Glow-worm 30ci, 30si Instructions For Use, Installation & Servicing

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Installation and Servicing

30ci

G.C. No. 47-047-20

4000123434-2. 01.03

Instructions for Use

To be left with the user

Fanned Flue

Combination Boiler

30si

G.C. No. 41-047-70

Fanned Flue

System Boiler

Hepworth Heating Ltd., Nottingham Road, Belper, Derbyshire. DE56 1JT

30si shown

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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 installation 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, 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 by telephoning

Heatcall our Customer Service Company on 00 44 (0)1773 828100.

RECORD YOUR GLOW-WORM APPLIANCE DIRECT BY CALLING

0208 247 9857

Customer Service:

Glow-worm GB Great Britain:

Tel. [phone]

Fax. [phone]

Hepworth Heating Ltd.,

Nottingham Road, Belper, Derbyshire. DE56 1JT

Glow-worm IE Ireland:

Tel. 00 353 (0)16305757

Fax. 00 353 (0)16305724

C & F

Quadrant Ltd.,

Quadrant House,

Chapelizod, Dublin 20

T echnical Advice Line:

Tel. [phone]

General and Sales enquiries :

Tel. [phone]

Fax. [phone]

4000123434-2

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Contents

CONTENTS DESCRIPTION SECTION PAGE No.

Important Information 4
Draining and Filling 5

INSTRUCTION

FOR USE

INSTALLATION

INSTRUCTIONS

Appliance Introduction 5
Appliance Safety Devices 6
Maintenance and Servicing 6
User Controls and Lighting 7
Analogue Programmer 24ci only 8
Digital Programmer 24ci only 8

Technical Data 1 11
General Information 2 12
Heating System Design 3 13
Domestic Hot Water System Design (30ci) 4 15
Boiler Schematic 30ci 5 16
Boiler Schematic 30si 5a 16
Boiler Location, Flue and Ventilation 6 17
Fixing jig 7 18
Boiler Preparation and System Connections 8 19
Boiler Installation 9 20
Horizontal Telescopic Rear Flue Installation 10 21
Horizontal Telescopic Top Flue Installation 11 23
Horizontal Top Flue Installation 12 25
Electrical Connection 13 27
Commissioning 14 39
Changing Gas Type 15 31
Bypass Settings 16 31

SERVICING

INSTRUCTIONS

Routine Cleaning and Inspection 17 32
Fault Finding 18 36
Wiring Diagram 30ci 19 42
Wiring Diagram 30si 19a 43
Replacement of Parts 20 44
Spare Parts 21 55

3

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Important Information

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 regulations.

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, for Ireland, install in accordance with
I.S.813 "Domestic Gas Installation". Manufacture's
instructions supplied must not be taken as overriding
statutory requirements.

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.

Control of 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

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.

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
at 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 0.75mm2 (24/0.20mm).

Gas leak or fault

WARNING: 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.

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.

Heating System Controls

The heating system must be controlled as described in the
relevant part of the current issue of :

Building Regulations, approved document L1, and the
references:

1) GIL 59, 2000: Central heating system specification (CheSS)
and

2) GPG 302, 2001: Controls for domestic central heating
system and hot water. BRECSU.

3) The domestic heating and hot water guide to the building
regulations 2001.

Thermostatic radiator valves may be installed, however they
must not be fitted in a room where the room thermostat is
located.

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.

Protection Against Freezing

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

This device operates the burner and system pump when the
temperature inside the boiler falls below 60C.

Any other exposed areas of the system should be protected by
a separate frost thermostat.

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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.

If the mains electricity and gas are to be turned off for any long
periods during severe weather, it is recommended that the
whole system, including the boiler, refer to diagram 1, should
be drained to avoid the risk of freezing. Make sure that, if fitted,
the immersion heater in the cylinder is switched off.

If in doubt, consult your servicing company.

30ci Only

• If the boiler loses water: the pressure will be indicated (a)

and the boiler ON indicator (b) will flash red indicating a fault.
Fill the system by the filling device (c) at the bottom of the boiler
until the pressure gauge reads 1.0 bar.

Reset boiler: refer to diagram 2, turn the On/Off switch to ( 0 ),
wait for five seconds. Turn the On/Off switch to ( I ) to reset the
appliance.

30si Only

• If the boiler loses water: the pressure will be indicated (a)

and the running lamp (b) will flash red indicating a fault. Fill the
system with the external filling device until the pressure gauge
reads 1.0 bar.

Reset boiler: refer to diagram 2, turn the On/Off switch to ( 0 ),
wait for five seconds. Turn the On/Off switch to ( I ) to reset the
appliance.

• Warning: Take care not to overfill the boiler.

At a pressure of 2.5 bar or above indicating over pressure, the
boiler ON indicator (b) will flash red indicating a fault. The
pressure must be reduced to 1.0 bar by opening the drain valve,
refer to diagram 1. If the fault continues call the relevant
Servicing organisation or Heatcall using the telephone number
on the inside front cover of this literature.

(a)

9744

BOILER DRAIN
VALVE

(b)

➜

(c)

Diagram 1

Appliance Introduction

The 30ci and 30si
with electronic ignition providing central heating and hot water.

The boiler is of the II
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 central heating and domestic hot water (30ci only)
temperatures are user adjustable.

30 ci Only. Domestic hot water demand always has priority over
heating demand.

The boiler is designed for use as part of a sealed water central
heating system with fully pumped circulation. 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.

boilers are wall mounted modulating boilers

category for use with Natural Gas (G20)

2H3+

This boiler may be installed in any room, although particular
attention is drawn to the installation of a boiler in a room
containing a bath or shower where reference must be made to
the relevant requirements.

Any electrical switch or boiler control utilising mains electricity
should be placed so that it cannot be touched by a person using
the bath or shower.

In GB this is the current I.E.E. WIRING REGULATIONS and
BUILDING REGULATIONS.

In IE reference should be made to the current edition of I.S.813
"Domestic Gas Installations" and the current ETCI rules.

These instructions should be carefully followed for the safe and
economical use of your boiler. The 'User Controls and Lighting'
section describes how to safely use the boiler.

Note: The boiler serial number is marked on the data label
attached to the rear of the control box.

Accessories

A range of accessories are available.

For further information contact your supplier.

5

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Appliance Safety Devices

Air flow rate safety device

If the flue is obstructed, the built in safety system will turn the
boiler OFF, the fan will continue to run. The boiler will be ready
to operate when the fault has been cleared.

Overheating safety

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

Electrical supply failure

The boiler will not operate without an electrical supply. Normal
operation of the boiler should resume when the electrical
supply is restored.

Reset any central heating system controls, to resume normal
operation.

If the boiler does not resume normal operation turn the mains
reset switch off and on. If the boiler does not resume normal
operation it is advisable to consult your installation / servicing
company.

Frost protection

The appliance has a built in frost protection device that
protects the boiler from freezing. With the gas and electric
supplies ON and irrespective of any room thermostat setting,
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.

Any other exposed areas of the system should be protected by
a separate frost thermostat.

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 competant

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

Maintenance and Servicing

Cleaning

WARNING: This appliance contains metal parts (components)

and care should be taken when handling and cleaning with
particular regard to edges of sheet metal parts to avoid any
possibility of personal injury.

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

Do not use abrasive or solvent cleaners.

Maintenance and Servicing

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 but in general once a year should
be enough, refer to guarantee registration on the inside front
cover of this literature.

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 the relevant service organisation
or Heatcall using the telephone number on the inside front
cover of this literature.

Please be advised that the ‘Benchmark’ logbook should be
completed by the 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
benchmark Logbook. You can check your installer is CORGI
registered by calling CORGI direct on: 00 44 (0)1256 372300.

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.

If a part or advice is required contact the relevant service
organisation or Heatcall using the telephone number on the
inside front cover of this booklet.

Please quote the name of the appliance, this infomation will be
on the name badge on the front of the appliance.

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User Controls and Lighting

Central heating temperature selector

minimum setting (approx. 38˚C) up to
maximum setting (approx. 87°C).
It is supplied factory set to 38˚C to 73˚C

2

4

Pressure gauge (bar)
and temperature
gauge (°C)

Domestic hot water temperature selector (30ci Only)

minimum setting approx. 38˚C up to maximum setting 65˚C.

The ECO setting is ideally suited for all the requirements of normal family
use (showers, washing up etc.). The maximum setting should be
reserved for occasional use when very hot water is required.

Boiler ON/RUNNING

5

(green) indicator
(fault indicated by
light flashing red)

3

On/Off switch

1

PROGRAMMER

6

30 ci Only

11887

1. Lighting the boiler :

Make sure that:

• The boiler is connected to the electrical supply.

• The gas service cock is open.

• The room thermostat is calling for heat.

• Turn the On/Off switch to ON ( I )

• The boiler ON indicator will illuminate green.

1

5

2. Stop the boiler :

• Turn the On/Off switch to OFF ( 0 ) the

electrical supply is OFF.

1

3. Domestic hot water adjustment

(30ci Only) :

Domestic hot water between
approx. 38˚C and 50˚C

3

ECO Maximum

recommended for
constant use

Occasional
use for water
above
approx. 50˚C

4. Heating temperature adjustment :

Winter: Set the

control knob
anywhere
between the 5

Summer: Set

the control
knob to

segments

2

5. 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 relevant
service organisation or Heatcall using the telephone
number on the inside front cover of this literature.

6. Pressure gauge:

• The boiler pressure gauge will show a reading

between 1.0 and 1.5 bar.
Refer to Section Draining and Filling if required.

5

4

Domestic hot
water OFF

7

Diagram 2

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Programmer Instructions for Use

Analogue Programmer (30 ci only)
Part

No. A20086. Fitted as standard.

Setting the time, see diagram 3

• Rotate the dial clockwise, by hand, until the indicator arrow is
pointing to the current time.

Note: The time is set in 24 hour format.

Setting the programme “on and off” times, see diagram 3

• Select the on times by pushing the black tappets to the outside.

• Select the off times by pushing the black tappets to the inside.
To override or advance the programmer
The clock has a manual on/off switch which operates as follows:
Upper position I : Heating on continuously

Middle position : Heating on timed
Lower position 0 : Heating off

To override or advance the programmer

Digital Programmer Kit. (30ci Only)
Part No. A20087. Not fitted as standard.

KEYPAD DESCRIPTION

See diagram 4 for position of keypads as described below,

Time/Automatic Run Mode selection

Prog. Programme selection
Res.* Reset clears all settings

ON/OFF selector in Prog. Mode, Manual Override selector
in Run Mode

±1h* Summer/Winter time setting

h Sets the Hour (12: - - AM)
m Sets the Minute (- -: 01 AM)
Day Sets Day(s) for time and programmes

*Recessed keys; use a pen point to press

11460

OFF
TIMES

ON TIMES

BLACK TAPPETS

INDICATOR
ARROW

Diagram 4

LCD Display

The LCD incorporates a number of different elements to display
various data and information.

Diagram 3

Programmes

The Digital Programmer will accept up to 20 events

Each event consists of:

1. An ON or OFF command

2. Time of day (Hour and Minute)

3. Single day or multiple days

An event is required for each ON and OFF.

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Programmer Instructions for Use

NOTE: MULTIPLE ON OR OFF EVENTS MAY BE
PROGRAMMED, SEE EXAMPLE.

BEFORE PROCEEDING WITH SETTING THE TIME AND
PROGRAMMING THE UNIT, PRESS THE RESET KEY TO
CLEAR ALL DATA FROM THE MEMORY.

Selecting AM/PM or 24 Hour Time

After pressing reset, the display may show AM (below). The
numbered day symbols will be flashing on and off.

