Glow-worm 18si Instructions For Use Installation And Servicing

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Instructions for Use

Installation and Servicing

To be left with the user

18si

Fanned Flue Combination Boiler

G.C. No. 41-047-61

2000225058A.04.02

10325

This is a Cat I2H Appliance

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.

Guarantee Registration

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 Guarantee.

This product is guaranteed for 24 months from the date of installation or 30 months from the date of manufacture,

whichever is the shorter, for parts. In addition this product is guaranteed for 12 months from the date of intallation or

18 months from the date of manufacture, whichever is the shorter, for labour.

The second year of the parts guarantee, from the beginning of the 13th month onwards after installation or

manufacture, is conditional upon the boiler having been serviced by a CORGI registered gas installer, in accordance

with the manufacturer's recommendations. We strongly recommend regular servicing of your gas appliance, but where

the condition is not met, any chargeable spare parts or components issued within the applicable guarantee period still

benefit from a 12 month warranty from the date of issue by the manufacturer.

We recommend you complete and return as soon as possible your guarantee registration return literature, supplied in

the document envelope.

If your guarantee registration return literature is missing you can obtain a copy or record your registration by

telephoning the Heatcall Customer Service number 01773 828100.

CALL 0208 247 9857

Customer Services: Tel: (01773) 828100

One Contact Local Service

Fax: (01773) 828070

Hepworth Heating Ltd.,

Nottingham Road, Belper, Derbyshire. DE56 1JT

General/Sales enquiries:

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

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Important Information

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.

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. The requirements are: The installation of this boiler must be carried out by a competent person in accordance with the current rules in force in the countries of destination at the time of installation. Manufacture's instructions supplied. Manufacture's instructions must not be taken as overriding statutory requirements.

Note: The boiler serial number is marked on the label attached to the inside of the drop down door. Refer to the 'Introduction' section for a description of the basic functions of the boiler. The 'Users' section describes how to safely operate the boiler.

Mandatory warning for CEE countries

Warning: This appliance is designed, approved and inspected to meet the requirements of the market. The identification plate located on the inside of the appliance certifies the origin where the product was manufactured and the country for which it is intended.

If you see any exception to this rule, please contact your nearest Glow-worm dealer. Thank you in advance for your assistance.

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.

Type test for purposes of Regulation 5 certified by: Notified body 0049. Product/production certified by: Notified body 0049. 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.

Substances Hazardous to Health

Under section 6 of the Health and Safety at Work Act 1974, we are required to provide information on substances hazardous to health. The adhesives and sealants used in this appliance are cured and give no known hazard in this state.

INSULATION PADS/CERAMIC FIBRE, GLASSYARN, MINERAL WOOL 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 to the eyes or severe irritation to the skin seek medical attention. The insulation is composed of non-combustible material.

Spare Parts

REMEMBER, When replacing a part on this appliance, use only spare parts that you can be assured conform to the safety and performance specification that we require. Do not use reconditioned or copy parts that have not been clearly authorised by Hepworth Heating Ltd.

Manual Handling Guidance

During the appliance installation it will be necessary to employ caution and assistance whilst lifting as the appliance exceeds the recommended weight for a one man lift.

In certain situations it may be required to use a mechanical handling aid. Take care to avoid trip hazards, slippery or wet surfaces.

2000225058A

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Contents

CONTENTS DESCRIPTION SECTION PAGE No.

Important Information 2 Introduction 4

INSTRUCTION

FOR USE

INSTALLATION

INSTRUCTIONS

Controls and Lighting 4 Programmer 6 Draining 6 Safety Devices 7 Servicing and Maintenance 7

Technical Data 1 8 Dimensions 2 9 Heating System Design 3 9 Boiler Schematic 5 11 Boiler Location, Flue and Ventilation 6 12 Fixing Jig pack 7 13 Piping System Installation 8 14 Boiler Installation 9 15 Horizontal Top Telescopic Flue Installation 10 16 Horizontal Top Flue Installation 10A 17 Electrical Connection 11 19 Commissioning 12 20 Changing Gas Type 13 21 Settings 14 22

SERVICING

INSTRUCTIONS

Routine Cleaning and Inspection 15 22 Fault Finding 16 26 Wiring Diagram 17 32 Replacement of Parts 18 33 Spare Parts 19 40

3 2000225058A

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Introduction

The 18si boiler is a wall mounted modulating boiler with electronic ignition providing central heating.

The boiler is of the II2H3+ category for use with Natural Gas (G20) as distributed in the United Kingdom, or Butane (G30), Propane (G31) with the appropriate conversion kit.

The boiler has a fan assisted balanced flue which both discharges the products of combustion to and draws the combustion air from the outside of the room.

The boiler is suitable for top outlet flue connection only but can be fitted with horizontal flue, vertical flue or twin-pipe flue. Refer to flue options guide for further information, this is available from your nearest stockist.

The central heating temperature is user adjustable from the boiler control panel.

Domestic hot water demand always has priority over heating demand.

The pump, expansion vessel and associated safety devices are all fitted within the boiler.

The boiler can be installed against either an external wall or on an adjacent inside wall, that is, the flue system will pass directly to the rear or to either side to the terminal fitted on the outside wall face.

The installation must be carried out by a qualified registered person in accordance with the relevant requirements of The Building Regulations, The Water Byelaws, The Building Standards (Scotland) Regulations and any applicable local regulations.

These instructions should be carefully followed for the safe and economical use of your boiler.

Electrical Supply

WARNING: This boiler must be earthed.

All system components shall be of an approved type and shall be connected in accordance with the current issue of BS7671 and any applicable local regulations.

All external wiring between the appliance and the electrical supply and earthing requirements shall comply with the current IEE Regulations.

Connection of the boiler and system controls to the mains supply must be through a common isolator and must be fused 3A, maximum. This method of connection must be by a fused double pole isolating switch, with a minimum contact separation of 3mm on both poles. The switch should be readily accessible and preferably adjacent to the appliance. It should supply the

appliance only and be easily identifiable as so doing. Alternatively, an unswitched shuttered socket outlet and 3A

fused 3 pin plug, both to the current issue of BS1363 may be used provided that they are not used in a room containing a bath or shower.

Wiring to the boiler must be PVC 85oC insulated cable, not less than 0.75mm

(24/0.20mm).

Gas safety (Installation and use) Regulations

In your interests and that of gas safety, it is the law that ALL gas appliances are installed and serviced by a qualified registered person in accordance with the above regulations.

Gas leak or fault

If a gas leak or fault exists or is suspected, turn the boiler off and consult the local gas supply company or your installation/ service company.

Air in the heating system

Persistent air in the heating system may indicate leaks in the system or corrosion taking place. Call your Installation/Servicing company.

Overheating safety

In the event of a problem, the overheating safety devices cause safety shutdown of the boiler. If this happens, call your Installation/Servicing company.

Boiler controls

The control panel, located at the lower front of the boiler casing, see diagram 1, allows the boiler to be started, shut down, controlled and monitored during use.

Flue

Do not obstruct the outside terminal of the flue.

Ancillary equipment

A range of flue accessories are available including vertical flues, twin-pipe flues, bends etc.

For further information contact your supplier.

Controls and lighting

Your 18si boiler has been factory configured to operate at the heart of an existing installation. However, because many installations are specially designed, do not hesitate to contact your installer who will be able to ensure that you get the best performance from your installation, by adjusting the heating circuit's maximum output or temperature.

Once these settings have been made, you can still adjust the temperature to suit your needs.

Central heating adjustment

The selector switch enables you to vary the temperature of the water in the central heating circuit from the minimum setting (approx. 38˚C) up to the maximum temperature ( approx. 87˚C)set by your installer. Most of the time, the mid position will meet your needs but the selector should be moved nearer to the maximum setting in very cold weather when your home is not reaching the required temperature.

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Controls and Lighting

1 - On/Off switch 2 - Central heating

temperature selector 3 - Pressure gauge (bar) and temperature gauge (ºC) 4 - Fault display (faults indicated by a red flashing light)

5 - Programmer (Optional)

1. Lighting the boiler :

Make sure that:

• The boiler is connected to the electrical supply.

• The gas service cock is open. Turn the switch ON ( I )

10326

Diagram 1

4. If a fault occurs (indicated by red flashing light) :

• Reset boiler: Turn the On/Off switch to ( 0 ), wait for five seconds. Turn the On/Off switch to ( I ) the boiler is reset. If the fault continues call your Installation/Servicing company or Heatcall. (Glow-worm’s own service organisation) using the telephone number on the front cover of this literature.

2. Stop the boiler :

• Turn the switch to OFF ( 0 ) the electrical supply is OFF.

• Turn the gas supply OFF at the gas service cock if the boiler is to be out of use for a long time.

3. Heating temperature adjustment :

• Winter: Set the control knob between 1 and 5

• Summer: Set the control knob to

10327

5. Installation filling :

• If the boiler loses water: the pressure gauge (a)

and fault display (b) will flash. Fill the system until the pressure gauge reads 1.5 bar.

