1 Reconnect supply YES NO Is APS neon lit ? Is fan running ? NO YES Is there 240V at the fan ? Has boiler been operating for 10 seconds yet ? NO Replace APS NO Is there 240V NO at C ? Replace ignition PCB YES YES Switch High/Low Switch to 'low' Will flue hood NO thermostat reset? Replace flue hood - is there 240V at thermostat the fan? NO Is there a spark at electrode ? YES YES YES 2 Replace fan Does gas ignite ? Flue hood overheatingblocked secondary heat exchange
13 Fault Finding NO PM5 2 Does the burner remain alight ? YES Is the low gas pressure setting correct (see Data Tables) at the test point on the gas valve ? Is condense drain blocked, repair. Does burner remain alight ? YES NO 3 Is the low gas pressure setting correct (see data tables)? Adjust as necessary. Does burner remain alight? NO Will burner remain alight if gas pressure is temporarily increased? YES YES YES YES NO Adjust gas pressure Turn High/Low switch to “High”.
9024 13 Fault Finding FAN AIR PRESSURE SWITCH g PLASTIC OVERHEAT g/y bk b PUMP SUPPLY RED LINK br * SL 1 L N br MAINS 240VAC 50Hz bk 3 LAMP 2 3 1 2 1LAMP 3 GV1 N2 CM1 GV21 32 21 1 4 3 PCB 2 1 PL PN b r g br y TB1 g/y REMOTE SWITCH LOW DEMAND FLAME NEON NEON p r w EARTH POST r r bk p r w HIGH/LOW (FLAME) SWITCH HIGH FLAME NEON bk b bk INTERCONNECTION P.C.B.
L PUMP OVERRUN I ✽ RED LINK br 9 7 y bk p b Stat(4) Stat(3) y PL DEMAND NEON SL Stat(2) 8 5548 13 Fault Finding bk Lamp(3) Lamp N(3) 3 CONTROL THERMOSTAT 6 N w PN PUMP OVERHEAT THERMOSTAT 8 FUSE TYPE F2A 1 10 IGNITION P.C.B. 6 9 5 7 P.C.B.(2) r r Stat(1) P.C.B.(1) b br bk PLASTIC OVERHEAT g bk P.C.B.(4) CM1(1) g NO AIR PRESSURE SWITCH NC P.C.B.
4067 S 7891 13 Fault Finding RESET BUTTON FLUE HOOD OVERHEAT THERMOSTAT RESET BUTTON INSTRUCTION LABEL Diagram 13.5 Diagram 13.4 14 Replacement of Parts SECURING SCREW (2) Replacement of parts must be carried out by a competent person. CONDENSATE FLEXIBLE TUBE 5549 Notes: Before replacing any parts isolate the boiler from the electrical supply and turn the gas supply off at the gas service cock, see diagram 8.1. Unless stated otherwise, all parts are replaced in the reverse order to removal.
14 Replacement of Parts 4065 14.3 Printed Circuit Boards (PCBs): diagram 14.3 Release the control box as Section 9. Control PCB: diagram 14.3 (top) Disconnect the electrical plug on the board. Release from its two support post and carefully pull the board away noting that the ignition lead is still connected. It may be necessary to hold some of the wires above the PCB clear with an electrical screwdriver on removal or refitting.
4078 14 Replacement of Parts CONTROL THERMOSTAT SECURING SCREW (2) RETAINING PIN OVERHEAT CUT OFF PHIAL ELECTRICAL CONNECTION (5) OVERHEAT CUT OFF LOCKNUT CONTROL THERMOSTAT PHIAL HIGH/LOW CONTROL KNOB 4066 CONTROLS FASCIA SECURING SCREW (3) 4067 S Diagram 14.4 CONTROL THERMOSTAT KNOB CONTROLS FASCIA ELECTRICAL CONNECTIONS RESET BUTTON FLUE HOOD OVERHEAT THERMOSTAT SECURING SCREW (2) Diagram 14.4A Diagram 14.5 14.5 “High/Low” Control: diagram 14.4 and 14.6 14.
14 Replacement of Parts Release union connections and the six securing screws, then remove the complete assembly. 14.7 Multifunctional Control: diagram 8.1. Disconnect the screws and electrical plugs at the multifunctional control. Heat Exchanger: Secondary - diagram 14.9 Support the multifunctional control and remove the four screws from the flanged connection, undo the union at the gas service cock and remove the support bracket securing screw. Disconnect the union connector.
14 Replacement of Parts Heat Exchanger - Primary - diagram 14.10 REAR INSULATION Disconnect the three union connections. 14.11 Burner: diagram 14.9 Note: To carryout the following operations it will be found more convenient if the whole of the heat exchanger and burner are removed as a unit. Follow the relevant parts of Servicing Section and remove the bypass heat shield, fan/flue hood, combustion chamber front panel, heat exchanger baffle, spark electrode, injector and thermostat phials.
14 Replacement of Parts 14.12 Insulation - Rear - diagram 14.10 With the heat exchangers and burner assembly removed, as Sections 14.10 and 14.11, the rear insulation pad can be removed as shown. CONDENSATE SENSOR SCREW 14.13 Insulation: Combustion Chamber Front Panel: diagram 14.11 Remove the two screws from the viewing window then slide the insulation pad out. 14.14 Insulation - Sides - diagram 14.12 Remove the spark electrode refer to Section 12.4. Remove the insulation by sliding it out. 14.
15 Spare Parts 15 Spare Parts When ordering spare parts, please quote the appliance name and serial number, to be found on the data label, visible when the outer casing is removed. If ordering from the British Gas also quote the GC number of the part. Key No. Description Part No. GC Part No.
15 Spare Parts 6291 6 23 5 13 3 14 4 7 11 15 10 16 1 12 8 9 Diagram 15.1 Because of our constant endeavour for improvement details may vary slightly from those in the instructions.