If the display does not show AM, it is in 24 hour time. To change
to AM/PM mode, press and hold the h key and press the ±1h
key once. AM will appear in display.

If display is in AM/PM mode and 24 hour time mode is desired,
press and hold the h key, press the ±1h key once.

Setting the Time

IF THE h AND m KEYS ARE HELD DOWN LONGER THAN 2
SECONDS, THE NUMBERS WILL ADVANCE RAPIDLY.

Press and hold the key during the following:
(If British Summer Time is in effect, press ±1h first)

1. Press h to advance to the current hour
(while holding down the key)

2. Press m to advance to the current minute
(while holding down the key)

3. Press Day repeatedly to advance to current day
(while holding down the key)

Day Key Selections

Press Day Key Display Shows Days
0 times 1 2 3 4 5 6 7 Every Day
1 time 1 2 3 4 5 6 Mon.–Sat.
2 times 1 2 3 4 5 Mon.–Fri.
3 times 6 7 Sat. & Sun.
4 times 1 Monday
5 times 2 Tuesday
6 times 3 Wed.
7 times 4 Thursday
8 times 5 Friday
9 times 6 Saturday
10 times 7 Sunday

NOTE: If the days are flashing, it indicates the day of the week
was not set when setting the time. The timer cannot be
programmed unless the day of the week is entered.

Manual GMT/BST Time Changeover

Each year, in the Spring, press ±1h to advance the time an
hour. In the Autumn, press ±1h to set back an hour.

Programming 24 Hour or 7 Day Schedules

It may be helpful to write out the programme schedules before
beginning.

THE CURRENT TIME OF DAY AND DAY OF WEEK MUST BE
SET PRIOR TO PROGRAMMING. SEE "SETTING THE TIME"

Example
Event 1: ON at 7:00AM Monday through Saturday
Event 2: OFF at 5:00PM Monday through Friday
Event 3: OFF at 7:00PM Saturday

Three events need to be entered.

Press Prog. key only once. Display shows :

Event 1 (ON at 7:00AM Monday through Saturday)
Press key once. ON symbol appears
Press h key to 07AM
Press m key once to 00
Press Day key once 1 2 3 4 5 6 is displayed
Press Prog. key to enter

Event 2 (OFF at 5:00PM Monday through Friday)
Press key twice. OFF symbol appears
Press h key to 05PM
Press m key once to 00
Press Day key two times 1 2 3 4 5 is displayed
Press Prog. key to enter

Event 3 (OFF at 7:00PM Saturday)
Press key twice. OFF symbol appears
Press h key to 07PM
Press m key once to 00
Press Day key 9 times until only 6 is displayed
Press Prog. key to enter
Press key to enter Run Mode

IF AN "ON" TIME WAS PROGRAMMED THAT IS EARLIER IN
THE DAY THAN THE CURRENT TIME, PRESS ONCE TO
TURN THE TIMER "ON". (IT DOES NOT "LOOK BACK" TO
DETERMINE IF IT SHOULD BE ON OR OFF AFTER
PROGRAMMING).

IF 24 HOUR TIME CONTROL (SAME SCHEDULE EVERY DAY
OF THE WEEK) IS DESIRED, IGNORE Day KEY.

If an ON or OFF symbol is not entered, the ON symbol will flash,
and programme will not be accepted.

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Programmer Instructions for Use

Event Review

To review the programs at any time, press Prog. key. Events
will appear in the order they were entered with repeated
presses of the Prog. key. After all events have been reviewed,
the blank display will appear to allow entering another event.
Another press of the Prog. key will display the number of free
events available, such as Fr 16 if 4 events have been entered.

Manual Override

While in the Run Mode, pressing the key once will reverse
the current mode; ON to OFF or OFF to ON. The symbol
appears in the display to indicate a temporary override.
At the next scheduled switching time, automatic control
resumes, eliminating the override.

CONTINUOUS OPERATION: While in the Run Mode, press

the key twice to turn the output to permanently ON.

symbol appears in display.

Pressing the key three times will turn the output OFF
permanently. symbol appears in display.

To terminate a continuous override, press the key until
appears in the display.

Changing an Event

Select the event to be changed with the Prog. key. A new set
of days may be selected with the Day key just as in initial
programming.

Hours and minutes can be changed with the h and m keys.
Press Prog. or key to store the new programme.

Deleting an Event

To delete only one or a few events: Press Prog. key until the

desired program is displayed.
Press m key to :59 and press once more to blank out.
Press h key to 11PM and press once more to blank out.

Press key, display will flash for several seconds and then
enter the Run Mode. Using the reset key will delete ALL events,
the time of day, and day of the week.

Troubleshooting

PROBLEM: Days are flashing, pressing any key does nothing

except key turns output ON and OFF.
SOLUTION: Time of Day and Day of Week have not been set.

See "SETTING THE TIME"

This is the condition after a reset. If the timer is found in this
condition after it has been installed, programmed and operating
for a while, it may indicate that interference has disrupted the
microprocessor causing a loss of programme information.

A second, but very unlikely cause of loss of programme is a
power failure with the backup capacitor low or dead. Check by
disconnecting power and monitoring how long the capacitor
keeps the time of day in the display. Typically, the capacitor will
maintain the time and programmes for 4 days, but not more
than 5 days.

PROBLEM: Time of day was set while holding the key
down, but days are still flashing.

SOLUTION: Current day of week was not set while holding
down the key. See "SETTING THE TIME"

PROBLEM: It is 10AM and an ON event for 8AM was entered,
but the output is not ON. Display shows the and

symbols.

SOLUTION: After programming, the timer does not "look back"
to determine if it should be ON. Press the key (temporary

override) to turn the output ON; appears in display.
The timer will assume automatic operation at the next
programmed event.

PROBLEM: An event for 8AM Monday through Friday was
entered,

but it will not accept it and is flashing.

SOLUTION: The ON or OFF was not entered as part
of the program. ON or OFF must be selected.

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1 T echnical Data

30ci

Heating

Heat input (max) NET Q 32,6 kW

111,231 BTU/H

Heat input (min) NET Q 13,3 kW

45,380 BTU/H

Heat output (max) NET P 29,6 kW

100,995 BTU/H

Heat output (min) NET P 10,8 kW

36,849 BTU/H
Efficiency - Sedbuk D 78,6%
Maximum heating temperature 87° C
Expansion vessel effective capacity 5 litres
Expansion vessel charge pressure 0,5 bar
Maximum system capacity at 75°C 156 litres
Safety valve, maximum service pressure 3 bar

Hot water

Heat input (max) NET Q 32,6 kW

111,231 BTU/H

Heat input (min) NET Q 13,3 kW

45,380 BTU/H
Heat output (max) NET P 29,6 kW

100,995 BTU/H

Heat output (min) NET P 10,8 kW

36,849 BTU/H
Maximum hot water temperature 60 °C
Minimum hot water temperature 38 °C
Specific flow rate (for 30°C temp rise) 17 litres/min.
Threshold flow rate 1,7 litres/min.
Maximum supply pressure 10 bar
Minimum supply pressure 0,5 bar

Combustion

Products outlet diameter 60 mm
Fresh air inlet diameter 100 mm
Combustion products values CO (40 ppm)

CO2 (7,6%)

NOx (82ppm)

Electrical

Electrical supply 230 V ~ 50Hz
Electrical rating 130 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 11,3 mbar
Mini. Burner pressure 1,96 mbar
Gas rate maximum 3,25 m3/h

30si

Heating

Heat input (max) NET Q 32,6 kW

111,231 BTU/H

Heat input (min) NET Q 13,3 kW

45,380 BTU/H

Heat output (max) NET P 29,6 kW

100,995 BTU/H

Heat output (min) NET P 10,8 kW

36,849 BTU/H
Efficiency - Sedbuk D 78,6%
Maximum heating temperature 87° C
Expansion vessel effective capacity 5 litres
Expansion vessel charge pressure 0,5 bar
Maximum system capacity at 75°C 156 litres
Safety valve, maximum service pressure 3 bar

Combustion

Products outlet diameter 60 mm
Fresh air inlet diameter 100 mm
Combustion products values CO (40 ppm)

CO2 (7,6%)

NOx (82ppm)

Electrical

Electrical supply 230 V ~ 50Hz
Electrical rating 130 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 11,3 mbar
Mini. Burner pressure 1,96 mbar
Gas rate maximum 3,25 m3/h

Butane Gas (G30)

Ø Burner injector 0,73 mm
Inlet pressure 29 mbar
Maxi. Burner pressure 25,5 mbar
Mini. Burner pressure 3,73 mbar
Gas rate maximum 2,57 kg/h

Propane Gas (G31)

Ø Burner injector 0,73 mm
Inlet pressure 37 mbar
Maxi. Burner pressure 32,5 mbar
Mini. Burner pressure 4,7 mbar
Gas rate maximum 2,53 kg/h

Butane Gas (G30)

Ø Burner injector 0,73 mm
Inlet pressure 29 mbar
Maxi. Burner pressure 25,5 mbar
Mini. Burner pressure 3,73 mbar
Gas rate maximum 2,57 kg/h

Propane Gas (G31)

Ø Burner injector 0,73 mm
Inlet pressure 37 mbar
Maxi. Burner pressure 32,5 mbar
Mini. Burner pressure 4,7 mbar
Gas rate maximum 2,53 kg/h

11

4000123434-2

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The 30ci and 30si are delivered in two
separate packages:

• The boiler including fixing jig complete with
isolating valves and fittings.

• The flue system

1 T ec hnical Data

11658

232

Net lift weight (boiler only)

798

30ci 37 kg
30si 36 k g

Gross lift weight
(boiler, fixing jig and packaging)
30ci 44 kg
30si 42 k g

2 General Information

IMPORTANT NOTICE.

Where no British Standards exists, materials and equipment
should be fit for their purpose and of suitable quality and
workmanship.

Refer to Manual Handling Operations, 1992 regulations.

The installation of this boiler must be carried out by a competent
person in accordance with the rules in force in the countries of
destination.

Manufacturer’s instructions must not be taken as overriding
statutory requirements.

2.1 Sheet Metal Parts

WARNING: When installing the appliance, care should be

taken to avoid any possibility of personal injury when handling
sheet metal parts.

2.2 Statutory Requirements

The appliance is suitable only for installation in GB and IE and
should be installed in accordance with the rules in force.

In GB the installation of the boiler MUST be carried out by a
competent person as discribed in the following regulations:

Manufacturer’s instructions, supplied.

The Gas Safety (Installation and Use) Regulations.

The appropriate Building Regulations, either The Building
Regulations, The Building Regulations (Scotland), The building
Regulations (Nothern Ireland).

365

450

Diagram 2.1

The Water Fittings Regulations or Water Bylaws in Scotland.
The Health and Safety at Work Act, Control of Substances
Hazardous to Health (COSHH).

The Current I.E.E. Wiring Regulations.

Where no specific instructions are given, reference should be
made to the relevant British Standard Code of Practice.

In I.E the installation must be carried out by a competent person
and installed in accordance with the current edition of I.S. 813

"Domestic Gas Installations", the current Building Regulations
and reference should be made to the current ETCI rules for
electrical installation.

In GB the following Codes of Practice apply:

BS4814, BS5440 Part 1 and 2, BS5449, BS5546 Part 1, BS6700,
BS6798, BS6891 and BS7074 Part 1 and 2, BS7478, BS7593,
BS7671.

In IE: I.S.813, BS5546, BS5449, BS7074, BS7593.

Manufacturer’s notes must not be taken as overriding statutory
requirements.

BSI Certification

This boiler certificated to the current issue of EN 483 for
performance and safety.