(b)

(a)

10327

• Warning: pressure of 2.5 bar or above indicating over pressure, the fault display (b) will flash. The pressure must be reduced to 1.5 bar by bleeding a radiator. If the fault continues call your Installation/ Servicing company or Heatcall. (Glow-worm’s own service organisation) using the telephone number on the front cover of this literature.

Take care not to overfill the boiler

. At a

Diagram 2

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Programmer Instructions for use

Optional Programmers inclusive of installation and user instructions:- These are available from your nearest stockist.

Electro/Mechanical Part No. S1010801 Digital Part No. S1011100

Draining

Protection against freezing

The boiler has a built in frost protection programme as long as the electricity and gas are left switched on.

If the temperature within the appliance falls to 3˚C the burner and system pump are activated.

When the temperature inside the appliance reaches 10˚C the burner will shut down and after a short period the pump will stop.

This device primarily protects the boiler. Any other exposed areas of the system should be protected by a seperate frost thermostat.

If the boiler is to be out of use for any long periods during severe weather conditions, it is recommended that the whole system, including the boiler, be drained to avoid the risk of freezing.

If in doubt, consult your servicing company.

Draining and filling

Caution: The boiler is installed as part of a sealed system which must only be drained and filled by a competent person.

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Safety Devices

The 18si incorporates a visual fault display that indicates certain fault conditions, (red flashing light) should they occur.

Should the boiler fail to operate during Commissioning, the most likely fault is that the gas supply to the boiler has not been turned on or purged sufficiently or that there is no pressure in the heating system.

General safety devices

Air flow rate safety device

If an obstruction, even partial, of the flue occurs, for any reason whatsoever, the built in safety system of the boiler will turn the boiler OFF, the red light will flash and the fan will continue to run. The boiler will be ready to operate when the fault has been cleared.

Heating safety valve

CAUTION: A heating safety valve with a discharge pipe is fitted

to this boiler. The valve MUST NOT BE TOUCHED except by a qualified

registered person. If the valve discharges at any time, switch the boiler off and isolate it from the electrical supply. Contact your installation/service company.

If the gas supply is interrupted

The boiler switches over to safety mode, the red light will flash. Call a qualified service engineer or Heatcall (Glow-worm’s own service organisation) using the telephone number on the front cover of this literature.

Air in pipes

Important: A central heating system can not operate correctly

unless it is filled with water and air bled from the system. If these conditions are not met the system may be noisy.

Bleed the air in the radiators and adjust the pressure if system requires. If the system requires filling to often this may be due to minor leaks or corrosion in the system. Call a qualified service engineer or Heatcall (Glow-worm’s own service organisation) using the telephone number on the front cover of this literature.

Frost protection

The 18si has a built in frost protection device that protects the boiler from freezing. If the boiler is to be left and there is a risk of frost, ensure that the gas and electrical supplies are left connected. The frost protection device will light the boiler when the temperature of the boiler water falls below 6°C. When the temperature reaches 16°C, the boiler stops.

Note : This device works irrespective of any room thermostat setting and will protect the complete heating system.

In case of power supply failure

The boiler no longer operates. As soon as power supply is restored, the boiler will be automatically restarted.

Servicing and Maintenance

To ensure the continued efficient and safe operation of the appliance 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.

If this appliance is installed in a rented property there is a duty of care imposed on the owner of the property by the current issue of the Gas Safety (Installation and Use) Regulations, Section 35.

Servicing/maintenance should be carried out by a competent person in accordance with the rules in force in the countries of destination.

To obtain service, please call your installer or Heatcall (Glow- worm’s own service organisation) using the telephone number behind the controls cover door.

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 boiler Logbook. You can check your installer is CORGI registered by calling CORGI direct on: 01256 372300.

Cleaning

The boiler casing can be cleaned with a damp cloth followed by a dry cloth to polish.

Do not use abrasive or solvent cleaners.

Boiler casing

CAUTION. Do not remove or adjust the casing in any way, as

incorrect fitting may result in faulty operation. If in doubt, consult your installation/service company.

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1 T echnical Data

Heating

Heat input (max) NET Q 20,7 kW

70,628 BTU/H

Heat input (min) NET Q 11 kW

37,532 BTU/H

Heat output (max) GROSS P 18,4 kW

62,780 BTU/H

Heat output (min) GROSS P 8,9 kW

30,366 BTU/H Efficiency - Sedbuk D 78,3% Maximum heating temperature 87° C Expansion vessel effective capacity 5 l Expansion vessel charge pressure 0,5 bar Maximum system capacity at 75°C 110 l Safety valve, maximum service pressure 3 bar

Combustion

Products outlet diameter 60 mm Fresh air inlet diameter 100 mm Combustion products values CO (25 ppm)

CO2 (5,5%)

NOx (48ppm)

Electrical

Electrical supply 230 V ~ 50Hz Electrical rating 122 W fused at 3A Level of protection IPX4D Fuse rating 1,25mA

Natural Gas (G20)

Ø Burner injector 1,2 mm Inlet pressure 20 mbar Maxi. Burner pressure 8 mbar Mini. Burner pressure 2,25 mbar Gas rate maximum 2,2 m3/h

Butane Gas (G30)

Ø Burner injector 0,73 mm Inlet pressure 29 mbar Maxi. Burner pressure 14,8 mbar Mini. Burner pressure 4,41 mbar Gas rate maximum 1,63 kg/h Gas rate minimum 0,87 kg/h

Propane Gas (G31)

Ø Burner injector 0,73 mm Inlet pressure 37 mbar Maxi. Burner pressure 19,2 mbar Mini. Burner pressure 5,4 mbar Gas rate maximum 1,61 kg/h Gas rate minimum 0,83 kg/h

Bypass fully shut

Open 1/4 turn

Open 1/2 turn

Open 1 turn

Open 2 turns

heating supply and return lines

Available pressure (kPa) between

0 500 1000

(10 kPa = 1 m WG)

Flow rate through heating system (I/h)

9700

Diagram 1.1

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The 18si is delivered in three separate packages:

• The boiler

• The fixing jig and hanging bracket

• The flue system

Net lift weight (boiler only) 33 kg

Gross lift weight (boiler and packaging) 35 kg

2 Dimensions

10328

184

740

3 Heating System Design

• The 18si is for use only with sealed central heating systems.

• Heating surfaces may consist of radiators, convectors or fan assisted convectors.

• The safety valve is an integral part of the boiler and it cannot be adjusted.

• The circulation pump is integral with the boiler. Pipe sectional areas shall be determined in accordance with

normal practices, using the output/pressure curve (diagram 1.1). The distribution system shall be calculated in accordance with the output requirements of the actual system, not the maximum output of the boiler. However, provision shall be made to ensure sufficient flow so that the temperature difference between the flow and return pipes be less than or equal to 20 through the boiler must not be allowed to fall below that given.

• The system can be fitted with a lockable balancing valve if necessary in the main flow or return pipes shown as valve “A”

in diagram 3.1.

• The piping system shall be routed so as to avoid any air pockets and facilitate permanent venting of the installation. Bleed fittings must be provided at every high point of the system and on all radiators.

• The total volume of water permitted for the heating system depends, amongst other things, on the static head in the cold condition. The expansion vessel on the boiler is pressurised at

0.5 bar and allows a maximum system volume of 110 litres for

°C. The minimum flow is 500 l/h. The flow rate

310

410

Diagram 2.1

an average temperature of 75°C and a maximum service pressure of 3 bar. This pressure setting can be modified at commissioning stage if the static head differs. An additional expansion vessel can be fitted to the system if required, see diagram 3.1. To check if an additional expansion vessel is required, an accurate calculation of vessel size is given in the current issue of BS5449 and BS7074 Part 1.

• Provision shall be made for a drain valve at the lowest point of the system.

• Where thermostatic radiator valves are fitted, not all radiators must be fitted with this type of valve, and in particular, where the room thermostat is installed.

• In the case of an existing installation, it is ESSENTIAL that the system is thoroughly flushed prior to installing the new boiler, using a proprietary product such as Fernox or Sentinel. Contact the product manufacturers for specific details.

3.1 Bypass

•The boiler is fitted with an adjustable automatic bypass. Ensure that under no circumstances does the flow rate drop below the figure specified.

• If the central heating circuit is fitted with thermostatic radiator valves to all radiators then an additional bypass should be fitted not less than 1.5 metres from the appliance, see diagram 3.1.

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3 Heating System Design

METHOD 1

METHOD 2

METHOD 3

SUPPLY STOP VALVE

SUPPLY PIPE

HOSE UNIONS

SERVICING VALVE

TEMPORARY HOSE

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

3.2 Filling the Sealed System

• Provision for filling the system at low level must be made. Three methods are shown in diagram 3.2. There must be no permanent connection to the mains water supply, even through a non-return valve.

