Glow-worm 30ci Plus User Manual

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Instructions for Use

Installation and Servicing

To be left with the user

30ci plus

G.C. No. 47-047-22

4000123944-2 07/03

Fanned Flue Combination Boiler

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

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

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

Glow-worm Service on 00 44(0)1773 828100.

RECORD YOUR GLOW-WORM APPLIANCE DIRECT BY CALLING

the document envelope.

0208 247 9857

Customer service :

Glow-worm GB Great Britain :

Tel. 00 44 (0) 1773 828100

Fax. 00 44 (0)1773 828070

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

Technical Advice Line:

Tel. 00 44 (0)1773 828300

4000123944-2

General and Sales enquiries:

Tel. (01773) 824141

Fax. (01773) 820569

Contents

CONTENTS DESCRIPTION SECTION PAGE No.

Important Information 4 Draining and Filling 5

INSTRUCTION

FOR USE

INSTALLATION

INSTRUCTIONS

Appliance Introduction 5 Appliance Safety Devices 5 Maintenance and Servicing 6 Controls and Lighting 7 Programmer instructions for use 9

Technical Data 1 10 General Information 2 11 Heating System Design 3 11 Domestic Hot Water System Design 4 12 Boiler Schematic 5 13 Boiler Location, Flue and Ventilation 6 14 Fixing Jig 7 16 Boiler Preparation and System Connections 8 17 Boiler Installation 9 18 Horizontal Telescopic Rear Flue Installation 10 20 Horizontal Telescopic Top Flue Installation 11 22 Horizontal Top Flue Installation 12 24 Electrical Connection 13 26 Commissioning 14 28 Boiler Settings 15 30 Changing Gas Type 16 32

SERVICING

INSTRUCTIONS

Routine Cleaning and Inspection 17 33 Fault Finding 18 37 Wiring Diagram 19 43 Replacement of Parts 20 44 Spare Parts 21 56

4000123944-2

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 85 than 0.75mm2 (24/0.20mm).

C insulated cable, not less

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 6

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

4000123944-2

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.

• 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. A mains inlet pressure of 2.0 bar is required to reach a fill pressure of 1.0 bar.

Reset boiler: refer to diagram 2, switch On/Off to ( 0 ), wait for five seconds. Switch On/Off 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 Glow-worm Service using the telephone number on the inside front cover of this literature.

(a)

0.4

11900

BOILER DRAIN VALVE

(b)

bar

Appliance Introduction

The 30ci plus boiler is a wall mounted modulating combination boiler with electronic ignition providing central heating and instantaneous hot water.

The boilers are equipped with a litre domestic hot water storage vessel that ensures maximum hot water temperature stability during domestic demand.

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.

Both the central heating and domestic hot water temperature are user adjustable.

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.

category for use with Natural Gas (G20)

2H3+

➜

(c)

Diagram 1

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.

Flue options

There are various flue systems to choose from, for detailed information refer to flue options guide, which is available from your nearest stockist.

Accessories

A range of accessories are available. For further information contact your supplier.

4000123944-2

Appliance Safety Devices

Air flow rate safety device

If the flue is obstructed, even partially, 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 competent

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

Domestic Hot Water safety valve

CAUTION: A domestic hot water safety valve, with a discharge

pipe is fitted to this boiler. The valve MUST NOT BE TOUCHED except by a competent

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 your installer or Glow-worm Service 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: 01256 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 is required contact Glow-worm Service 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.

If in doubt seek advice from the local gas company or Glowworm Service using the telephone number on the inside front cover of this booklet.

4000123944-2

Controls and lighting

Central heating adjustment

The temperature of the water in the central heating circuit can be set between, approx. 38OC and 87OC.

It is supplied, factory set to 38

C - 73OC

Domestic hot water

The temperature can be adjusted from approx. 38°C up to 65°C.

11524

1 - OFF/ON switch 2 - Display 3 - Programing buttons 4 - Running lamp illuminated green when boiler

is ON (flashing red when fault indicated)

1. Lighting the boiler:

Make sure that:

• The boiler is connected to the electrical supply.

• The gas service cock is open. Switch ON (I)

The running lamp will illuminate green.

1144411445

Timed central heating and

instantaneous domestic hot water Central heating and domestic hot water

Domestic hot water only Central heating only

Long absence / Holiday mode and Appliance frost protection

Diagram 2

3. Domestic hot water temperature adjustment:

• Press button once, is displayed and the current temperature setting flashes.