It is important that no alteration is made to the boiler, without
permission, in writing, from Hepworth Heating Ltd.

Any alteration that is not approved by Hepworth Heating Ltd.,
could invalidate the warranty and could also infringe the current
issue of the Statutory Requirements.

4000123434-2

12

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0

10

20

30

40

50

60

70

0 200 400 600 800 1000 1200 1400

Flow rate through heating system l/h

Available pressure (kPa)

between heating supply and return

1

2

3

4

5

2 General Information

2.3 Gas Supply

The gas installation must be in accordance with the relevant
standards.

In GB this is BS 6891.

In IE this is the current edition of I.S.813 "Domestic gas
installation".

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.

3 Heating System Design

Bypass fully shut

1

Open 1/4 turn

2

Open 1/2 turn

3

Important Notice

If your boiler has been converted to use L.P.G. Propane the
following note applies:

Propane cylinders are under pressure and should never be
stored or used indoors residentially.

They should only be kept outside.

Under no circumstances should L.P.G. Propane cylinders be
fitted or stored in basement areas or boiler houses.

On completion, test the gas installation for soundness using the
pressure drop method and suitable leak detection fluid, purge in
accordance with the above standard.

11357

Open 1 turn

4

Open 2 turns

5

(10 kPa = 1 m WG)

The installation of the boiler must comply with the requirements
of the current issue of BS6798, in Ireland, refer also to the
current edition of I.S.813"Domestic Gas Installations".

In GB it is necessary to comply with the Water Supply (Water
Fittings) Regulations 1999 (for Scotland, the Water Byelaws
2000, Scotland).

To comply with the Water Regulations your attention is drawn
to: The Water Regulations guide published by the Water
Regulation Advisory Service (WRAS) which gives full details of
the requirements.

In IE the requirements given in the current edition of I.S.813
"Domestic Gas Installations" and the current Building Regulations
must be followed.

• The 30ci and 30si are for use 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 3.1). 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°C. The minimum flow rate is shown in table 1.

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

in diagram 3.2.

• 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 156 litres for
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 3.2.

Guidance on vessel sizing is also given in a current issue of a
BS5449 and BS7074 Part 1, for IE refer to the current edition of
I.S.813 "Domestic Gas Installations".

• 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
a 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 from Fernox or Sentinel.

13

Diagram 3.1

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TEMPORARY
CONNECTION

HOSE

UNION

HOSE

UNION

SUPPLY

PIPE

CONTROL

VALVE

CONTROL

VALVE

DOUBLE

CHECK

VALVE

BOILER

RETURNFLOW

HEATING
CIRCUIT

DRAIN
POINT

SUPPLY

PIPE

AIR GAP

TUNDISH

CONTROL

VALVE

CONTROL

VALVE

TYPE CA BACKFLOW

PREVENTION DEVICE

BOILER

RETURNFLOW

HEATING
CIRCUIT

DRAIN
POINT

Method 1

Method 2

3 Heating System Design

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, see Table 1.

• A system bypass is not required on the central heating circuit
unless the system controls will not ensure a minimum water flow
rate.

• Where a bypass has to be fitted, the bypass must be place at
least 1.5 metres away from the appliance, see diagram 3.1.

3.2 Filling the system 30ci

A filling device is fitted to the boiler to initially fill the system and
replace water lost during servicing, see the relevant parts of

diagram 2 controls and lighting and diagram 3.1.

Additional
expansion
vessel
(if required)

Domestic

water

Boiler

Filling device

3.3 Filling the system 30si

• Provision for filling the system must be made. The 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.

TABLE 1. FLOW RATE

Model Minimum flow rate
30ci 21.26 litres per minute
30si 21.26 litres per minute
This is equal to 20°C differential at maximum
heat input

9898

11593

30ci

Hot water out

Cold supply in

Drain
point

Control

valve

Drain
point

Bypass

valve

*

'A'

Flow

Heating

circuit

Boiler

Additional

*

Bypass valve
(if required)

Return

Additional
expansion
vessel
(if required)

10157

Bypass

valve

Control

valve

Drain
point

30si

4000123434-2

*

'A'

Flow

Heating

circuit

Additional

*

Bypass valve
(if required)

Return

Diagram 3.2

14

Diagram 3.3

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4 Domestic Hot Water System Design. 30ci Only

General - All domestic hot water circuits, connections, fittings

must be in accordance with the relevant standards and water
supply regulations.

For GB: Guidance G17 to G24 and recommendation R17 to
R24 of the Water Regulation Guide.

For IE: The current edition of I.S.813 "Domestic Gas Installations".

• Copper tubing or plastic Hep20 may be used for the domestic
hot water system. Unnecessary pressure losses should be
avoided.

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

• The flow restrictor, supplied in the document envelope, must
be fitted as diagram 7.1, limiting the flow through the boiler to
a maximum of 12 litres/min.

• The boiler will operate with a minimum supply pressure of 0.5
bar, at a reduced flow rate.

Best operating performance will be obtained from a supply
pressure of 1 bar or greater.

4.1 Hard Water Areas

In areas where the water is 'hard', more than 200mg/litre, it is
recommended that a proprietary scale reducer is fitted in the
cold water supply to the boiler.

15

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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 unit.
13 - By-pass.
14 - Gas control valve.
15 - Loss of water sensor.
16 - Domestic heat exchanger
17 - 3 way valve
18 - Domestic water flow sensor
19 - Filter cold water inlet
20 - Filling system
21 - Discharge safety valve (3bar)
22 - Drain valve
23 - Heating filter

5 Boiler Schematic 30ci

9899

FITTED TO
REAR OF
APPLIANCE

A - Heating flow
B - Domestic hot water outlet
C - Gas
D - Cold water inlet
E - Heating return

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 unit.
13 - By-pass.
14 - Gas control valve.
15 - Loss of water sensor.
16 - Heating filter.
17 - Discharge safety valve (3bar).
18 - Drain valve

5a Boiler Schematic 30si

11450

FITTED TO
REAR OF
APPLIANCE

A - Heating flow.
B - Gas.
C - Heating return.

4000123434-2

16

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6 Boiler Location, Flue and Ventilation

6.1 Boiler Location

The recommended clearances are shown in diagram 6.1.
Note: The boiler must be mounted on a flat wall which is

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

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

6.2. For Ireland the minimum distances for the flue terminal
positionning must be those detailed in I.S.813 "Domestic Gas
Installations".

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

6.2 Terminal guard, see diagram 6.3.

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.

A suitable terminal guard type K3 can be 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 telescopic rear flue pack.

Horizontal telescopic top flue pack.

Horizontal top flue pack.

Horizontal extended flue pack.

Vertical flue pack.

Twin flue pack.

Extensions, 90° and 45° bends.

For detailed information refer to flue options guide. 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.

300mm

50mm

*

above boiler

(rear flue only)

20mm

5mm

*

25mm
above
elbow

11651

11508

MINIMUM SITING DIMENSIONS FOR THE
POSITIONING OF FLUE TERMINALS MM

HORIZONTAL FLUES

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 150
F FROM INTERNAL/EXTERNAL CORNERS

OR TO A BOUNDARY ALONGSIDE THE
TERMINAL 300

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

VERTICAL FLUES

M FROM ADJACENT WALL TO FLUE 300
N FROM ANOTHER TERMINAL 600
P FROM ADJACENT OPENING WINDOW 1000
Q ABOVE ROOF LEVEL 300

Diagram 6.2

*Note: It is permissible

to install the boiler with
smaller clearances than
those quoted PROVIDING
that consideration is given
for Servicing/Repairs.

600mm

450mm

*

300mm

20mm

5mm

*

Diagram 6.1

17

Diagram 6.3

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7 Fixing jig

The fixing jig supplied within the

boiler pack and is made up as follows:

A - Heating flow isolating valve.
B - 30ci only Domestic hot water outlet.
C - Gas service cock.
D - 30ci only Cold water inlet isolating

valve.

E - Heating return isolating valve.

Documentation envelope, inclusive;

Wall template.
Literature (not illustrated).
Cold Water Inlet Restrictor.
Flue Restrictor (not illustrated).

Connections pack, inclusive;

Fixing jig connection pipes and seals.
Boiler connection pipes and seals.
Discharge Safety Valve connection
pipe(s), seals, filling loop extension
knob and 230V Connection plug.(not
shown).

Sealing Washers used :

FIXING JIG
Inclusive Isolating Valves

Wall template

11940

APPLIANCE
HANGING
BRACKET

x 15 mm (4 off)

y 22 mm large bore (3 off)

z 22 mm small bore (8 off)

NOTE:
An extra washer of each type
is supplied for your convenience.

z

z

z

x

x

y

15mm

22mm

x

y

22mm

A

15mm

B

z

C

y

D

x

z

z

E

22mm

z

Cold water

30ci shown

4000123434-2

inlet restrictor

18

z

Diagram 7.1

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8 Boiler Preparation and System Connections

C.H. flow

Gas supply

Cold water in

C.H. return

22mm.
CENTRAL HEATING
15mm.
DOMESTIC WA TER
22mm.
GAS SUPPLY

KEY

8.1 Cutting the flue hole

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

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

• Horizontal Rear hole cutting

• Mark position of Rear flue outlet hole from template, then
remove template, before cutting, for use, later. The core drill
used should be 115 mm diameter.

• Top Outlet Side / Rear hole cutting

• Mark the centre line for the hole on the wall. Extend the
horizontal centre line to the side wall if required and mark the
vertical centre line of the hole as shown in diagram 8.1.

• Making allowance for the slope of the flue, cut hole in wall,
preferably using a core drill. For installations with internal and
external access use a 105mm diameter core drill. For installations
with only internal access use a 125mm diameter core drill.

IMPORTANT NOTE: 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 35mm per metre of flue
downward towards the terminal. There MUST never be a
downward incline towards the boiler.

Note: If the appliance is not to be fitted for some time, cover the
hole in the wall.

*

140

TOP

OF

BOILER

REAR
FLUE
OUTLET

80 min.

11942

REAR TOP FLUE
OUTLET

65

*

NOTE

*

MINIMUM
CLEARANCES
refer diagram 6.1

232

8.2 Rear Flue - Internal Installation Only

Refer to "Horizontal Telescopic Rear Flue" instructions, section
10 and prepare the flue system. Insert the flue system into the
hole such that it will not interfere with the appliance when lifting
into position.

8.3 Fixing jig, refer to diagram 7.1

• IMPORTANT NOTE: Ensure that the fixing jig is fitted to a flat
and true wall area for correct alignment with the boiler. If this
cannot be achieved it is acceptable to pack out the fixing jig to
obtain the correct alignment.

Side Flue - Check the horizontal centre line and reposition the
template if necessary.

Rear Flue - Reposition the wall template over the hole in wall.

• Mark the securing position holes.

• Check that the fixing jig is level.

• Drill, plug and secure the jig to the wall, using suitable screws
(not supplied) for the wall type and capable of supporting the
total weight of the appliance.

8.4 Water connection

IMPORTANT NOTE: Do not subject the isolating valves to heat

from blowlamp, when making connection.

Connect the system pipework to the fixing jig connection pipes
and the fixing jig isolating valves, observing the correct flow and
return as shown in diagram 8.1.

Diagram 8.1

8.5 Gas connection
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.

• The whole of the gas installation, including the meter, should
be inpected, tested for soundness and purged in accordance
with the current issue of BS6891 and in IE the current edition of
I.S.813 "Domestic Gas Installations".

19

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9 Boiler Installation

9.1 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.