NOTE: It is important that fittings used for connection to potable water comply with the water undertakings requirements.

ADDITIONAL EXPANSION VESSEL (if required)

3132

10157

BOILER

HEATING CIRCUIT

* Refer to section 11.6

2000225058A

RETURN

FLOW CONTROL VALVE

* BYPASS (if required)

'A'

DRAIN POINT

Diagram 3.1 Diagram 3.2

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5 Boiler Schematic

1 - Fan. 2 - Air pressure switch. 3 - Heat exchanger. 4 - Overheat thermostat. 5 - Combustion chamber. 6 - Expansion vessel. 7 - Flame sense electrode. 8 - Burner. 9 - Ignition electrode. 10 - Pump. 11 - Heating thermistor.

12 - Ignition module. 13 - By-pass. 14 - Gas valve. 15 - Loss of water sensor. 16 - Heating filter. 17 - Discharge safety valve (3bar).

A - Heating Return. B - Heating Flow. C - Gas.

ABC

10294

11 2000225058A

Diagram 5.1

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6 Boiler Location, Flue and Ventilation

If the appliance has to be stored for any length of time before installation it should be kept in a safe place where it will not be a hazard to persons or obstruct any access.

6.1 Clearances

The position of the boiler must be such that there is adequate space for servicing.

The recommended clearances are: 20 mm either side of the boiler. 600 mm at the front of the boiler. 300 mm below the boiler. 25 mm above the flue elbow. Note: The boiler must be mounted on a flat wall which is

sufficiently robust to take its weight when full, that is, 36 kg. If in doubt, expert advice should be obtained, in the event of the wall being found not suitable.

Note: It is permissible to install the boiler with smaller clearances than those quoted above PROVIDING that adequate consideration is given for Servicing/Repairs at a later date. If any doubt exists, contact the Glow-worm’s Technical Helpline

01773 828300.

The minimum acceptable spacings from the terminal to obstructions and ventilation openings are shown in diagram

6.1.

The boiler must be installed so that the terminal is exposed to the external air.

Should any doubt exist as to the permissible position of the terminal, contact the Glow-worm’s Technical Helpline 01773

828300.

6.2 Terminal guard

A terminal guard is required if persons could come into contact with the terminal or the terminal could be subject to damage.

If a terminal guard is required, it must be positioned to provide a minimum of 50mm clearance from any part of the terminal and to be central over the terminal.

Terminal guard type K3 supplied by:

Tower flue components Ltd. Morley road Tonbridge Kent TN9 1RA

6.3 Flue options

There are various flue systems to choose from as follows: Horizontal standard telescopic top flue pack Horizontal top flue pack. Horizontal extended flue pack Vertical flue pack. Twin flue pack. Extensions, 90° and 45° bends. Flue options and accessories. For detailed information refer to flue options guide. For further

information, this is available from your nearest stockist.

6.4 Cupboard or compartment ventilation

The boiler can be fitted in a cupboard or compartment without the need for permanent ventilation.

MINIMUM SITING DIMENSIONS FOR THE POSITIONING OF FLUE TERMINALS MM

A DIRECTLY BELOW, ABOVE OR HORIZONTALLY TO AN OPENING, AIR BRICK, OPENING WINDOWS, AIR VENT, OR ANY OTHER VENTILATION OPENING 300 B BELOW GUTTER, DRAIN/SOIL PIPE 75 C BELOW EAVES 200 D BELOW A BALCONY OR CAR PORT 200 E FROM VERTICAL DRAIN PIPES AND

SOIL PIPES 300

F FROM INTERNAL CORNERS AND

EXTERNAL CORNERS 150

G ABOVE ADJACENT GROUND OR

BALCONY LEVEL 300

H FROM SURFACE OR A BOUNDARY

FACING THE TERMINAL 600 I FACING TERMINALS 1200 J FROM OPENING (DOOR/WINDOW)

IN CAR PORT INTO DWELLING 1200 K VERTICAL FROM A TERMINAL 1500 L HORIZONTALLY FROM A TERMINAL 300

UNDER CAR PORT etc.

11401

B,C

H,I

B,C

Diagram 6.1

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7 Fixing Jig Pack

Please note that the 18SI uses standard ISO arrangement for the fittings on the jig - You may refer to the 30SI for details

Working from left to right, A Heating Flow B Gas C Heating Return

The fixing jig is made up as follows: A - Heating flow fitting with isolating valve (v). B - Gas Fitting. C - Heating Return.

LEFT HAND SUPPORT BRACKET

COPPER CONNECTIONS AND WASHERS (3 OFF)

ISOLATING VALVE PLATE

Other components within the fixing jig pack.

D - Hanging bracket E - wall template F - copper connections G - sealing washers and screws

1 Heating system connections

- Pipe diam. 22mm 2 Gas connection

- Pipe diam. 15mm

RIGHT HAND

SCREW

SUPPORT BRACKET

10296

10295

NOTE: The fixing jig is shown assembled

Diagram 7.1

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8 Piping System Installation

8.1 Fixing jig, refer to diagram 7.1

• Remove the contents of the fixing jig pack.

• Secure the left and right hand support brackets to the isolating valve plate with the securing screws (2 OFF) supplied.

• Connect the three copper connections and sealing washers to the isolating valves.

1 Heating system connections - Pipe diam. 22mm 2 Gas connection - Pipe diam. 15mm

8.2 Cutting the flue hole

• Remove the wall template, follow the instructions given on the wall template.

• Determine the flue application, length and terminal position before starting.

• Position the wall template, taking due regard of the minimum clearances for the selected flue application, see diagram 8.1.

• Rear hole cutting Mark correct position of Top Rear flue outlet hole from template.

• Side hole cutting Mark the horizontal centre line for the hole on the rear wall.

Extend the horizontal centre line to the side wall and mark the vertical centre line of flue hole as shown in diagram 8.1.

• Making allowance for the slope of the flue, cut hole in external wall, preferably using a core drill. For installations with internal and external access use a 105 mm diameter core drill.

For installations with internal access only use a 125 mm diameter core drill.

8.4 Gas connection

• The supply from the governed gas meter must be of adequate size to provide a constant inlet working pressure of 20 mbar (8 in w.g.).

To avoid low gas pressure problems, it is recommended that the 15 mm gas supply on the boiler is connected to using 22 mm pipe (as close as possible to the boiler within 1 metre).

• On completion, the gas installation must be tested using the pressure drop method and purged in accordance with the current issue of BS6891.

Gas Safety (Installation and use) Regulations

In your interests and that of gas safety, it is the law that ALL gas appliances are installed and serviced by a competent person in accordance with the above regulations.

Important

When cutting the flue hole and when extending the flue centre line to a side wall, remember that the flue system must have a fall of about 35 mm per metre of flue DOWNWARD towards the terminal. There must NEVER be a downward incline towards the boiler.

• Reposition the wall template over hole in wall.

• Mark the hanging bracket and jig position holes.

• Drill, plug and fix the hanging bracket to the wall using suitable screws (not supplied).

• Check that the hanging bracket is level.

• Drill plug and fix the fixing jig to the wall.

8.3 Water connection

Connect the system pipework to the copper connections on the fixing jig observing the correct flow and return format as shown in diagram 3.1. Do not subject the isolating valves to heat.

80min.

10297

184mm

20mm

MIN.

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Diagram 8.1

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9 Boiler Installation

9.1 Statutory requirements

The installation of this boiler must be carried out by a qualified registered person in accordance with the relevant requirements of the current issue of:

The Gas Safety (Installation and Use) Regulations The Building Regulations The local water company Byelaws The Building Standards Regulations (Scotland) The Health and Safety at Work Act

9.2 Sheet metal parts

WARNING. When installing or servicing this boiler, care should be taken when handling the edges of sheet metal parts to avoid the possibility of personal injury.

9.3 Installing the boiler

Prior to starting work, the system must be thoroughly flushed using a propriety cleanser such as Sentinel X300 to eliminate any foreign matter and contamination e.g. metal filings, solder particles, oil, grease etc.

Note. Solvent products could cause damage to the system. The boiler pack consists of the boiler and a document envelope/

fittings pack which contain, literature, self adhesive wiring diagram label, magnetic user instruction label, mains voltage external controls connection plug, guarantee return form, sealing washers, screws, flue restrictor and discharge safety valve pipe.

• Stand the boiler upright.

• Remove all packaging from around the boiler.

• Remove front panel, unscrew and remove the two retaining screws from the bottom of the front panel. Remove front panel by lifting up and forward.

• Remove the self adhesive wiring diagram label from from the document envelope. Fit the self adhesive wiring diagram label to the inside of the front panel, put front panel in a safe place to avoid damaging it.

• Ensure the plastic plugs are removed from water and gas pipes. NOTE: There will be some spillage of water.