• Press - or + to set a temperature between 38°c to 65°c.

• The display will default to normal after 5 seconds if no buttons are pressed.

2. Stop the boiler:

• Switch to OFF (0) the electrical supply is OFF.

11525

4000123944-2

Controls and lighting

4. Central heating temperature adjustment:

• Press button twice, is displayed and the current temperature setting flashes.

• Press - or + to set a temperature between 38°c to 87°c.

• The display will default to normal after 5 seconds if no buttons are pressed.

5. Heating Mode select:

• Press button three times, is displayed and

• Press - or + to set as required.

• The display will default to normal after 5 seconds if no buttons are pressed.

will flash along side the current mode setting.

11526

7. If a fault occurs:

• The green running light will change to a red flashing light and the display will flash the letter ‘F’ with the type of fault.

• Reset the boiler: Switch the boiler OFF ( 0 ), wait for five seconds. Switch the boiler ON ( I ), the boiler is reset. If the fault continues call your Installation/Servicing company or Glow-worm Service using the telephone number on the inside front cover of this literature.

11528

(Ignition fault shown)

8. Installation filling:

• If the boiler loses water: The green running light will change to a red flashing light and the display will flash the letter ‘F’ with the low system water pressure fault and the current system pressure.

• Fill the system by the filling device at the bottom of the boiler until the pressure gauge reads 1.0 bar.

6. Long absence / Holiday mode:

• This mode protects the boiler against frost

11529

11527

• Warning: Take care not to overfill the boiler. At a pressure of 2.5 bar or above the high system water pressure fault will be displayed. The pressure must be reduced to 1.0 bar by opening the drain valve, see diagram

1. If the fault continues call your Installation/Servicing company or Glow-worm Service using the telephone number on the inside front cover of this literature.

4000123944-2

Programmer instructions for use

Setting the time.

Make sure there is an electrical supply to the boiler and the boiler is switched ON ( I ).

Press button four times, is displayed and the time will flash, press - or + to set the correct time (24hr clock).

press "+" and displayed along with 0 to 24 hour ON / OFF settings and 1 to 7 days of the week.

Set ON / OFF times at 30min intervals for each day 1 to 7 of the week.

A flashing square is displayed below the current day of the

115301153611537

, and the will be

1153811539

Setting the day.

Press button five times, is displayed and the current day setting will flash, press - or + to set the correct day.

1=MON, 2=TUE, 3=WED, 4=THU, 5=FRI, 6=SAT, 7=SUN

Setting the programmer.

Press button six times, is displayed.

week selected, Press - or + to select the day 1 to 7 to be set.

Press displayed, a flashing square will now be displayed below the 0 along the top of the display along with the corresponding time

00:00

00:30 is set to OFF, to set this to ON press + , or to set

to OFF press - for the remainder of that day / 24hr period in 30min intervals.

to set ON / OFF times, and are

to the right of the display, this indicates that 00:00 to

OFF

, continue setting the ON / OFF times

Press the next day or - to select the previous day to be set, continue setting the remaining days as required.

The display will default to normal after 60 seconds if no buttons are pressed.

, and is displayed, press + to select

4000123944-2

1 Technical Data

30ci plus

Heating

Heat input (max) NET Q 32,6 kW

111,231 BTU/H

Heat input (min) NET Q 12,5 kW

42,650 BTU/H

Heat output (max) NET P 29,6 kW

100,995 BTU/H

Heat output (min) NET P 10,3 kW

35,144 BTU/H Efficiency - Sedbuk D 79,6% Maximum heating temperature 87° C Expansion vessel effective capacity 8 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 12,5 kW

42,650 BTU/H Heat output (max) NET P 29,6 kW

100,995 BTU/H

Heat output (min) NET P 10,3 kW

34,155 BTU/H Maximum hot water temperature 65 °C Minimum hot water temperature 38 °C Specific flow rate (for 35°C temp rise) 12,1 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 (81ppm)

Electrical

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

Net lift weight (boiler only) 41 kg

Gross lift weight (boiler and packaging) 47 kg

365

232

11542a

798

450

The 30ci plus is delivered in two separate packages:

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

• The flue system. Diagram 1.1

Natural Gas (G20)

Ø Burner injector 1,2 mm Inlet pressure 20 mbar Maxi. Burner pressure 13,3 mbar Mini. Burner pressure 2,15 mbar Gas rate maximum 3,45 m3/h

Butane Gas (G30)

Ø Burner injector 0,73 mm Inlet pressure 29 mbar Maxi. Burner pressure 25,5 mbar Mini. Burner pressure 4,7 mbar Gas rate maximum 2,53 kg/h

Propane Gas (G31)

Ø Burner injector 0,73 mm Inlet pressure 29 mbar Maxi. Burner pressure 32,5 mbar Mini. Burner pressure 4,7 mbar Gas rate maximum 2,53 kg/h

4000123944-2

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).