9.2 Installing the boiler

IMPORTANT NOTE: The system must be thoroughly flushed

using a propriety cleanser from Fernox or Sentinel to eliminate
any foreign matter and contamination e.g. metal filings, solder
particles, oil, grease etc.

Solvent products could cause damage to the system.

• 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.

• To remove the self adhesive wiring diagram label 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.

(Horizontal Telescopic Rear Flue Only)

Fit the flue spigot and gasket , refer to diagram 9.3, supplied in
the flue pack to the rear of the appliance, having first moved and
secured the blanking plate to the top outlet.

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

• (30ci Only) Fit the cold water inlet restrictor (supplied in the
document envelope) into cold water inlet isolating valve, see

diagram 7.1.
Important Note. 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 onto the hanging bracket,
refer to diagram 7.1.

• Fit the boiler jig connection pipes and washers between the
boiler and isolating valves, see diagram 7.1.

KNURLED
UNION NUT
finger tighten only

11581

DISCHARGE
SAFETY VALVE
PIPE

Diagram 9.1

10088

FILLING DEVICE

9.3 Discharge safety valve (diagram 9.1)

The discharge safety valve pipe and sealing washer supplied
in the connections pack, when fitted to the safety valve, will
extend the valve below the boiler. The discharge pipe must be
extended using pipe not less than 15 mm o.d. to discharge in a
visible position outside the building, facing downward preferably
over a drain.

IMPORTANT NOTE: To facilitate servicing of the appliance,
the discharge pipe MUST ONLY be extended using a
compression fitting supplied.

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.

9.4 Filling loop extension 30ci Only

The filling loop extension knob is supplied in the discharge
safety valve pipe connection pack. Fit to the filling device on/off
knob, this is a push fit, see diagram 9.2.

9.5 Filling loop extension knob 30si

The filling loop extension is not required for this boiler, it can be
discarded.

30ci Only

SPIGOT

FILLING LOOP
EXTENSION

Diagram 9.2

SECURING
SCREW (4)

Diagram 9.3

4000123434-2

20

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10 Horizontal Telescopic Rear Flue Installation

10.1 Horizontal Telescopic Rear flue ­kit No. A2018000, refer to diagram 10.1

Suitable for installations that require a flue length "L" 193 ­510mm. For flue lengths less than 328mm the duct will need to
be cut, see diagram 10.2.

To make a neat finish to the flue outlet, a flue collar kit, part No.
900850, with instructions, is available, see diagram 10.3.

Flue and Air Duct preparation

Extend the telescopic flue to the required length, making sure
that the minimum overlap is no less than 25mm, see diagram

10.2, and that the flue terminal projects 15mm minimum beyond
the wall face.

Carefully drill though air duct pilot hole and secure with self
tapping screw provided in fittings pack.

Seal the joint with the tape provided.

Fit the self adhesive foam seal provided in the flue pack around
the air duct at a position such that it will be in the wall, shown in
diagram 10.2.

Make sure that the ductings do not slope down towards the
boiler.

Push the flue assembly into and through the hole such that it is
within the wall, and does not stick out into the room. Do not push
the flue assembly too far into the hole as it has to be pulled back
into the boiler and secured.

Now continue with Fixing Jig and system connections, see
section 8, then complete the flue installation as described in the
following paragraphs 10.2 to 10.6.

B

A

C

D

G

H

The flue kit No. A2018000 comprises:

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

- Sensing tube cap (fitted) ......................................B

- Gasket ..................................................................... C

- Spigot ...................................................................... D

- Tape .........................................................................E

- Foam seal ................................................................ F

- Screws 6 off ............................................................ G

- Restrictor (not required on this model) .............. H

Horizontal Rear Telescopic flue kit

Diagram 10.1

12060

E

F

NOTE: If it is necessary to cut the "flue length", make sure
that the overlaps are as follows:- air duct = 25mm

flue duct = 50mm

"L" FLUE LENGTH =
"Y" WALL THICKNESS + 133mm

FOAM SEAL

Diagram 10.2

12007

Pho 087

21

Diagram 10.3

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10 Horizontal Telescopic Rear Flue Installation

10.2 Sealed chamber cover

• Unscrew and remove the two retaining screws from the sealed
chamber cover, see diagram 10.2

• Lift cover up and off pins on top of boiler.

10.3 Fan Removal, refer to diagram 10.3

• 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.

10.4 Flue Connection, refer to diagram 10.4

Pull the flue assembly into the spigot bayonet connection and
twist anti-clockwise to lock.

10.5 Restrictor, refer to diagram 10.5

For flue systems less than 0.5m long, fit the flue restrictor
supplied in document envelope into the fan outlet, see diagram

10.5.

10.6 Fan Securing, refer to diagram 10.3

Ensure fan outlet seal is in position, see diagram 10.5, then fit
the fan into the flue duct and secure to the flue collector with
screws previously removed.

Replace chamber cover and secure with screws previously
removed.

EARTH

9741

LEAD

FAN RETAINING
BOLTS

POWER
SUPPLY
LEADS

Diagram 10.3

TWIST ANTI-CLOCKWISE
& LOCK AT 90O POSITION

Diagram 10.2

9533

NOTE: Please check orientation
when engaging bayonet spigot

Diagram 10.4

10316

SEAL

RESTRICTOR

FAN

Diagram 10.5

4000123434-2

22

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11 Horizontal Telescopic Top Flue Installation

The

Horizontal Telescopic Top Flue,

A2004500

Suitable for installations that require a flue length "L" from 430
minimum to 660 maximum. If longer flueing is required
extensions and bends are available, see note below.

If the flue length, see diagram 11.2. is less than 430 'L' Do Not
cut this flue but use the horizontal top flue 86285H.

Note: Additional 1 metre extensions, 90° and 45° bends are
available. The maximum extended flue is 3.5m. The use of flue
bends requires the max extended flue lengths to be reduced by
1m. for 90° and 0.5m. for 45°.

11.1 Horizontal Telescopic Top Flue

Kit of parts, refer to diagram 11.1.

Kit No.

L

70mm

205mm

11886

65mm

Note :
Top of boiler
casing not
front panel

11.2 Horizontal telescopic flue system

Rear and side flue lengths and dimensions, see diagram 11.2.

Drill, Screw and
Tape (not supplied)

10322

A

*

J

E

D

*

G

*

H

*

F

C

*

B

The flue kit A2004500 is 660 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 6 off ...........................................................G

- *'O' rings .................................................................. H

- *Screws 4 off ............................................................ J

H

SIDE FLUE

L

70mm

184mm

410 mm

20mm

* refer to diagram 6.1

Min. Clearance

65mm

Note :
Top of boiler
casing not
front panel

* supplied in plastic bag

Telescopic Top flue kit

Diagram 11.1

23

REAR FLUE

Diagram 11.2

4000123434-2

Supplied By www.heating spares.co Tel. [phone]

11 Horizontal Telescopic Top Flue Installation

11.3 Installation of telescopic flue assembly

• For flue lengths less than 0.5m fit the restrictor (supplied in the
document envelope) inside the fan outlet, see diagram 11.3.

• Remove the elbow (D) and the telescopic flue assembly (A)
from the flue kit.

• Refer to Step 1. diagram 11.4. Fit the telescopic flue assembly
(A) into the prepared hole in the wall. Position the elbow (D) on
the boiler, do not secure. Position the telescopic flue assembly
(A) as it would be fitted.

• Refer to Step 2. diagram 11.4. Remove the telescopic flue
assembly (A) from the prepared hole in the wall, make sure the
air duct is extended to its required length. The flue duct at the
elbow end must protrude 25mm. Drill ,secure with two screws
and tape to secure the air duct, take care not to drill the inner
flue pipe. Fit the fixing collar seal (B) to the telescopic flue
assembly (A).

• Refer to Step 3. diagram 11.4. Fit the telescopic flue assembly
(A) with the fitted fixing collar seal into the prepared hole in the
wall. Remove the backing from the self adhesive gasket (F) and
carefully fit gasket to base of flue elbow. Fit the ‘O’ rings (H) into
the grooves in the flue ducts within the elbow (D). Lubricate the
‘O’ rings with a suitable lubricant. Fit flue elbow (D) onto boiler
and secure with the four screws (G).

• Refer to Step 4. diagram 11.4. Fit rubber sealing collar (E),
into groove at the outer end of the air duct pipe (A). Carefully
pull flue duct pipe into the elbow (D). (If the telescopic flue has
been pulled apart care must be taken not to damage the ‘O’ ring
on the flue duct when re-assembling). Secure with two screws
(G). Pull telescopic flue assembly (A) inwards to bring rubber
sealing collar hard up against external wall.

• Refer to Step 5. diagram 11.4. Fit the fixing collar (C) using
the two screws (G).

STEP 1.

Outside

wall face

17mm

STEP 2.

25mm minimum
Air Duct over lap

2 off

Drill, screw 2 off

(G)

and tape the Air Duct

STEP 3.

FLUE LENGTH

(A)

IMPORTANT

"BUTT FIT"

(B)

25mm

(A)

(D)

90mm

centre line

BOILER

FIXING

COLLAR

SEAL

ELBOW

C

L

Flue

11879

(D)

4 off

(G)

11874

The restrictor must be fitted
to the inside of the fan outlet.

RESTRICTOR
fitted for flue lengths
less than 0.5m

Diagram 11.3

(A)

(E)

EXTERNAL RUBBER

SEALING COLLAR

STEP 4.

(A)

(E)

STEP 5.

(E)

'O' RING

(G)

(A)

FIXING

COLLAR

(H)

BOILER

(D)

2 off

(G)

(C)

Diagram 11.4

GASKET

(F)

2 off

(D)

4000123434-2

24

Supplied By www.heating spares.co Tel. [phone]

12 Horizontal Top Flue Installation

12a.1 The

Suitable for installations that require a max. flue length "L" of
740mm.

If a shorter flue length is required, the flue can be cut to a min.
length"L" of 260mm rear or 300mm side. See diagram 12a.2 for
min. flue lengths.

Horizontal Top flue

- kit 86285H

12a.2 Flue systems rear and side, refer to
diagram 12a.1.

12a.3 Flue cutting, refer to diagram 12a.3.

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

ends of the pipes.

G

E

L

70mm

205mm

410 mm

20mm

* refer to diagram 6.1

Min. Clearance

11886

65mm

Note :
Top of boiler
casing not
front panel

F

B

A

J

H

The flue kit 86285H is 810 mm long and comprises:

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

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

- Elbow ....................................................................... C

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

- Fixing collar .............................................................. E

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

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

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

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

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

Horizontal Top flue kit

Diagram 12a.1

C

D

11646

SIDE FLUE

L

I

70mm

184mm

65mm

Note :
Top of boiler
casing not
front panel

25

REAR FLUE

Diagram 12a.2

4000123434-2

Supplied By www.heating spares.co Tel. [phone]

12 Horizontal Top Flue Installation

12a.4 Installation of horizontal top flue
assembly

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.4.

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

• 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 suitable lubricant to each ‘O’ ring when fitting.

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

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

• Insert flue duct pipe (B) into inner end of air duct pipe (A),
rotate flue duct pipe to locate into groove inside air duct pipe.

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

• Fit internal plastic flange (G) onto air duct pipe (A).

• Fit the fixing collar seal (D) onto the flue duct pipe (B) ensuring
it is the correct way round (the larger diameter onto the pipe).

• Pull air/flue duct pipe assembly inwards to bring rubber
sealing collar (F) hard up against external wall, while carefully
pushing the fixing collar seal onto the elbow ensuring that the
flue duct pipe locates into the flue elbow outlet while taking
care not to tear the ‘O’ ring.