• IMPORTANT: With regards to the manual handling operations, 1992 regulations, the following operation exceeds the recommended weight for one man lift.

• Lift the boiler up and engage boiler upper part onto the hanging bracket.

• Fit the washers between the boiler pipes and the inlet and outlet fittings on the fixing jig and connect the various couplings between the boiler and jig.

9.4 Discharge safety valve, refer to diagram

9.1.

WARNING: It must not discharge above an entrance or window

or any type of public access area. A short discharge pipe is supplied in the fittings pack, when

fitted to the safety valve it will end below the boiler. The discharge pipe must be extended using not less than 15 mm o.d. pipe, to discharge in a visible position outside the building, facing downward preferably over a drain.

Note: Fit a compression fitting to facilitate service of the appliance.

The pipe must have a continuous fall and be routed to a position so that any discharge of water, possibly boiling or steam, cannot create any danger to persons, damage to property or external electrical components and wiring. Tighten all pipe connection joints.

10329

DISCHARGE SAFETY VALVE (3 bar)

15 2000225058A

DISCHARGE SAFETY VALVE PIPE

Diagram 9.1

Page 16

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10 Horizontal Telescopic Top Flue Installation

The

Horizontal Telescopic Top Flue,

A2004500 is suitable for installations that require a flue length from 425 minimum to

659.5 maximum. If longer flueing is required extensions and bends are available, see note below.

Note: Additional 1 metre extentions, 90° and 45° bends are available. The maximum extended flue is 3.5m. The use of flue bends requires the flue lengths to be reduced by 1m. for 90° and

0.5m. for 45°.

Kit No.

10.1 Horizontal Telescopic Top Flue kit of parts, refer to diagram 10.1.

10.2 Installation of telescopic flue assembly

• Carefully pull to remove the elbow (D) from the air duct pipe and flue duct pipe (A).

• Fit rubber sealing collar (D), see diagram 10.2, into groove at the outer end of the air duct pipe (A).

• Fit air/flue duct pipe assembly, into wall from the outside with rubber sealing collar to the outside.

• Pull pipe assembly inwards to bring rubber sealing collar hard up against external wall.

• If the telescopic flue is pulled apart care must be taken not to damage the ‘O’ ring on the flue duct when re-assembling.

• Remove the backing from the self adhesive gasket (F) and carefully fit gasket to base of flue elbow.

• Fit the restrictor (a) inside the fan outlet, see diagram 10.6.

• Fit elbow onto boiler and secure with the four screws (G).

• Re-fit the telescopic flue duct pipe to the flue elbow . Secure with the fixing collar (C) and fixing collar seal (B).

10332

The flue kit A2004500 is 659.5 mm long and comprises:

-Telescopic flue assembly ..................................... A

- Fixing collar seal ..................................................... B

- Fixing collar............................................................. C

- Elbow....................................................................... D

- External rubber sealing collar ............................... E

- Gasket ...................................................................... F

- Screws .....................................................................G

Horizontal Telescopic Top flue kit

Diagram 10.1

Pho 087

Diagram 10.2

Horizontal Telescopic flue system (rear and side)

The maximum permissible length (L) for the telescopic flue system is 659.5mm. The restrictor (a) must be fitted to inside the fan outlet.

FLUE RESTRICTOR

Gasket

11379

184

MINIMUM WALL THICKNESS 239mm.

Diagram 10.3

2000225058A

Page 17

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10A Horizontal Top Flue Installation

10A.1 Horizontal top flue - kit 86285

Max. Std flue length 930mm

Min. Std flue length 300mm

70mm

205mm

410 mm

20mm Min. Clearance

75mm Min. Wall Thickness

SIDE FLUE

Max. Std flue length 930mm

Min. Std flue length 309mm

65mm

10090

The

Horizontal top flue

is suitable for installations that require a flue length from 300 minimum to 930 maximum (without extensions).

Note: Additional 1 metre extentions, 90° and 45° bends are

available. The maximum extended flue is 3.5m. The use of flue bends requires the flue lengths to be reduced by 1m. for 90° and

0.5m. for 45°. The boiler is only suitable for top outlet flue connection.

10A.2 Flue systems rear and side, refer to diagram 10A.1.

10A.3 Flue cutting, refer to diagram 10A.2.

Important: Do not leave any burrs or sharp edges on the cut

ends of the pipes.

Outside

wall face

(adjustable by cutting)

Flue

centre line

160mm

10091

70mm

184mm

75mm Min. Wall Thickness

REAR FLUE

65mm

Diagram 10A.1

17mm

X minus 160mm

cutting length

plus 17mm =

cutting length

Air duct cutting length

Air duct

Flue duct cutting length = air duct cutting length + 152mm

Air duct

Flue duct

95mm

check

dimension

(cut end)

Diagram 10A.2

17 2000225058A

Page 18

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10A Horizontal Top Flue Installation

10A.4 Installation of horizontal top flue assembly

• Fit rubber sealing collar (F), see diagram 10A.3, into groove at the outer end of pipe (A).

• Fit air duct pipe (A) into wall with groove to the outside.

• Pull pipe inwards to bring rubber sealing collar hard up against external wall, see diagram 10A.4.

• Fit internal plastic flange (G) onto air duct pipe. Push along the pipe until engaged against internal wall.

• From inside, insert flue duct pipe (B) into air duct pipe.

• Fit both ‘O’ rings (J) into the flue elbow (C), one at the inlet, one at the outlet. By necessity, they are a loose fit, apply a small amount of silicone grease to each ‘O’ ring when fitting.

• Fixing collar (D) over air duct pipe (A) and elbow (C) ensuring it is the correct way round (Note: the fixing collar can only be fitted one way due to the different diameters of the flue elbow and air duct.

• Take hold of the flue duct pipe and push gently onto the elbow outlet taking care not to tear the ‘O’ ring.

• Open fixing collar (D) and locate between elbow and air duct pipe (A). Close fixing jig.

• Engage the two fixing clips (E) onto the collar (D) and press down to lock into position. Secure clips with screws provided.

Important: If the flue has been cut, ensure that there are no burrs that could damage the ‘O’ ring.

• For flue systems less than 0,5 m long, fit the flue restrictor (a) into the fan outlet, see diagram 10A.5.

• Remove the backing from the self adhesive gasket (H) and carefully fit gasket to base of flue elbow.

• Fit elbow onto boiler and secure with the four screws (I).

The flue kit 86285 is 1000 mm long and comprises:

- Air duct pipe .......................................................... A

- Flue duct pipe ........................................................ B

- Flue elbow .............................................................. C

- Fixing collar............................................................. D

- Locking clips ............................................................ E

- External rubber sealing collar ............................... F

- Internal flange ....................................................... G

- Gasket ..................................................................... H

- Screws .......................................................................I

- 'O' rings..................................................................... J

Horizontal top flue kit

Diagram 10A.3

Pho 451

Pho 087

Diagram 10A.4

Horizontal top flue system

The maximum permissible length (L) is 3.5 m. For flue systems up to 0.5 m length, the flue restrictor must be fitted (a) inside the fan outlet. For longer flue systems, the restrictor must be removed.

For each 90° flue elbow used, (or two 45° elbows) the maximum permissible length (L) must be reduced by 1 metre.

FLUE RESTRICTOR

Gasket

184

11344

2000225058A

Diagram 10A.5

Page 19

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11 Electrical Connection

Warning. This boiler must be earthed.

All system components must be of an approved type. Connection of the whole electrical system and any heating

system controls to the electrical supply must be through a common isolator.

Isolation should preferably be by a double pole switched fused spur box having a minimum contact separation of 3 mm on each pole. The fused spur box should be readily accessible and preferably adjacent to the boiler. It should be identified as to its use.

A fused three pin plug and shuttered socket outlet may be used instead of a fused spur box provided that:

a) They are not used in a room containing a fixed bath or shower.

b) Both the plug and socket comply with the current issue of BS1363.

The mains electrical supply must be maintained at all times in order to provide domestic hot water.

Do not interrupt the mains supply with a time switch or programmer.

WARNING: UNDER NO CICUMSTANCES MUST ANY MAINS VOLTAGE BE APPLIED TO ANY OF THE TERMINALS ON THE VOLTAGE FREE HEATING CONTROLS CONNECTION PLUG.

Warning: This appliance must be wired in accordance with

these instructions. Any fault arising from incorrect wiring cannot be put right under the terms of the Glow-worm guarantee.

Important: If a replacement supply cable is required it must be purchased. Part No. S1008600.

11.1 External controls - Voltage Free

This boiler will operate on heating as supplied, provided that the wire link (E) fitted between the two terminals of the heating controls conection plug is left in place, see diagram 11.1.

External controls e.g. room thermostat, frost thermostat etc. should be fitted in accordance with the rules in force.