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.

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.

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.

3 Heating System Design

• The 30ci plus is for use with sealed central heating systems.

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

• The safety valves are an integral part of the boiler and 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 is shown in Table 1.

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

in diagram 3.2.

• 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.

• 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 such as Fernox or Sentinel. Contact the product manufacturers for specific details.

4000123944-2

3 Heating System Design

Bypass fully shut

Open 1/4 turn

Open 1/2 turn

Open 1 turn

Open 2 turns

Additional expansion vessel (if required)

Available pressure (kPa)

between heating supply and return

(10 kPa = 1 m WG)

Boiler

Filling device

0 200 400 600 800 1000 1200 1400

Flow rate through heating system l/h

Diagram 3.1

3.1 Bypass

•The boiler is fitted with an adjustable automatic bypass.

Domestic

water

10015

Ensure that under no circumstances does the flow rate drop below the figure specified, see Table 1.

TABLE 1. FLOW RATE

Hot

Cold supply

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

11357

Bypass

(If required)

Drain point

Heating circuit

Return

Flow

control valve

'A'

Bypass

valve

Diagram 3.2

4 Domestic Hot Water System Design

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

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

• The flow restrictor must be fitted limiting the flow through the boiler to a maximum of 12 l/min.

• A bypass is not required on the central heating circuit unless the system controls could allow the boiler to operate when there is no flow.

• Where a bypass has to be fitted, the bypass must be placed at least 1.5 metres from the appliance, see diagram 3.2.

3.2 Filling the system

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 3.2.

• The boiler will operate with a minimum supply pressure of 0,5 bar, at reduced flow rate.

Best operating comfort will be obtained from a supply pressure of 1 bar.

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.

4000123944-2

5 Boiler Schematic

1 - Fan. 2 - Air pressure switch. 3 - Heat exchanger. 4 - Overheat thermostat. 5 - Combustion chamber. 6 - Expansion vessel. 7 - Flame sense electrode. 8 - Burner. 9 - Ignition electrode. 10 - Pump. 11 - Heating thermistor. 12 - Ignition unit. 13 - By-pass.

14 - Gas 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 24 - Domestic safety valve 10 bar 25 - Micro accumulator vessel thermistor 26 - Micro accumulator vessel 27 - Heating element

11560

FITTED TO REAR OF

APPLIANCE

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

AB EDC

Diagram 5.1

4000123944-2

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.

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.

300mm

50mm

above boiler

(rear flue only)

20mm

5mm

25mm above elbow

11651a

600mm

450mm

300mm

20mm

5mm

*Note: It is permissible to install the boiler with smaller

clearances than those quoted PROVIDING that consideration is given for Servicing/Repairs.

Diagram 6.1

4000123944-2

6 Boiler Location, Flue and Ventilation

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.

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

Diagram 6.3

4000123944-2

7 Fixing Jig

22mm

15mm

22mm

The fixing jig is supplied within the boiler pack and is made up as follows : A - Heating flow isolating valve. B - Domestic hot water outlet. C - Gas service cock. D - Cold water inlet isolating valve. E - Heating return isolating valve.

Documentation Pack, inclusive

- Literature (not illustrated)

- Benchmark Book (not illustrated)

- Guarantee Registration form (not illustrated)

- Rewards Club leaflet (not Illustrated)

- Wiring Diagram (not illustrated)

- Flue restrictor (not illustrated)

Bag containing :

- 1 x 15mm green fibre washer (shown as "v" in diagram)

- Cold Water Inlet Restrictor

- 5 x 22mm fibre washers (shown as "w" in diagram)

Fittings Pack, inclusive

- Wall template

- Discharge Safety valve connection incl. Knurled nut and O ring seal 15mm compression fitting

- Discharge Safety Valve Instruction sheet

- 230V External connection instruction sheet

- Filling loop extension knob

- 230V External controls connection plug

Bag containing :

- 3 x 22mm Installation connection pipes

- 2 x 15mm Installation connection pipes

Bag containing :