• Fit the fixing collar (E) around the fixing collar seal (D) and
secure with 2 screws provided.

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

Outside

wall face

centre line

L

90mm

17mm

Air duct cutting length

L minus 90mm

plus 17mm =

cutting length

Flue duct cutting length

Air duct cutting length

+ 95mm = cutting length

Flue

C

L

Air duct

dimension

(cut end)

Diagram 12a.3

11643

Flue duct

25mm

check

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 not be fitted.

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

L

FLUE
RESTRICTOR

a

Gasket

65

184

Diagram 12a.4

10092

4000123434-2

26

Supplied By www.heating spares.co Tel. [phone]

13 Electrical Connection

WARNING: This appliance must be earthed. 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.

All system components must be of an approved type.

Electrical components have been tested to meet the equivalent
requirements of the BEAB.

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

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 3mm 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.

13.1 Mains Cable

Important: If a replacement supply cable is required it must be

purchased. Part No. S1008600.

13.2 Voltage Free External Controls

WARNING: UNDER NO CIRCUMSTANCES MUST ANY

MAINS VOLTAGE BE APPLIED TO ANY OF THE TERMINALS
ON THE VOLTAGE FREE HEATING CONTROLS
CONNECTION TERMINAL.

This boiler will operate continuously on heating, as supplied, if
the wire link (E), fitted between the two terminals of the heating
controls connection, is left in place, see diagram 13.1.

External heating controls e.g. Room thermostat, should be
fitted in accordance with the rules in force and as shown in the
example, diagram 13.2.

RETAINING SLOTS

VOLTAGE FREE
HEATING CONTROLS
CONNECTION
TERMINAL

CONTROLS PANEL REAR
COVER

SECURING SCREW (3)

WIRE LINK(E)

11911

11994

Diagram 13.1

27

Diagram 13.2

4000123434-2

Supplied By www.heating spares.co Tel. [phone]

13 Electrical Connection

13.3 Mains Voltage External Controls

WARNING: UNDER NO CIRCUMSTANCES MUST ANY

MAINS VOLTAGE BE APPLIED TO ANY OF THE TERMINALS
ON THE VOLTAGE FREE HEATING CONTROLS
CONNECTION TERMINAL.

When mains voltage external controls are used, remove the
MAINS VOLTAGE HEATING CONTROLS CONNECTION PLUG
from the fittings pack and install on the control interface PCB
as follows.

Gain access to the control interface by unclipping the fascia
panel and hinging forward, see diagram 13.3.

Route the external heating controls cable (not supplied) and
connect to the plug

Insert plug onto controls interface PCB, see diagram 11.3.

Close the fascia panel and remove the screws to open the rear
cover of control panel, see diagram 13.1.

Secure the external heating control cable in the strain relief, and
thread the cable through rear of the control panel and out of the
cables exit, see diagram 13.4.

Close and secure rear cover of control panel.

IMPORTANT: Remove the wire link from the voltage free
heating controls connector, see diagram 13.1.

Connect external heating controls as diagram 13.5.

External controls should be fitted in accordance with the rules
in force.

13.4 Electrical Connections - Testing

Carry out preliminary electrical system checks as below:

1. Test insulation resistance to earth of mains cables.

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

3. Test the polarity of the mains.

CONTROL PANEL USER INTERFACE

, see diagram 13.3.

RETAINING LATCHES

➜

➜

11659

ci only

CONTROLS

INTERFACE PCB

3
2
1

HEATING CONTROLS

CONNECTION PLUG

EXTERNAL

ROOM

X

DO NOT

CONNECT

MAINS VOLTAGE

PROGRAMMER

EXTERNAL

FROST

THERMOSTAT

THERMOSTAT

INTERNAL PROGRAMMER
EXTERNAL 230V AC ROOM THERMOSTAT
EXTERNAL 230V AC FROST THERMOSTAT

TO MAIN PCB

CONNECTOR J15

HEATING CONTROLS

REMOVE LINK
WHEN ANY EXTERNAL
CONTROLS ARE USED

EXTERNAL

JUNCTION BOX

3 AMP FUSE

DOUBLE POLE

ISOLATOR

STRAIN
RELIEF

MAINS
CABLE

EXTERNAL
CONTROLS
CABLE

Diagram 13.4

VOLTAGE FREE

CONNECTION

(ON CONTROLS

BOX COVER)

ON/OFF

SWITCH

LNE

230V~ 50Hz

PERMANENT

MAINS

SUPPLY

11992

The type of plug and
orientation may be
different to that
illustrated but the

EXTERNAL
CONTROLS
CABLE(MAINS
VOLTAGE)

wiring should always
be as wiring diagrams

11974

PLUG

CONTROLS
INTERFACE
PCB

Diagram 11.3

4000123434-2

28

si only

INTERFACE PCB

EXTERNAL

FROST

THERMOSTAT

EXTERNAL

ROOM

THERMOSTAT

EXTERNAL

PROGRAMMER

EXTERNAL PROGRAMMER/CLOCK

EXTERNAL 230V AC ROOM THERMOSTAT

EXTERNAL 230V AC FROST THERMOSTAT

X

DO NOT

CONNECT

MAINS VOLTAGE
HEATING CONTROLS
CONNECTION PLUG

CONTROLS

3
2
1

TO MAIN PCB

CONNECTOR J15

HEATING CONTROLS

REMOVE LINK
WHEN ANY EXTERNAL
CONTROLS ARE USED

EXTERNAL

JUNCTION BOX

DOUBLE POLE

ISOLATOR

VOLTAGE FREE

CONNECTION

(ON CONTROLS

BOX COVER)

ON/OFF
SWITCH

3 AMP FUSE

LNE

230V~ 50Hz

PERMANENT

MAINS

SUPPLY

Diagram 13.5

11993

Supplied By www.heating spares.co Tel. [phone]

14 Commissioning

Important: The commissioning and first firing of the boiler must

only be done by a competant person.

Gas installation

If conversion from G20 to 30 or 31 is required, refer to section

13.

It is recommended that any air is purged from the supply at the
gas purge point on the gas valve, see diagram 14.1.

Filling the system

The following steps 1 - 8, show how to fill the system.

1.

Make sure that:

• The boiler is connected to the
electrical supply.

• The gas service cock is open.

Turn the switch OFF ( 0 )

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.

GAS
PURGE
POINT

11898

30ci shown

Diagram 14.1

9796

2.

• Open the three water isolating valves.

HEATING
FLOW

24ci shown

3.

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

DOMESTIC HOT
WATER OUT

(24ci Only)

Note: Isolating valves are shown in the: OFF position

COLD
GAS SERVICE
COCK

4.

• Turn the switch ON ( I )

• 24ci Only Open the tap on the filling device

• Fill the system until the pressure indicated on
the display is 1 bar. Close filling device.

9810

WATER IN

(24ci Only)

HEATING
RETURN

11933

9792

NOTE: On initial fill there may be a small discharge
of water from the Reduced Pressure Zone valve

29

➜

➜

4000123434-2

Supplied By www.heating spares.co Tel. [phone]

14 Commissioning

5.

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

• If necessary repressurise the system, refer to
procedure 4

➜

7.

• Ensure the display indicates a system pressure
of 1.0 bar adjust if necessary.

12.4 Adjusting the Central heating output.

The central heating output is factory preset to approx. 15kW.

If a different central heating output is required, proceed as
follows:

To gain access to potentiometer P3, unclip the control box,

see diagram 11.1.

Ins 061a

10217

6.

• Leave cap open on automatic air vent.

8.

• Open various hot water taps to bleed system

The potentiometer P3, is shown in diagram 12.2,to adjust to
the required heating output, insert a small flat edge screw
driver into the arrowed slot in potentiometer P3, turn clockwise
to adjust to the desired setting. Use a manometer to monitor
the burner pressure.

9810

Ins 062a

maxi

15 kW

P.

P3

max.

mini

P3

POTENTIOMETER P3

234
1

ON DIP

POTENTIOMETER P6

P6

P7

11890

USER
INTERFACE
BOARD

Diagram 12.2

MANOMETER

SW1
DIP
SWITCH

15 kW

P.
max.

mini

ON DIP

Factory set in
"OFF" position

234
1

maxi

0

P6

+

12.5 Dip Switches

The position of the SW1Dip Switch(es), see diagram 12.2, and
the table below can be used to change the operation of the

PUMP OPERATION DIP SWITCH 1 DIP SWITCH 2 HEATING TEMP DIP SWITCH 3 DIP SWITCH 4

CONTINUOUS ON ON 53OCON ON

WITH BURNER ON OFF 87OC ON* OFF*

CONTINUOUS OFF ON 53OC OFF ON

WITH HEATING OFF* OFF* 73OC OFF OFF

DEMAND

pump and maximum heating temperature of your boiler.

FACTORY SETTING * GB/IE PREFFERED SETTING

4000123434-2

30

Supplied By www.heating spares.co Tel. [phone]

14 Commissioning

When all adjustments are completed.

• 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 air contained in the water of the central heating system.

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

• The air trapped at the highest point of the system must be
released by bleeding the radiators. Check the burner gas rate
required, ten minutes after 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, refer to technical data.

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

• 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. If necessary, refer to section 16 to adjust the bypass.
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.

30ci Only Flush the domestic hot water system by opening the
hot water taps for several minutes.

Completion

Adjust the boiler temperature control and any system controls
to their required settings.

For IE, it is necessary to complete a "Declaration of Conformity"

to indicate compliance to I.S.813. An example of this is given
in the current edition of I.S.813.

Please ensure the “Benchmark” logbook is completed and left
with the user and the magnetic lighting instruction label is
placed 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 heatingsystem
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 in the UK.

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.

15 Changing Gas Type

Should it be necessary to change the gas type, a conversion kit
with instructions will be required.

This modification must only be carried out by a competent
person.

Conversion natural gas (G20) to G30/G31 Part No. A2011900.

Setting the step pressure.

Adjusting the step pressure may be a necessary operation after
gas conversion or after changing the gas control valve when a
new replacement part is required.

Proceed as follows:

• Gain access to the gas control valve, connect a pressure
gauge.

16 Bypass Settings

Bypass

The boiler

The boiler is supplied with the bypass open half a turn. It should
not be necessary to adjust the bypass, but if required ensure
that under no circumstances does the flow rate fall below the
figures specified, refer to table 1. in section 3 (turn clockwise
'A' to close the valve).

has a built-in bypass, refer to diagram 16.1.

• Unclip the control box, see diagram 11.1.

• Run the appliance in heating mode.

• Read the burner pressure setting in heating mode, before the
boiler modulates.

• Adjust the central heating output to the minimum setting by
adjusting potentiometer P3, refer to commissioning section.

• Adjust the potentiometer P6 burner pressure to the desired
value, by inserting a small flat edge screw driver into the
arrowed slot, turn to adjust to the desired setting, see diagram

12.2.

• Return the potentiometer P3 to its initial value.

A

9718

30ci shown

31

Diagram 16.1

4000123434-2

Supplied By www.heating spares.co Tel. [phone]

17 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 competant
person.

17.1 Products of combustion check

Top Flue: 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 17.1.

Rear Flue: To obtain a products of combustion reading, remove
the sampling point cap on the flue, located between the boiler
and the wall, see diagram 17.1.

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.

PRODUCTS
SAMPLING
POINT

(view showing top of boiler)

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

SAMPLING
POINT CAP

Diagram 17.1

17.2 Service Check and Preparation.

• Isolate boiler from the gas and electrical supplies.

• (30ci Only) Drain the Domestic hot water circuit, refer to

diagram 17.2.

9532

To Drain the Domestic hot water circuit (30ci Only)

• Close boiler isolating valve (d).