WARNING: UNDER NO CICUMSTANCES MUST ANY MAINS VOLTAGE BE APPLIED TO ANY OF THE TERMINALS ON THE VOLTAGE FREE HEATING CONTROLS CONNECTION PLUG. If mains voltage controls are required, see section

11.2. Refer to the wiring diagram Section 17.

11.3 Testing - Electrical

Checks to ensure electrical safety must be carried out by a competent person.

After installation of the system, preliminary electrical system checks as below should be carried out.

1. Test insulation resistance to earth.

2. Test earth continuity and short circuit of all cables.

3. Test the polarity of the mains. The installer is requested to advise and give guidance to the

user of the controls scheme used with the boiler. Note: For further information, see the building regulations 1991

- Conservation of Fuel and Power - 1995 edition - appendix G, Table 4b.

(E) Wire link VOLTAGE FREE HEATING CONTROLS CONNECTION PLUG

Diagram 11.1

➜

10238

10330

11.2 External controls - Mains Voltage

Remove the MAINS VOLTAGE HEATING CONTROLS CONNECTION PLUG from the fittings pack and install on the 230V interface control board as shown on the instruction sheet, also provided in the fittings pack and diagram 11.2

Gain access to the 230V interface by unclipping the control panel and hinge forward.

The wire link (E) must be removed from the voltage free heating controls connection plug.

External controls e.g. room thermostat, frost thermostat etc. should be fitted in accordance with the rules in force.

Refer to the wiring diagram Section 17.

MAINS VOLTAGE EXTERNAL CONTROLS CONNECTION PLUG

230V CONTROLS BOARD

19 2000225058A

CONTROL PANEL

10240

Diagram 11.2

Page 20

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12 Commissioning

Please ensure the “Benchmark” logbook is completed and left with the user.

The commissioning and first firing of the boiler must only be done by a qualified registered person.

Gas installation

It is recommended that any air is purged from the supply at the gas inlet test point on the gas valve, see diagram 12.1.

Filling the system 1 to 7

Make sure that:

• The boiler is connected to the electrical supply.

• The gas service cock is open. Turn the switch OFF ( 0 )

10331

GAS INLET TEST POINT

• Open the two boiler isolating valves. The slot of the screw corresponds to flow direction. (To unscrew turn anti-clockwise).

➜

HEATING FLOW

• Undo cap on automatic air vent on top of pump and leave undone.

GAS SERVICE COCK

Fully open valves by turning anti-clockwise.

➜

11345

Diagram 12.1

10332

➜

HEATING RETURN

• Turn the switch ON ( I )

• Fill the system until the pressure indicated on the display is 2 bar.

2000225058A

Page 21

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12 Commissioning

• Bleed each radiator to remove air, ensure all bleed screws are re-tightened.

• If necessary repressurise the system, refer to procedure 4

➜

• Leave cap on automatic air vent on top of pump open.

• Adjust heating temperature to maximum .

• Check that any external controls, if fitted, are calling for heat (set room thermostat to maximum).

• Allow the temperature to rise to the maximum value, with all radiator valves open. The temperature rise will cause release of the gases contained in the water of the central heating system.

• Gases driven towards the boiler will be automatically released through the automatic air vent.

• The gases trapped at the highest point of the system must be released by bleeding the radiators. Check the burner gas rate required, ten minutes from lighting. Refer to Data Label on electrical controls box. Should there be any doubt about the gas rate it should be checked at the meter.

On reaching maximum temperature, the boiler should be turned off and the system drained as rapidly as possible whilst still hot.

• Ensure the display indicates a system pressure

Ins 061a

11345

of 1.5 bar adjust if necessary.

• Refill system to a pressure of between 1 and 2 bar and vent as before.

• Restart boiler and operate until a maximum temperature is reached. Shut down boiler and vent heating system. If necessary, top up heating system and make sure that a pressure of at least 1 bar is indicated when system is COLD.

Remove the magnetic user instructions label from the document envelope and position it on the surface of the boiler casing.

Instruct the User

Instruct and demonstrate the lighting procedure and advise the user on the safe and efficient operation of the boiler.

Instruct on and demonstrate the operation of any heating system controls.

Advise the user on the use and maintenance of any scale reducer and pass on any relevant instructional documents.

Advise that 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 installation conditions and usage, but in general, once a year should be enough.

Draw attention, if applicable, to the current issue of the Gas Safety (Installation and Use) Regulations, Section 35, which imposes a duty of care on all persons who let out any property containing a gas appliance.

It is the Law that any servicing is carried out by a competent person.

Advise the user of the precautions necessary to prevent damage to the system, boiler and the building, in the event of the heating system being out of use during frost or freezing conditions.

Advise the user that the permanent mains electrical supply SHOULD NOT be switched off, as the built in frost protection and pump saver program would not be operable.

Reminder, leave these instructions and the ‘Benchmark’ logbook with the user.

13 Changing Gas Type

Should it become necessary to change the gas type, a conversion kit with instructions will be required. This modification must only be carried out by a suitably qualified engineer. Conversion natural Gas (G20) to G30/G31 Part No. A2002701.

21 2000225058A

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14 Settings

Bypass

The

18si

boiler has a built-in bypass. This must be adjusted according to the requirements of the system, refer to the flow rate pressure curve (diagram 1.1). The boiler is supplied with the built-in bypass open a half a turn. It is adjusted by turning the bypass screw (a), see diagram 14.1. Turn the screw clockwise to close the bypass. When using thermostatic radiator valves (TRV’s) on all of the radiators, it is essential that a separate, adjustable bypass of 15 mm minimum diameter is fitted between the flow and return of the heating circuit, see diagram 3.1. Any bypass must be fitted before system controls.

15 Routine Cleaning and Inspection

REMEMBER, when replacing a part on this appliance, use only spare parts that you can be assured conform to the safety and performance specification that we require. Do not use reconditioned or copy parts that have not been clearly authorised by Hepworth Heating.

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 conditions and usage, but in general once a year should be enough.

It is the law that any servicing is carried out by a qualified registered person.

11346

Diagram 14.1

9532

PRODUCTS SAMPLING POINT

Diagram 15.1

15.1 Products of combustion check

Note: To obtain a products of combustion reading, unscrew the left hand sampling point cap on the flue elbow, located on top of boiler, see diagram 15.1.

Connect the analyser tube onto sampling point. Refer to the combustion product values in Section 1 Technical

Data.

Switch on the electrical supply and gas supply, then operate the boiler.

On completion of the test switch off the electrical supply and the gas supply, remove analyser tube and replace sampling point cap.

15.2 Service Check and Preparation.

• Isolate boiler from the gas and electrical supplies.

• Drain the Domestic hot water cuircuit and the boiler, refer to diagram 15.2.

• On completion check all gas-carrying parts for soundness with leak detection fluid.

• Remove boiler casing as follows:

15.3 Front panel

• Unscrew and remove the two retaining screws from the bottom of the front panel.

• Remove front panel by lifting up and forward.

15.5 Sealed chamber cover

• Unscrew and remove the two retaining screws from the sealed chamber cover, see diagram. 15.3.

• Lift cover up and off pins on top of boiler. To replace remove the old seal, thoroughly clean the casing

surfaces. Fit new seal, it is supplied to the correct length, see

diagram 18.20

15.6 Side panels (for ease of access if available), refer to diagram 15.4

• Unscrew and remove the two retaining screws from front of each side panel.

• Left hand side panel only disconnect the control panel retaining strap at the control panel.

15.4 Control panel

• Lower forwards to gain access to lower part of boiler.

2000225058A

Page 23

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15 Routine Cleaning and Inspection

To Drain the boiler

• Close isolating screws on the isolating valves (b) and (c) turn from vertical to horizontal to close.

• Open the boiler drain valve (a).

(b)

HEATING FLOW

Note: Isolating water cocks are shown in the: OFF position

BOILER DRAIN VALVE

11347

(a)

11380

(c)

HEATING RETURN

Diagram 15.2

9533

11348

10246

Diagram 15.3

23 2000225058A

11349

Diagram 15.4

Page 24

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15 Routine Cleaning and Inspection

• Unhook each panel from the front retaining tabs.

• Pull each panel forward from the rear retaining tabs to remove.

15.7 Combustion chamber cover

• Unscrew and remove the two screws securing combustion chamber cover to combustion chamber, see diagram 15.5.

• Remove combustion chamber cover from boiler.

15.8 Spark and Sense Gaps

• Check that the spark and sense gaps as shown in diagram

15.6. Note: To gain access to spark and sense electrodes for removal, refer to Section, 18.11 and 18.12 in Replacement of Parts.

15.9 Burner, refer to diagram 15.7

• Unscrew and remove the two burner retaining screws.

• Remove burner from boiler by easing it forward off the two burner guides, taking care not to damage the insulation.

• Clean burner by washing in soapy water. Dry thoroughly before refitting.

Note: To gain access to injectors for removal and cleaning, refer to Section, 18.8.

11350

Diagram 15.5

3.5mm 11351

3.5mm

15.10 Fan, refer to diagram 15.8

• Disconnect power supply leads and earth lead from fan.

• Unscrew and remove the two fan retaining bolts.

• Ease the fan down and forwards to remove.

15.11 Heat exchanger, refer to diagram 15.9

• Remove air pressure switch sensing tube from the side of the flue hood.

• Unscrew and remove the two retaining screws from front of each side panel.

• Unhook each panel from the front retaining tabs and ease outwards.

• Remove the flue hood. When refitting ensure the rear of the flue hood locates in the tabs.

• Use a soft brush or vacuum clean the heat exchanger.

DO NOT USE ANY TOOL LIKELY TO DAMAGE PAINTED FINISH OF HEAT EXCHANGER.

15.12 Central Heating Filter, refer to diagram

15.10

Remove the filter retaining clip and filter clean or renew if necessary.

Push the filter fully into its housing, ensuring the correct orientation. The flat and hole in the filter as shown. Secure with retaining clip.

15.13 Inner Casing Panel Seal Check

Check the condition of the seal, replace as required. To replace remove the old seal, thoroughly clean the casing

sufaces. Fit the new seal, it is supplied to the correct length, see

diagram 18.20.

SPARK GAP

3.5mm

SENSE GAP

Diagram 15.6

15.14 Combustion Chamber Insulation

Check the condition of the combustion chamber insulation. If renewing, refer to Section 18.20.

15.145 Flue system

• Check externally to make sure that flue is not blocked

• Inspect flue system to make sure that all fittings are secure.

15.16 Reassembly of parts removed for servicing

All parts are replaced in reverse order to removal. Note before replacing parts removed inspect the condition of all seals and joints, renew them as necessary.

11352

2000225058A

Page 25

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15 Routine Cleaning and Inspection

11353

BURNER RETAINING SCREWS

11356

BURNER GUIDE

9742

11354

AIR PRESSURE SWITCH SENSING TUBE

FLUE HOOD

11355

11358

Diagram 15.7

EARTH

9741

LEAD

POWER SUPPLY LEADS

FAN RETAINING BOLTS

Diagram 15.8

HEAT EXCHANGER

11359

FILTER

RETAINING CLIP

Diagram 15.9

Diagram 15.10

25 2000225058A

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16 Fault Finding

Before trying to operate the boiler make sure that :

• All gas supply cocks are open and that the gas supply has been purged of air.

• The heating system pressure is at least 1 bar.

• There is a permanent mains supply to the boiler.

• The fuse on the PCB is intact. WARNING. Always isolate the boiler from the electrical supply

before carrying out any electrical replacement work. Always check for gas soundness after any service work. Should there be any doubt about the voltage supply to any of

the components, it is possible to carry out a simple electrical test to ensure all is operational in that area.

To carry out the electrical test, gain access to the main Printed Circuit Board (PCB), as described previously, and measure the voltages according to table 2.

Table 2

Voltage Measured value Measuring point

230 Volt 230V AC Between terminals H8.1 and H8.2

IMPORTANT: On completion of the fault finding task which has required the breaking or remaking of the electrical connections, the continuity, polarity, short circuit and resistance to earth checks must be repeated using a suitable multimeter.

24 Volt maximum 33V DC Between terminals J2.4 and J2.7

minimum 20V DC

15 Volt 15V ± 0.5V Between terminals J2.4 and J2.2

Display 5V ± 0.5V Between terminals J2.4 and J4.2

TYPE OF FAULT CHECK

No central heating • 230V supply (No flashing warning light on control panel) • Is fuse blown

• Loose connections on control board (PCB)

• Wrong flue length

• Connections on air pressure switch (electrical or tubes) disconnected

• Faulty control or interface board (PCB's)

No central heating • Water pressure (A flashing warning light on control panel) • Shortage of air or gas

• Faulty temperature sensor

• Overheating

No central heating • 230V supply

• Fuse blown

• Loose connections on control board (PCB).

• Wrong flue length

• Connections on air pressure switch (electrical or tubes) disconnected

• Faulty control board or interface board (PCB's).

2000225058A

Page 27

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16 Fault Finding

COMPONENT NORMAL MEASURE CHECK

Gas control valve Resistance of coil 116Ω 24V dc for 1 to 2 seconds, then is not faulty.

Adjustment valve ( step motor) Dismantle the step motor (screw not Check the connections at both

Under demand during ignition sparks: If 0 Volt:

12Vdc (constant) at the gas control valve electrical connection.

If 24 Volts and then 12 Volts but no gas at the burner:

Check if the gas control valve is stuck. If not, check the stepper valve.

the gas control valve

Close the gas inlet: If the valve does not move:

sealed in). Trigger a demand and check motor and control board (PCB). that the valve opens during the ignition. Change the motor. Replace the

control board (PCB).

Overheat thermostat reset button

Refer to Section 18.8 to locate the overheat thermostat reset button.

Depress the button to reset.

RESET BUTTON

11360

OVERHEAT THERMOSTAT

Diagram 16.1

27 2000225058A

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16 Fault Finding

FAULT: NO HEATING

Is the heating set high enough ?

YES

Is the room thermostat in demand ?

YES

Check by overriding the room thermostat at the connector. Does the fault persist ?

YES

Is the system fitted with

a external sensor ?

The setting is too low or the boiler

is set to summer mode.

YES

Turn the setting up by turning the

central heating temperature

control knob clockwise.

Adjust the setting.

Check the thermostat, the line,

YES

the connections both

to the room thermostat and

the control board (PCB).

Check the electrical connections

to the control board (PCB).

If the problem persists fit a

replacement control board (PCB).

YES

Unplug the sensor

and test it individually.

2000225058A

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16 Fault Finding

FAULT: THE BURNER LIGHTS BUT THEN GOES OUT. THERE IS NO FLAME DETECTED.

The flame is not spreading across

the whole burner and is not reaching

the sensing electrode. Is the gas

pressure correct?

YES

Adjust the low flow setting of the gas control valve. Clean the gas filter. Clean the burner.

FAULT: THE BURNER LIGHTS, THEN GOES OUT.

Check that the gas taps are fully open Check the gas pressure.

The flame is spreading across the

whole burner, but not being detected.

CHECK THE MAINS

Check the 230V mains supply.

FAULT NOT FOUND

If the problem persists, change the control board (PCB). (flame detection module faulty).

CHECK

THE

PROBE

With the power turned off, check the resistance between the spark electrode and terminal H23 on the control board (PCB). Check the connector on the end of the wire. Check that the spark electrode is pointing towards the flame. Check the spark electrode. Change it.

Check the earth: no power and neutral

Note: the boiler is independent of phase and neutral; reversing phase and neutral on the electric plug will have no effect.

29 2000225058A

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16 Fault Finding

FAULT: THE BURNER DOES NOT LIGHT AT ALL, BUT THERE IS AN IGNITION SPARK.

Are the gas taps on?

YES

Is there 24Vdc at the gas control valve?

YES

Test the gas control valve. Check resistance of safety valve coil.

FAULT: THE RADIATORS ARE LUKE-WARM.

Is the installation fitted with an

external sensor?

YES

Turn on the gas taps.

Check the wiring. If the problem persists, change the control board (PCB).

The temperature of the radiators depend on the outside temperature. If the room temperature is not sufficient, adjust

Is the installation fitted with a room thermostat?

Is the heating setting high enough?

YES

Is the heating power adequate?

- Check set point P3.

- Check the adjustment of the by-pass (too far open).

- Check the 3-way valve is not passing into the domestic hot water heat exchanger.

- Check the circulation in the radiators.

- Check the thermistor.

- If problem persists, change the interface board or the control board (PCB).

YES

The radiators will only be hot if the thermostat is demanding heat. If the room temperature is not sufficient, turn the setting of the room thermostat up.

Turn it up.

2000225058A

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16 Fault Finding

FAULT: THE FAN DOES NOT START.

Does the warning light flash 45 seconds

after the start of the demand?

YES

Check the fan (loose terminal connector, windings burnt out). Interface board or control board (PCB).

FAULT: THE FAN RUNS BUT THERE ARE NO SPARKS.

Does the warning light flash 45 seconds

after the start of the demand?

YES

Check the power from the room thermostat. Replace the interface board or control board (PCB).

Thermistor. Control board (PCB).

The air flow switch is not operating or is unplugged.

CONNECTIONS TO THE AIR PRESSURE SWITCH

Air flow switch take-off.

Check the pressure drop on the flue pipe. Is the plastic tube on the correct pressure connection of the air pressure switch? Are the electrical connections in place.

Electrical contacts.