• Turn on one or more hot water taps.

• Open the domestic hot water circuit drain valve.

To Drain the boiler

• Close isolating valves (e) and (a).

• Open the boiler drain valve (f).

BOILER DRAIN VALVE

9839

(f)

11933

(a)

HEATING
FLOW

30ci shown

4000123434-2

(b)

DOMESTIC HOT
WATER OUTLET

(30ci Only)

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

(c)

GAS
SERVICE
COCK

32

(d)

COLD WATER
INLET

(30ci Only)

(e)

HEATING
RETURN

Diagram 17.2

Supplied By www.heating spares.co Tel. [phone]

17 Routine Cleaning and Inspection

• Drain the boiler, refer to diagram 17.2.

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

17.3 Front panel

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

• Remove front panel by lifting up and forward.

17.4 Control panel

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

17.5 Sealed chamber cover

• Unscrew and remove the two retaining screws from the sealed
chamber cover, see diagram. 17.3.

• Lift cover up and off pins on top of boiler.

17.6 Side panels (for ease of access if
available), refer to diagram 17.4

• 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.

• Unhook each panel from the front retaining tabs.

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

9533

Diagram 17.3

97999800

9797

30ci shown

33

Diagram 17.4

4000123434-2

Supplied By www.heating spares.co Tel. [phone]

17 Routine Cleaning and Inspection

17.7 Combustion chamber cover

• Unscrew and remove the two screws securing combustion
chamber cover to combustion chamber, see diagram 17.5.

• Remove combustion chamber cover from boiler.

17.8 Ignition and Flame Sensing Gaps

• Check that the ignition and flame sensing gaps are as shown
in diagram 17.6. Note: To gain access to ignition and sensing
electrodes for removal, refer to Section, 20.11 and 20.12 in

Replacement of Parts.

17.9 Burner, refer to diagram 17.7

• 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, 20.8.

17.10 Fan, refer to diagram 17.8

• 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.

17.14 Sealed chamber cover seal check

Check the condition of the seal, replace as required.

To replace remove the old seal, thoroughly clean the casing
surfaces. Fit new seal, it supplied to the correct length, see

diagram 20.25.

17.15 Combustion chamber insulation

Check the condition of the combustion chamber insulation. If
renewing, refer to section 20.14.

17.16 Flue system

• Check externally to make sure that flue is not blocked

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

17.17 Reassembly of parts removed for
servicing

All parts are replaced in reverse order to removal.

9811

17.11 Heat exchanger, refer to diagram 17.9

• 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.

17.12 Domestic water inlet filter 30ci Only,
refer to diagram 17.10

If the water flow rate through the appliance has reduced it may
be necessary to clean or replace the domestic water inlet filter.

• Pull out slotted clip securing the filter in its housing, remove
the filter to clean or renew if necessary.

Push the filter fully into its housing and replace the securing
clip.

• Open isolating valve (d) diagram 17.2 on cold water inlet and
test the Domestic Hot Water circuit for soundness.

Diagram 17.5

3.5mm

9752

3.5mm

IGNITION
GAP

17.13 Central Heating Filter, refer to diagram

17.11

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.

FLAME
SENSING
GAP

4000123434-2

34

3.5 mm

9816

Diagram 17.6

Supplied By www.heating spares.co Tel. [phone]

9812

17 Routine Cleaning and Inspection

BURNER
RETAINING
SCREWS

BURNER
GUIDE

9742

9818

AIR PRESSURE
SWITCH
SENSING TUBE

FLUE HOOD

9817

9825

9815

EARTH

9741

LEAD

11934

POWER
SUPPLY
LEADS

Diagram 17.7

FAN RETAINING
BOLTS

Diagram 17.8

HEAT EXCHANGER

DOMESTIC WATER
INLET FILTER
HOUSING

Diagram 17.9

CLIP

9822

FILTER

Diagram 17.1030ci Only

11935

FILTER

RETAINING
CLIP

30ci shown

35

FLAT

Diagram 17.11

4000123434-2

Supplied By www.heating spares.co Tel. [phone]

18 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 and that the
polarity is correct.

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.

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.

Overheat thermostat reset button

Refer to Section 20.10 to locate the overheat thermostat
reset button.

Depress the button to reset.

OVERHEAT
THERMOSTAT

RESET
BUTTON

9826

Diagram 18.1

DISPLAY FAULT

'01' Ignition fault (lockout) caused by no gas, no detection

'02' Air fault, pressure switch, no power to fan

'03' Air fault lock

'04' Ignition fault (lockout) caused by no gas, no detection

'05' Overheat fault

'06' Central heating flow NTC fault

'07' Domestic hot water NTC fault

'08' Micro accumulation vessel NTC fault

'09' Water pressure sensor fault

'10' Central heating return NTC fault

'11' No reception by the main board (MMI Lead)

'12' User interface or distant control panel fault

'13' Main board fault

'14' Over temperature on primary water circuit

'15' Stepper motor fault (gas valve)

'16' Gas safety valve failure

'17' Power supply <170V

'18' Local user interface fault

'19' Central heating NTC not connected to pipe

'20' User interface not compatible with boiler

'0.5bar' Lack of water fault (<0.5b)

'2.7bar' Upper water pressure (>2.7b)

4000123434-2

36

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18 Fault Finding

TYPE OF FAULT CHECK

No display on control panel • 230V supply

• PCB fuse

• Connection between PCBs

No domestic hot water 30ci Only) • Loose connections on control board (PCB), Fault F9

No central heating • Connections on air pressure switch (electrical or tubes)
(Red flashing warning light and flashing disconnected, Fault F2
fault code in display) • Faulty control or interface board (PCB's), Fault F9

• Water pressure, flashing pressure

• Shortage of air or gas, Fault F1 or F2

• Faulty temperature sensor, Fault F9

• Overheating, Fault F9

COMPONENT TESTING DATA

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

(30ci Only)

Three way valve.
Electrical supply to motor 230V ac between 1 and 2 of the motor. Connections.
0Ω between 1 and 3. About 25V ac to 35V ac between 2 and 3. Control board (PCB).

9.6kΩ between 1 and 2.

9.6kΩ between 1 and 3. 230V ac between 2 and 3 of the motor. 3 2 1
(1, 2 and 3 marked on About 25V ac to 35V ac between 1 and 2.
the motor).

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

the gas control valve

stuck. If not, check the
adjustment 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).

When heating is on: If voltages are different:

When hot water is on:

Three way valve lead.

Thrust action of the motor. Unfasten the clip (YES, no risk of water If electrical supply is OK.
(remove gas control valve leak), pull out the motor and leave it but the motor axle does not move
before testing) plugged in. Replace the motor, or replace

(30ci Only)

Domestic water flow

When hot water is on:

pull in.
should push out.

When heating is on :

the spindle should the control board (PCB).

37

the spindle

To test:

connect it electrically in place of
the faulty one . Blow through to
simulate a demand for water.

Use a new detector and

4000123434-2

Supplied By www.heating spares.co Tel. [phone]

18 Fault Finding

FAULT: NO HEATING

Are the external heating

controls calling for heat?

YES

Is the polarity correct?

YES

Connect 1 and 2 on J10,

does boiler fire in central heating?

YES

Faulty 230V controls board.

NO

NO

NO

Rectify fault on external controls.

Rectify, check the 230V

controls board.

Faulty main PCB.

30ci ONLY

FAULT: NO HOT WATER, BUT THE HEATING IS WORKING

Is the water pressure greater

than 0.5 bar ?

YES

Is the water flow rate greater

than 1.7l/min. (threshold figure).

YES

Is flow detector operating ?

YES

Check the connectors on the

flow sensor and the control board (PCB).

If the fault persists, fit a relplacement

control board (PCB).

NO

NO

NO

Insufficient water pressure.

The appliance will not operate.

Find out why the pressure is so low.

Check the cold water inlet filter

for dirt. Is the cold water tap fully open ?

Check the heat exchanger for scaling.

Change or clean it.

4000123434-2

38

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18 Fault Finding

F1 FAULT DISPLAYED

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

• Clean the gas filter.

• Clean the burner.

NO

• Check that the gas taps are fully open

• Check the gas pressure.

F1 or F4 FAULT DISPLAYED

FAULT: THE BURNER LIGHTS, THEN GOES OUT.

The flame is spreading across the

whole burner, but not being detected.

CHECK
THE MAINS

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
continuity between the flame sense
electrode and terminal H2 . 4 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.

11873

39

4000123434-2

Supplied By www.heating spares.co Tel. [phone]

18 Fault Finding

F1 FAULT DISPLAYED

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?
for testing see component testing data.

YES

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

NO

NO

Turn on the gas taps.

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

FAULT: THE ROOM TEMPERATURE IS INADEQUATE AND RADIATORS ARE LUKE-WARM.

Is the room thermostat and or radiator

set high enough and calling for duty?

NO

Turn up settings

Is the heating power adequate?

YES

Is the heating temperature on the boiler
set high enough?

YES

- Check set point P3. (Refer to Commissioning)

- Check dip switch setting. (Refer to Commissioning)

- Check the adjustment of the by-pass internal and

external (If fitted). - 30ci Only Check the 3-way valve

is not passing into the domestic hot water heat exchanger.

4000123434-2

40

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18 Fault Finding

30ci ONLY

FAULT: THE WATER AT THE TAPS IS LUKE-WARM.

Is the temperature higher if you reduce

the flow through the taps?

YES

Check that the cold water inlet restrictor
is fitted.
Check the rate of flow.
Check burner pressure is correct.

FAULT: THE FAN DOES NOT START.

Is there is 230V ac

at fan during demand?

NO

NO

Check the 3-way valve is not passing
into the radiators. (The radiators should
stay cold in Summer setting)

11875

Check continuity of fan harness.

YES

Faulty fan, replace.

Faulty PCB, replace.

YES

FAULT: THE FAN RUNS BUT THERE ARE NO SPARKS.

• CHECK CONTINUITY OF IGNITION (ELECTRODES AND LEADS)

• CHECK POWER SUPPLY FROM PCB TO IGNITION UNIT

CONNECTIONS TO THE AIR PRESSURE SWITCH

Pr

P2

P1

3

21

11876

LH

Air flow switch take-off.

Electrical contacts.

41

11877

4000123434-2

Supplied By www.heating spares.co Tel. [phone]

19 Wiring Diagram 30ci

Y

g

or

w

WATER
PRESSURE
SENSOR

FAN

OVERHEAT

THERMOSTAT

THERMISTOR

CH

bb

br

bg/y

bk bk

g

3

1

ww

p

w

AIR PRESSURE
SWITCH

ELECTRODE

GAS

CONTROL

VALV E

w

SENSE

w

pory

g

gn

g

IGNITION
ELECTRODES

PUMP

THREE-WAY

VALV E

MAINS VOLTAGE HEATING CONTROLS PLUG

230V SWITCHED LIVE FROM OPTIONAL FROST STAT.

230V SWITCHED LIVE FROM HEATING CONTROLS.

IGNITOR

UNIT

CHASSIS

EARTH

PLUG

3

1

g/y

bk

4

2

10224

USER INTERFACE

FLOW
SENSOR

PROGRAMMER

J10

J1

S1

J12

J4

J2

J7

bk- BLACK
w- WHITE
g/y- GREEN/

YELLOW

J15

w

y

r

J11

KEY

br - BROWN
b- BLUE
p- PINK
g- GREY

REMOVE VOLTAGE FREE LINK

CONTROLS
INTERFACE

b

gn

J13

FUSE
125mAT

r - RED
or- ORANGE
gn- GREEN
y- YELLOW

VOLTAGE FREE
HEATING CONTROLS
PLUG

LINK

REMOVE THE LINK IF FITTING
VOLTAGE FREE OR 230V
EXTERNAL CONTROLS.
IF THE LINK IS NOT REMOVED
THE BOILER WILL RUN
CONTINUOUSLY.

H2

H5
H1

H4

H3

g/y

br

b

g/y

br

b
b

br
g/y

b
br

H8
H6

br

b

H7

wr

ON/OFF
SWITCH

g/y

b

br

230V~50Hz

PERMANENT

MAINS SUPPL

FUSED AT 3A

CHASSIS
EARTH

g/y

4000123434-2

42

Supplied By www.heating spares.co Tel. [phone]

19a Wiring Diagram 30si

g

or

w

WATER
PRESSURE
SENSOR

FAN

OVERHEAT

THERMOSTAT

THERMISTOR

CH

bb

bg/y

br

bk bk

3

1

ww

AIR PRESSURE
SWITCH

GAS

CONTROL

VALV E

SENSE

ELECTRODE

w

g

pory

w

g

gn

IGNITION
ELECTRODES

IGNITOR

UNIT

PUMP CH

MAINS VOLTAGE HEATING CONTROLS PLUG

230V SWITCHED LIVE FROM OPTIONAL FROST STAT.

230V SWITCHED LIVE FROM HEATING CONTROLS.

3

CHASSIS

EARTH

1

g/y

PLUG

4

2

bk

10298

NOT
USED

USER INTERFACE

J1

S1

J12

J4

J2

J7

bk- BLACK
w- WHITE
g/y- GREEN/

YELLOW

J15

br - BROWN
b- BLUE
p- PINK
g- GREY

J11

KEY

CONTROLS
INTERFACE

J13J10

r - RED
or- ORANGE
gn- GREEN
y- YELLOW

REMOVE VOLTAGE FREE LINK

VOLTAGE FREE
HEATING CONTROLS
PLUG

REMOVE THE LINK IF FITTING
VOLTAGE FREE OR 230V
EXTERNAL CONTROLS.
IF THE LINK IS NOT REMOVED
THE BOILER WILL RUN
CONTINUOUSLY.

H2

H5
H1

H4

H3
H8

FUSE
125mAT

H6
H7

wr

ON/OFF
SWITCH

LINK

g/y

br

b

b
br
g/y

b
br

CHASSIS

br

b

b

br

EARTH

g/y

g/y

230V~50Hz

PERMANENT

MAINS SUPPLY

FUSED AT 3A

43

4000123434-2

Supplied By www.heating spares.co Tel. [phone]

20 Replacement of Parts

To Drain the central heating circuit

• Open drain valve fitted at the lowest point in the system.

• Allow air into the system by opening a radiator bleed screw or the boilers drain
valve (f).

(30ci Only) To Drain the Domestic hot water circuit

• Close boiler isolating valve (d).

• Turn on one or more hot water taps.

To Drain the boiler

• Close isolating screws on the isolating valves (a), (d) and (e).

• Open the boiler drain valve (f).

BOILER DRAIN VALVE

9839

(f)

11933

(a)

HEATING
FLOW

Note: Isolating cocks water and gas are shown in the: OFF position30ci shown

(b)

DOMESTIC HOT
WATER OUTLET

(30ci Only)

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 of assembly to test
for gas soundness and purge in accordance with the current
issue of BS6891 or in IE, the current edition of I.S.813 "Domestic
Gas Installations".

20.1 Central heating thermistor

Before starting refer to the front of Section 20 Important
information.

• Remove the front panel, refer to Section 17.3.

• Lower the control panel, refer to Section 17.4.

• Locate central heating thermistor on heating flow pipe on
centre of boiler, see diagram 20.2.

(c)

GAS
SERVICE
COCK

30ci shown

• 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.

(d)

COLD WATER
INLET

(30ci Only)

CENTRAL HEATING
THERMISTOR

(e)

HEATING
RETURN

Diagram 20.1

Diagram 20.2

10227

4000123434-2

44

Supplied By www.heating spares.co Tel. [phone]

20 Replacement of Parts

20.2 Fan, refer to Section 17.10.

Before starting refer to the front of Section 20 Important
information.

• Remove the front panel, refer to Section 17.3.

• Remove the sealed chamber cover, refer to Section 17.5.

• Remove the fan, refer to Section 17.10.

20.3 Air pressure switch

Before starting refer to the front of Section 20 Important
information.

• Remove the front panel, refer to Section 17.3.

• Remove the sealed chamber cover, refer to Section 17.5.

• Locate air pressure switch situated at the top right hand side,
see diagram 20.3.

• 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.

RETAINING
CLIPS

ELECTRICAL
CONNECTORS

SENSING
TUBE

UNION NUT

9646

AIR PRESSURE
SWITCH

Diagram 20.3

COLD WATER INLET
RESTRICTOR

20.4 (30ci Only) Domestic water inlet filter

If the water flow rate through the appliance has reduced it may
be necessary to clean or replace the water inlet filter.

Before starting refer to the front of Section 20 Important

information.

• Remove the front panel, refer to Section 17.3.

• Lower the control panel, refer to Section 17.4.

• Clean or replace the water inlet filter, refer to section 17.12.

20.5 Central Heating Filter

It may be necessary to clean or replace the central heating filter.
Before starting refer to the front of Section 20 Important

information.

• Clean or replace the central heating filter, refer to section

17.13.

20.6 (30ci Only) Cold water inlet restrictor

Before starting refer to the front of Section 20 Important
information.

• Remove the front panel, refer to Section 17.3.

• Lower the control panel, refer to Section 17.4.
Drain down domestic hot water circuit of boiler only, refer to

relevant part of diagram 20.1.

• Remove the retaining wire.

• Undo union nuts from boiler cold water in isolating valve.

• Clean and inspect restrictor, replace if necessary, see diagram

20.4.

20.7 Burner, refer to Section 17.9.

Before starting refer to the front of Section 20 Important
information.

• Remove the front panel, refer to Section 17.3.

• Lower the control panel, refer to Section 17.4.

11939

11932

COLD WATER IN

30ci Only

• Remove the sealed chamber cover, refer to Section 17.5.

• Remove the combustion chamber cover, refer to Section

17.7.

• Remove the burner, refer to Section 17.9.

ISOLATING VALVE

Diagram 20.4

20.8 Burner injectors, refer to diagram 20.5.

Before starting refer to the front of Section 20 Important
information.

• Remove the front panel, refer to Section 17.3.

• Lower the control panel, refer to Section 17.4.

• Remove the sealed chamber cover, refer to Section 17.5.

• Remove the combustion chamber cover, refer to Section

17.7.

• Remove burner from boiler, refer to Section 17.9.

• 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 implement.

45

4000123434-2

Supplied By www.heating spares.co Tel. [phone]

20 Replacement of Parts

20.9 Burner injector assembly, refer to diagram

20.6.

Before starting refer to the front of Section 20 Important
information.

• Remove the front panel, refer to Section 17.3.

• Lower the control panel, refer to Section 17.4.

• Remove the sealed chamber cover, refer to Section 17.5.

• Remove the combustion chamber cover, refer to Section 17.7.

• Remove burner from boiler, refer to Section 17.9.

• 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.

20.10 Overheat thermostat

Before starting refer to the front of Section 20 Important
information.

• Remove the front panel, refer to Section 17.3.

• Remove the sealed chamber cover, refer to Section 17.5.

• Locate overheat thermostat on heating flow pipe on left hand
side of boiler, see part of diagram 20.7.

• 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.

BURNER INJECTOR

98199820

BAR

IGNITION ELECTRODE
ASSEMBLY

9813

OVERHEAT

9826

THERMOSTAT

ELECTRICAL
LEADS

PIPE SECURING
CLIP 2 OFF

Diagram 20.5

GROMMET

GAS SUPPLY
PIPE

SENSE ELECTRODE
ASSEMBLY

9814

Diagram 20.6

CLIP

20.11 Ignition electrode

Before starting refer to the front of Section 20 Important
information.

• Remove the front panel, refer to Section 17.3.

• Lower the control panel, refer to Section 17.4.

• Remove the sealed chamber cover, refer to Section 17.5.

• Remove the combustion chamber cover, refer to Section 17.7.

• Remove burner, refer to Section 17.9.

• Remove the left hand side panel, refer to Section 17.6.

• Undo and remove screw securing electrode assembly to the
burner injector assembly, see diagram 20.6.

• Disconnect the electrical connections at the ignition unit, see

diagram 20.22. Note the routing of the cables.

20.12 Flame sense electrode

Before starting refer to the front of Section 20 Important
information.

4000123434-2

9825

• Remove the front panel, refer to Section 17.3.

• Lower the control panel, refer to Section 17.4.

• Remove the sealed chamber cover, refer to Section 17.5.

• Remove the combustion chamber cover, refer to Section

17.7.

• Remove burner, refer to Section 17.9.

• Remove the right hand side panel, refer to Section 17.6.

• Undo and remove screw securing sense assembly to the
burner injector assembly, see diagram 20.6.

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

46

HEAT
EXCHANGER

Diagram 20.7

Supplied By www.heating spares.co Tel. [phone]

20 Replacement of Parts

20.13 Heat exchanger, refer to diagram 20.7.

Before starting refer to the front of Section 20 Important
information.

• Remove the front panel, refer to Section 17.3.

• Remove the sealed chamber cover, refer to Section 17.5.

• Remove the combustion chamber cover, refer to Section

17.7.

• Drain down central heating water circuit of the boiler only,
refer to relevant part of diagram 20.1.

• Remove the fan, refer to Section 17.10.

• Remove air pressure switch sensing tube from the side of the
flue hood, see diagram 17.9.

• Release both side panels, refer to section 17.6.

• 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.

20.14 Combustion chamber insulation, refer to
diagram 20.8.

Before starting refer to the front of Section 20 Important
information.

• Remove the front panel, refer to Section 17.3.

• Remove the sealed chamber cover, refer to Section 17.5.

• Remove the combustion chamber cover, refer to Section

17.7.

• Remove the heat exchanger, refer to Section 20.13.

• Pull out side insulation panels from combustion chamber.

• Tilt rear insulation panel forwards and out.

• Fit replacement insulation in reverse order to removal.

20.16 User interface board, refer to diagram

20.10.

Before starting refer to the front of Section 20 Important
information.

• Remove the front panel, refer to Section 17.3.

• 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.

20.17 230V Controls board, refer to diagram

20.10.

Before starting refer to the front of Section 20 Important
information.

• Remove the front panel, refer to Section 17.3.

• 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.

20.18 Mains switch, refer to diagram 20.10.

Before starting refer to the front of Section 20 Important
information.

• Remove the front panel, refer to Section 17.3.

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

• Remove the mains switch.

• Disconnect the electrical connections from the mains switch.

20.15 Printed circuit board (PCB), refer to
diagram 20.9.

Before starting refer to the front of Section 19 Important
information.

• Remove the front panel, refer to Section 17.3.

• Lower the control panel, refer to Section 17.4.

• 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.

INSULATION

9824

Diagram 20.8

47

4000123434-2

Supplied By www.heating spares.co Tel. [phone]

10021

CONTROL BOARD
COVER

20 Replacement of Parts

PCB (CONTROL BOARD)

10001

230V CONTROLS
BOARD

➜

CONTROL PANEL

30ci shown

PROGRAMMER

➜

➜

➜

Diagram 20.9

11659

➜

➜

➜

➜

USER INTERFACE BOARD

30ci shown

4000123434-2

48

11660

➜

➜

MAINS SWITCH

Diagram 20.10

Supplied By www.heating spares.co Tel. [phone]

20 Replacement of Parts

20.19 (30ci Only) Analogue Programmer, refer
to diagram 20.10.