31 2000225058A

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17 Wiring Diagram

THERMOSTAT

WATER PRESSURE SENSOR

FAN

OVERHEAT

THERMISTOR

THERMOSTAT 2 INPUT (FROST STAT)

THERMOSTAT 1 INPUT (ROOM STAT)

MAINS VOLTA GE

EXTERNAL CONTROLS

CONNECTION PLUG

AIR PRESSURE SWITCH

SENSE

ELECTRODE

GAS

CONTROL

VALVE

230V CONTROLS BOARD

IGNITION ELECTRODES

PUMP CH

HEATINGS

CONTROLS

CONNECTION

IGNITOR

UNIT

CHASSIS

EARTH

VOLT AGE

FREE

PLUG

10298

PLUG

USER INTERFACE

J11

J13J15

J12

The wires are not colour coded

REMOVE LINK IF USING

230V EXTERNAL CONTROLS

H5 H1

H3 H8

FUSE 125mAT

H6 H7

ON/OFF SWITCH

CHASSIS EARTH

230V~50Hz

PERMANENT

MAINS SUPPLY

FUSED AT 3A

2000225058A

Page 33

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18 Replacement of Parts

To Drain the boiler

• Close isolating screws on the isolating valves (b) and (c) turn from vertical to horizontal to close.

• Open the boiler drain valve (a).

(b)

HEATING FLOW

Note: Isolating water cocks are shown in the: OFF position

BOILER DRAIN VALVE

11347

(a)

11380

(c)

HEATING RETURN

Diagram 18.1

IMPORTANT INFORMATION

WARNING: Before commencing the replacement of any

component, isolate appliance from electrical supply and turn off gas at service cock.

Replacement of parts must be carried out by a competent person.

When replacing components it may be necessary to renew sealing washers, gaskets and 'O' rings. If new ones are supplied with replacement components they must be used.

All parts are replaced in reverse order to removal. If any gas-carrying components are disturbed, removed or

replaced it will be necessary on completion to check for gas soundness with leak detection fluid.

18.1 Central heating thermistor

Before starting refer to the front of Section 18 Important information.

• Remove the front panel, refer to Section 15.3.

• Lower the control panel, refer to Section 15.4.

• Locate central heating thermistor on heating flow pipe on centre of boiler, see diagram 18.2.

• Unclip thermistor from pipe.

• Disconnect electrical connections from thermistor.

• Fit electrical connections to replacement thermistor and fit thermistor to pipe. The polarity is not important.

CENTRAL HEATING THERMISTOR

Diagram 18.2

18.2 Fan, refer to ‘Section 15.10 Routine Cleaning and Inspection’.

18.3 Air pressure switch

Before starting refer to the front of Section 18 Important information.

• Remove the front panel, refer to Section 15.3.

• Remove the sealed chamber cover, refer to Section 15.5.

• Locate air pressure switch situated at the top right hand side, see diagram 18.3.

10283

33 2000225058A

Page 34

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18 Replacement of Parts

• Remove air pressure switch tube from sensing probe on flue hood.

Note: Do not fit tube until the air pressure switch is in position.

• Disconnect air pressure switch electrical connections.

• Unclip to remove air pressure switch.

18.4 Central Heating Filter

Before starting refer to the front of Section 18 Important information.

It may be necessary to clean or replace the central heating filter,

refer to section 15.12.

18.5 Burner, refer to Section 15.9.

Before starting refer to the front of Section 18 Important information.

18.6 Burner injectors, refer to diagram 18.5.

Before starting refer to the front of Section 18 Important information.

• Remove burner from boiler, refer to Section 15.9.

• Remove and replace injectors as required. Note: The injectors may be cleaned, remove injectors inspect

and clean. Note: Make sure that injector size, marked on each injector, is

the same as that given in ‘Section 1 Technical Data’ for the type of gas being used.

Do not use a wire or sharp instrument.

18.7 Burner injector assembly, refer to diagram 18.6.

Before starting refer to the front of Section 18 Important information.

• Remove burner from boiler, refer to Section 15.9.

• Undo the gas supply union nut from under the sealed chamber. Note: The fibre washer between the burner injector assembly

and gas supply must be kept for use on reassembly.

• Undo and remove the sense and ignition electrode assemblies.

• Remove the burner injector assembly securing screws.

• Remove the burner injector assembly by lifting up, easing the gas connection through the grommet in the sealing chamber.

Note: Take care not to damage the insulation.

• When refitting burner injector assembly ensure the gas connection locates correctly through the grommet.

Note: Make sure that injector size, marked on each injector, is the same as that given in ‘Section 1 Technical Data’ for the type of gas being used.

18.8 Overheat thermostat

Before starting refer to the front of Section 18 Important information.

• Remove the front panel, refer to Section 15.3.

• Remove the sealed chamber cover, refer to Section 15.5.

• Locate overheat thermostat on heating flow pipe on right hand side of boiler, see part of diagram 18.7.

• Disconnect electrical connections from thermostat

• Remove the thermostat and bracket assembly from heating flow pipe by unclipping at the side of the bracket. Remove the thermostat, fit new thermostat and replace assembly.

• When refitting electrical connections to replacement thermostat the polarity is not important.

18.9 Ignition electrode

Before starting refer to the front of Section 18 Important information.

• Remove the front panel, refer to Section 15.3.

• Lower the control panel, refer to Section 15.4.

• Remove the sealed chamber cover, refer to Section 15.5.

• Remove the combustion chamber cover, refer to Section

15.7.

• Remove the left hand side panel, refer to Section 15.6.

• Undo and remove screw securing electrode assembly to the burner injector assembly, see diagram 18.6.

• Disconnect the electrical connections at the igniter unit, see

diagram 18.18. Note the routing of the cables.

18.10 Flame sense electrode

Before starting refer to the front of Section 18 Important information.

• Remove the front panel, refer to Section 15.3.

• Lower the control panel, refer to Section 15.4.

• Remove the sealed chamber cover, refer to Section 15.5.

• Remove the combustion chamber cover, refer to Section

15.7.

• Remove burner, refer to Section 15.9.

• Remove the right hand side panel, refer to Section 15.6.

• Undo and remove screw securing sense assembly to the burner injector assembly, see diagram 18.6.

• Disconnect the electrical connection from the inline connector, Note the routing of the cable.

9646

RETAINING CLIPS

AIR PRESSURE SWITCH

ELECTRICAL CONNECTORS

SENSING TUBE

Diagram 18.3

2000225058A

Page 35

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18 Replacement of Parts

18.11 Heat exchanger, refer to diagram 18.7.

Before starting refer to the front of Section 18 Important information.

• Remove the front panel, refer to Section 15.3.

• Remove the sealed chamber cover, refer to Section 15.5.

• Remove the combustion chamber cover, refer to Section

15.7.

• Drain down central heating water circuit of the boiler only, refer to relevant part of diagram 18.1.

• Remove the fan, refer to Section 15.10.

• Remove air pressure switch sensing tube from the side of the flue hood, see diagram 15.8.

• Release both side panels, refer to section 15.6.

• Remove the flue hood, lift up and off. When refitting ensure the rear of the flue hood locates in the tabs.

• Disconnect the electrical leads from the overheat thermostat.

• Remove the two pipe securing clips.

• Lift to remove the heat exchanger taking, care not to damage the insulation.

18.12 Combustion chamber insulation, refer to diagram 18.8.

Before starting refer to the front of Section 18 Important information.

• Remove the front panel, refer to Section 15.3.

• Remove the sealed chamber cover, refer to Section 15.5.

• Remove the combustion chamber cover, refer to Section

15.7.

• Remove the heat exchanger, refer to Section 18.11.

• Pull out side insulation panels from combustion chamber.

• Tilt rear insulation panel forwards and out.

• Fit replacement insulation in reverse order to removal.

11363

11364

OVERHEAT THERMOSTAT

RESET BUTTON

ELECTRICAL LEADS

PIPE SECURING CLIP 2 OFF

GROMMET

GAS SUPPLY PIPE

SENSE ELECTRODE ASSEMBLY

IGNITION ELECTRODE ASSEMBLY

11365

Diagram 18.6

CLIP

11360

9750

11362

BURNER INJECTOR BAR

Diagram 18.5

HEAT EXCHANGER

INSULATION

35 2000225058A

Diagram 18.7

Diagram 18.8

11366

Page 36

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18 Replacement of Parts

18.13 Printed circuit board (PCB), refer to diagram 18.9.

Before starting refer to the front of Section 18 Important information.

• Remove the front panel, refer to Section 15.3.

• Lower the control panel, refer to Section 15.4.

• Gain access to rear of control panel.

• Undo and remove the two front retaining screws.

• Hinge up the control panel cover and ease forwards from the rear retaining lugs to gain access to PCB. Do not strain the cables attached to the PCB. Note the routing of the cables.

• Carefully pull off electrical connections to PCB.

• Unclip and lift out PCB.

• Fit replacement PCB in reverse order to removal. Be careful not trap any of the cables.

Make sure that PCB connections are fully pushed onto replacement PCB.

18.14 User interface board, refer to diagram

18.10.

Before starting refer to the front of Section 18 Important information.

• Unclip control panel user interface and hinge forward . Do not strain the cables.

• Disconnect the electrical connections from the user inter face board.

• Remove the two user inter face board retaining screws.

• Remove the user inter face board.

18.15 230V Controls board, refer to diagram

18.10.

Before starting refer to the front of Section 18 Important information.

• Unclip control panel user interface and hinge forward . Do not strain the cables.

• Disconnect the electrical connection from the 230V controls board and the electrical connection from printed circuit board (PCB).

• Remove the 230V controls board retaining screw.

• Remove the 230V controls board.

CONTROL BOARD COVER

➜

PCB (CONTROL BOARD)

11368

11367

➜

230V CONTROLS BOARD

➜

Diagram 18.9

11369

10330

CONTROL PANEL

2000225058A

USER INTERFACE BOARD

➜

MAINS SWITCH

➜

Diagram 18.10

Page 37

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18 Replacement of Parts

18.16 Central heating pump head, refer to diagram 18.11.

Before starting refer to the front of Section 18 Important information.

• Remove the front panel, refer to Section 15.3.

• Lower the control panel, refer to Section 15.4.

• Drain down central heating water circuit of the boiler only, refer to relevant part of diagram 18.1.

Note: it is not necessary to drain down the entire heating system to carry out this work.

• For ease of access if required remove the right hand side panel, refer to Section 15.6.

• Undo four head fixing screws and remove pump head.

• Gain access to the pump electrical connection box and remove cover.

• Disconnect pump cable from pump (avoid straining cables).

• Connect electrical connection to replacement pump head.

• Fit replacement pump head in reverse order to removal.

• Open isolating valves on flow (d) and return (b) connections, refill, and pressurise boiler.

• Check for leaks.

HEX HEAD SCREW (4 OFF)

11370

PUMP ELECTRICAL CONNECTION BOX

PUMP HEAD

Diagram 18.11

11347

18.17 Boiler drain point, refer to diagram

18.12.

Before starting refer to the front of Section 18 Important information.

• Remove the front panel, refer to Section 15.3.

• Lower the control panel, refer to Section 15.4.

• Drain down the boiler only, refer to relevant part of diagram

18.1. Pull out slotted metal clip securing boiler drain valve into

housing, remove boiler drain valve.

18.18 System water pressure sensor, refer to diagram 18.13.

Before starting refer to the front of Section 18 Important information.

• Remove the front panel, refer to Section 15.3.

• Lower the control panel, refer to Section 15.4. Drain down the boiler, refer to relevant part of Section 18.1.

• Remove electrical connections from water pressure sensor.

• Pull off slotted metal clip and remove water pressure sensor.

BOILER DRAIN VALVE

SYSTEM WATER PRESSURE SENSOR

➜

Diagram 18.12

BYPASS VALVE

11371

37 2000225058A

➜

11372

Diagram 18.13

Page 38

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18 Replacement of Parts

18.19 Bypass valve, refer to diagram 18.13.

Before starting refer to the front of Section 18 Important information.

• Remove the front panel, refer to Section 15.3.

• Lower the control panel, refer to Section 15.4.

• For ease of access if required remove the right hand side panel, refer to Section 15.6.

Drain down the boiler, refer to relevant part of Section 18.1. Remove the Igniter Unit, refer to Section 18.24. Pull out slotted metal clip, ease out bypass valve from bypass

valve housing.

CAP

11345

AIR VENT

Diagram 18.14

18.20 Automatic air vent, refer to diagram

18.14.

Before starting refer to the front of Section 18 Important information.

• Remove the front panel, refer to Section 15.3.

• Lower the control panel, refer to Section 15.4.

• Drain down the boiler only, refer to relevant part of diagram

18.1.

• Unscrew to remove automatic air vent.

• After fitting replacement automatic air vent ensure the cap is open.

18.21 Gas Control valve, refer to diagram

18.15.

Before starting refer to the front of Section 18 Important information.

• Remove the front panel, refer to Section 15.3.

• Lower the control panel, refer to Section 15.4.

• Disconnect gas supply pipe union nuts at the gas control valve.

• Disconnect injector supply pipe union nut at the gas control valve. Slacken the union nut at the burner injector bar.

• Remove gas control valve retaining clip from the underside of gas control valve.

• Remove the wire restraining clip from underside of gas control valve

• Ease gas control valve forwards and disconnect electrical connections to gas control valve.

Note: The washers must be kept for use on reassembly.

• Withdraw gas control valve assembly.

• Fit replacement gas control valve.

10018

➜

GAS CONTROL VALVE

9781

➜

11373

9782

➜

Diagram 18.15

2000225058A

GAS CONTROL VALVE

➜

STEPPER MOTOR

➜

Diagram 18.16

Page 39

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18 Replacement of Parts

18.22 Gas control valve stepper motor, refer to diagram 18.16

Before starting refer to the front of Section 18 Important information.

• Remove the front panel, refer to Section 15.3.

• Lower the control panel, refer to Section 15.4.

• Remove the gas control valve, refer to Section 18.21.

• Disconnect the electrical connection from stepper motor.

• Remove the two screws securing stepper motor to the gas

control valve.

• Fit replacement gas control valve stepper motor.

• Note: Take care not to damage the 'O' ring.

➜

10329

DISCHARGE SAFETY VALVE (3 bar)

18.23 Discharge safety valve, refer to diagram

18.17.

Before starting refer to the front of Section 18 Important information.

• Remove the front panel, refer to Section 15.3.

• Lower the control panel, refer to Section 15.4.

• Undo discharge pipe union nut.

• Pull out slotted metal clip from valve body and remove valve.

18.24 Igniter unit, refer to diagram 18.18.

Before starting refer to the front of Section 18 Important information.

• Remove the front panel, refer to Section 15.3.

• For ease of access if required remove the right hand side panel, refer to Section 15.6.

• Disconnect electrical connections.

• Remove ignition unit securing screw.

• Pull upwards to release and remove the ignition unit from the retaining slot.

18.25 Expansion vessel, refer to diagram

18.19.

Before starting refer to the front of Section 18 Important information.

Renewal of the expansion vessel requires the boiler to be removed from the wall. As an alternative, a separate expansion vessel of the same specification may be connected as close as possible to the boiler, leaving the original in position, refer to the installation instructions.

• IMPORTANT: With regards to the manual handling operations, 1992 regulations, the following operation exceeds the recommended weight for one man lift.

• Remove the front panel, refer to Section 15.3.

• Lower the control panel, refer to Section 15.4.

• Drain down the boiler only ,refer to relevant parts of diagram

18.1.

• For this operation the boiler must be removed from the wall.

• Disconnect the flue system.

• Disconnect the boiler pipes at the fixing jig.

• Disconnect the pressure relief valve discharge pipe.

➜

11378

➜

11376

➜

Diagram 18.17

11374

IGNITER UNIT

Diagram 18.18

11377

EXPANSION VESSEL

39 2000225058A

Diagram 18.19

Page 40

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18 Replacement of Parts

• Disconnect the mains cable and any external controls cables.

• IMPORTANT: With regards to the manual handling operations, 1992 regulations, the following operation exceeds the recommended weight for one man lift.

• Lift up to remove the boiler from the wall.

• Remove sealed chamber cover, refer to Section 15.4.

• Remove the right hand side panel, refer to Section 15.6.

• From the rear of the boiler.

• Unclip wiring harness retaining wire.

• Undo pipe coupling on expansion vessel.

• Unscrew and remove expansion vessel bracket retaining screw.

• Slide expansion vessel to the left and forward to remove. Note: Check that expansion vessel pressure is correct, see

‘Section 1 Technical Data’.

18.26 Inner casing panel seal, refer to diagram

18.20

Before starting refer to the front of Section 18 Important information.

• Remove the front panel, refer to Section 15.3.

• Remove the sealed chamber cover, refer to Section 15.5.

• Remove the old seal, thoroughly clean the casing. Fit the new seal, it is supplied to the correct length.

Note: Ensure the seal is fitted correctly giving an air tight seal.

9771

INNER CASING PANEL

SEAL

FRONT CASING PANEL

Diagram 18.20

19 Spare parts

When ordering spare parts, quote the part number and description, stating the appliance model number and serial number from the data badge.

Short parts list

No. Description Part No. G.C. No.

1 Central heating thermistor S57398 2 Fan S10088 3 Air pressure switch S10089 4 Printed circuit board - Main S10082 5 Pump head (30W) S10052 6 System water pressure sensor S57205 7 Gas control valve (G20) S10045 8 Discharge safety valve S10067 9 Overheat thermostat S10080 10 Ignition electrode S10038 11 Flame sense electrode S10037 12 230V controls board S10091 13 User interface PCB S10081 14 Stepper motor (G20) S57434 15 Igniter unit S57427 16 Pressure relief valve S10067 17 Heat exchanger S10030 18 Burner / 14 blades S10042

Because of our constant endeavour for improvement details may vary slightly from those in the instructions.

2000225058A