Before starting refer to the front of Section 20 Important
information.

• Remove the front panel, refer to Section 17.3.

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

• Disconnect the electrical connections from the programmer.

• Undo the two securing screws and remove the programmer.

20.20 Central heating pump head, refer to
diagram 20.11.

Before starting refer to the front of Section 20 Important
information.

• Remove the front panel, refer to Section 17.3.

• Lower the control panel, refer to Section 17.4.

• Drain down central heating water circuit of the boiler only,
refer to relevant part of diagram 20.1.

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 17.6.

• 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.

HEX HEAD SCREW (4 OFF)

30ci shown

REDUCED PRESSURE
ZONE VALVE (RPZ)

➜

9823

PUMP
ELECTRICAL
CONNECTION
BOX

PUMP
HEAD

Diagram 20.11

11936

➜

20.21 (30ci Only) Filling system tap, refer to
diagram 20.12.

Before starting refer to the front of Section 20 Important
information.

• Remove the front panel, refer to Section 17.3.

• Lower the control panel, refer to Section 17.4.

• Drain the hot water circuit only, refer to relevant part of
diagram 20.1.

• Pull of the filling loop tap extension.

• Pull out slotted metal clip securing tap into housing, remove
tap.

• Pull out slotted metal clip and remove pipe from tap.

20.22 (30ci Only) Reduced pressure zone valve
(RPZ), refer to diagram 20.12.

Before starting refer to the front of Section 20 Important
information.

• Remove the front panel, refer to Section 17.3.

• Lower the control panel, refer to Section 17.4.

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

20.1.

• Pull out slotted metal clip securing pipe to RPZ.

• Pull out slotted metal clip securing RPZ into housing, remove
RPZ.

➜

30ci Only

➜

FILLING TAP

Diagram 20.12

49

4000123434-2

Supplied By www.heating spares.co Tel. [phone]

20 Replacement of Parts

20.23 Boiler drain point, refer to diagram

20.13.

Before starting refer to the front of Section 20 Important
information.

• Remove the front panel, refer to Section 17.3.

• Lower the control panel, refer to Section 17.4.

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

20.1.

Pull out slotted metal clip securing boiler drain valve into
housing, remove boiler drain valve.

20.24 (30ci Only) Water flow sensor, refer to
diagram 20.14.

Before starting refer to the front of Section 20 Important
information.

• Remove the front panel, refer to Section 17.3.

• Lower the control panel, refer to Section 17.4.
Drain down the boiler, refer to relevant part of Section 20.1.

• Undo the union nut on the cold water inlet isolating valve.

• Pull out slotted metal clip securing filling system tap into
housing, swing the tap forwards.

• Pull out the two slotted metal clips retaining the domestic
water inlet filter housing.

• Remove domestic water inlet filter housing.

• Remove electrical connections from water flow sensor.

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

➜

➜

➜

➜

BOILER
DRAIN
VALVE

Diagram 20.13

9846 9841

➜

20.25 System water pressure sensor, refer to
diagram 20.15.

Before starting refer to the front of Section 20 Important
information.

• Remove the front panel, refer to Section 17.3.

• Lower the control panel, refer to Section 17.4.
Drain down the boiler, refer to relevant part of Section 20.1.

• Remove electrical connections from water pressure sensor.

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

30ci Only

➜

➜

9847

WATER
FLOW
SENSOR

➜

Diagram 20.14

➜

9833

SYSTEM
WATER
PRESSURE
SENSOR

30ci shown

4000123434-2

50

Diagram 20.15

Supplied By www.heating spares.co Tel. [phone]

20 Replacement of Parts

20.26 Bypass valve, refer to diagram 16.1.

Before starting refer to the front of Section 20 Important
information.

• Remove the front panel, refer to Section 17.3.

• Lower the control panel, refer to Section 17.4.
Drain down the boiler, refer to relevant part of Section 20.1.

• Remove the igniter unit, refer to Section 20.33.

Pull out slotted metal clip, ease out bypass valve from bypass
valve housing.

20.27 Automatic air vent, refer to diagram

20.16.

Before starting refer to the front of Section 20 Important
information.

• Remove the front panel, refer to Section 17.3.

• Lower the control panel, refer to Section 17.4.

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

20.1.

• Unscrew to remove automatic air vent.

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

20.28 Gas Control valve, refer to diagram

20.17.

Before starting refer to the front of Section 20 Important
information.

• Remove the front panel, refer to Section 17.3.

• Lower the control panel, refer to Section 17.4.

• 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 the wire restraining clip from underside of gas
control valve

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

Note: Use the new washers supplied with the gas control valve.

• Withdraw gas control valve assembly.

• Fit replacement gas control valve.

If the step pressure requires adjusting, refer to Section 13
Changing Gas Type.

30ci shown

➜

➜

30ci shown

10018

9810

CAP

AIR VENT

Diagram 20.16

➜

11936

GAS CONTROL
VALVE

9842

➜

Diagram 20.17

20.29 Gas control valve stepper motor, refer to
diagram 20.18

Before starting refer to the front of Section 20 Important
information.

• Remove the front panel, refer to Section 17.3.

• Lower the control panel, refer to Section 17.4.

• Remove the gas control valve, refer to Section 20.28.

• 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.

51

GAS CONTROL
VALVE

➜

STEPPER
MOTOR

➜

➜

Diagram 20.18

4000123434-2

Supplied By www.heating spares.co Tel. [phone]

20 Replacement of Parts

20.30 Discharge safety valve, refer to diagram

20.19.

Before starting refer to the front of Section 20 Important
information.

• Remove the front panel, refer to Section 17.3.

• Lower the control panel, refer to Section 17.4.

• Undo discharge pipe union nut.

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

9794

PRESSURE
RELIEF
VALVE

➜

20.31 (30ci Only) Three-way valve head, refer
to diagram 20.20.

Before starting refer to the front of Section 20 Important
information.

• Remove the front panel, refer to Section 17.3.

• Lower the control panel, refer to Section 17.4.

• Remove the gas control valve, refer to Section 20.28. (It will
not be necessary to remove gas control valve electrical
connections).

• Remove electrical plug from valve head.

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

• Fit replacement valve head.

Note :

1) When refitting clip, ensure that letters YES are as shown.

2) It is not necessary to drain boiler to carry out this work.

20.32 (30ci Only) Three-way valve actuator,
refer to diagram 20.21.

Before starting refer to the front of Section 20 Important
information.

• Remove the front panel, refer to Section 17.3.

• Lower the control panel, refer to Section 17.4.

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

20.1.

• Remove the gas control valve, refer to Section 20.28.

• Remove 3-way valve head, refer to Section 20.31.

• Remove the three way valve actuator, see diagram 20.21

30ci shown

30ci Only

➜

➜

THREE WAY
VALVE HEAD

➜

Diagram 20.19

10230

Diagram 20.20

10229

THREE WAY
VALVE/ BYPASS
HOUSING

30ci Only

4000123434-2

52

THREE WAY
VALVE

➜

ACTUATOR

Diagram 20.21

9785

Supplied By www.heating spares.co Tel. [phone]

20 Replacement of Parts

20.33 Ignition unit, refer to diagram 20.22.

Before starting refer to the front of Section 20 Important
information.

• Remove the front panel, refer to Section 17.3.

• Lower the control panel, refer to Section 17.4.

• For ease of access remove the left hand side panel, refer to

Section 17.6.

• Disconnect electrical connections.

• Remove ignition unit securing screw.

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

20.34 (30ci Only) Domestic hot water plate to
plate heat exchanger

Before starting refer to the front of Section 20 Important
information.

• Remove the front panel, refer to Section 17.3.

• Lower the control panel, refer to Section 17.4.

• Drain down the boiler only ,refer to relevant parts of
diagram 20.1.

• Unclip the central heating thermistor.

• Unscrew the heating flow pipe union nut, swing pipe forwards,

see diagram 20.23.

• Supporting domestic hot water plate to plate heat exchanger,
unscrew and remove two screws securing it onto pump
mounting and 3-way valve/bypass housing.

• Remove plate to plate heat exchanger from boiler.

• Fit replacement plate to plate heat exchanger.
Note: Plate to plate heat exchanger mounting screws are offset

to ensure correct fitting.

➜

➜

1023111598

IGNITION
UNIT

➜

➜

Diagram 20.22

DOMESTIC HOT WATER
PLATE TO PLATE HEAT
EXCHANGER

➜

➜

➜

30ci Only

11599

Diagram 20.23

53

4000123434-2

Supplied By www.heating spares.co Tel. [phone]

20 Replacement of Parts

20.35 Expansion vessel

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.

Replacing the expansion vessel

Before starting refer to the front of Section 20 Important
information.

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

• 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 17.3.

• Lower the control panel, refer to Section 17.4.

• Drain down the boiler only ,refer to relevant parts of
diagram 20.1.

• Disconnect the flue system.

• Disconnect the fixing jig connection pipes at the boiler.

• Disconnect the pressure relief valve discharge pipe.

• Disconnect the mains cable and any external controls cables.

• Lift up to remove the boiler from the wall.

• Remove sealed chamber cover, refer to Section 17.4.

• Remove the combustion chamber cover, refer to Section

17.5.

• Remove the fan, refer to Section 17.10.

• Remove air pressure switch sensing tube from the side of the
flue hood, see diagram 17.9.

• Release both side panels, refer to Section 17.6.

• Remove the flue hood, lift up and off to release from rear
location tabs.

• Remove the expansion vessel retaining screw.

• From the rear of the boiler.

• Undo pipe coupling on expansion vessel.

• Lift to remove expansion vessel.
Note: Check that expansion vessel pressure is correct, see

‘Section 1 Technical Data’.

20.36 Sealed chamber cover seal, refer to
diagram 20.25

Before starting refer to the front of Section 20 Important
information.

EXPANSION VESSEL

11600

30ci shown

11640

PIPE
COUPLING

11582

4000123434-2

54

SECURING
SCREW

Diagram 20.24

Supplied By www.heating spares.co Tel. [phone]

20 Replacement of Parts

• Remove the front panel, refer to Section 17.3.

• Remove the sealed chamber cover, refer to Section 17.5.

• 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.

FRONT
CASING
PANEL

10063

SEALED
CHAMBER
COVER

SEAL

Diagram 20.25

21 Spare parts

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

Short parts list

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

1 Central heating thermistor 801935 E91-959
2 Fan 801860 E92-062
3 Air pressure switch 801862 E92-063

4 30ci Only Domestic water flow sensor 801910 E84-014

5 Printed circuit board - Main 801915 E91-904
6 Pump head (50W) 801857 E92-064
7 System water pressure sensor 801911 E83-997
8 Gas control valve (G20) 801891 E91-945
9 Gas control valve (G30) 801978 E92-058
10 Discharge safety valve 801904 E84-000
11 Overheat thermostat 801913 E91-949
12 Ignition electrode 801888 E91-917
13 Flame sense electrode 801887 E91-922
14 230V controls board 801923 E84-018
15 User interface PCB 802038 E94-797
16 Stepper motor (G20) 801892 E91-924
17 Stepper motor (G30) 801979 E92-059
18 Ignition unit 801936 E91-960

19 30ci Only Three way valve head 801912 E88-839

20 Three way valve cartridge 801903 E88-838
21 Heat exchanger 801853 E92-054
22 Burner/17 blades 801854 E92-057

55

4000123434-2

Supplied By www.heating spares.co Tel. [phone]

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

4000123434-2

56