- 4 x 22mm boiler connection pipes

- 1 x 15mm boiler connection pipe

11940a

Wall template

APPLIANCE HANGING BRACKET

FIXING JIG Inclusive Isolating Valves

Bag containing :

- 4 x 15mm fibre washers (shown as "x" in diagram)

- 4 x 22mm fibre washers - large bore (shown as "y" in diagram)

- 5 x 22mm fibre washers - small bore (shown as "z" in diagram)

Sealing Washers :

30ciplus Description

V 1 (1) 15 mm Gas valve Connection only*

W 4 (5) 22 mm - smal bore

X 3 (4) 15 mm Y 3 (4) 22 mm - large bore Z 4 (5) 22 mm - smal bore

The quantity shown in bracket ( ) denotes the number supplied * It is essential that this green sealing washer is only fitted to the gas valve connection in the position shown in the Fixing Jig diagram

4000123944-2

Cold water inlet restrictor

Diagram 7.1

8 Boiler Preparation and System Connections

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.

REAR FLUE OUTLET

11942

80 min

145

REAR TOP FLUE OUTLET

20mm*

min.

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.

KEY

22 mm. CENTRAL HEATING 15 mm.

C.H. flow

Gas supply

D.H.W. hot out

Cold water in

DOMESTIC WA TER 22mm.

C.H. return

GAS SUPPLY

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".

4000123944-2

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.

• 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.

• 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

4000123944-2

FILLING LOOP EXTENSION

Diagram 9.2

SPIGOT

SECURING SCREW (4)

Diagram 9.3

9 Boiler Installation

9.3 Heating safety valve (3 bar RED) and domestic safety valve (10 bar BLUE) discharge, refer to diagrams 9.4.

Two short discharge pipes and washers are supplied in the fittings pack, fit these to the heating safety valve 3 bar and the domestic water safety valve 10 bar. The discharge must be extended using pipe not less than 15mm. od. 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 the compression fittings supplied.

The pipes 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

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.

HEATING SAFETY VALVE (3 bar RED)

11581

DISCHARGE PIPE

Finger tighten the knurled union nut

DISCHARGE PIPE

DOMESTIC SAFETY VALVE(10 bar BLUE)

11588

Diagram 9.4

4000123944-2

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.

10.2 Sealed chamber cover

• Unscrew and remove the two retaining screws from the sealed chamber cover, see diagram 10.4

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

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

12007

Diagram 10.2

Pho 087

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 flue hood outlet ................................... H

Horizontal Rear Telescopic flue kit

Diagram 10.1

Diagram 10.3

12060

9533

Diagram 10.4

4000123944-2

10 Horizontal Telescopic Rear Flue Installation

EARTH

9741

LEAD

FAN RETAINING BOLTS

POWER SUPPLY LEADS

Diagram 10.5

10.3 Fan Removal, refer to diagram 10.5

• 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 10.6

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

TWIST ANTI-CLOCKWISE & LOCK AT 90O POSITION

NOTE: Please check orientation when engaging bayonet spigot

Diagram 10.6

FAN

10316

10.5 Flue Hood Outlet Restrictor, refer to diagram 10.8

Secure restrictor, supplied with flue pack, to the flue hood as shown in diagram 10.8.

10.6 Fan Securing, refer to diagram 10.5

Ensure fan outlet seal is in position, see diagram 10.7, 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.

SEAL

Diagram 10.7

10316

RESTRICTOR

FLUE HOOD

Diagram 10.8

4000123944-2

11 Horizontal Telescopic Top Flue Installation

The Horizontal Telescopic Top Flue, Kit No. 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°.

SIDE FLUE

70mm

11886a

65mm

11.1 Horizontal Telescopic Top Flue

Kit of parts, refer to diagram 11.1.

11.2 Horizontal telescopic flue system

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

Drill, Screw and Tape (not supplied)

10322a

225mm

REAR FLUE

450 mm

20mm

* refer to diagram 6.1

Min. Clearance

Note : Top of boiler casing not front panel

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

* supplied in plastic bag

Telescopic Top flue kit

Diagram 11.1

70mm 232 mm

65mm

Note : Top of boiler casing not front panel

Diagram 11.2

4000123944-2

11 Horizontal Telescopic Top Flue Installation

11.3 Installation of telescopic flue assembly

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

• Refer to Step 1. diagram 11.3. 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 11.3. 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 11.3. 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 11.3. 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 11.3. Fit the fixing collar (C) using the two screws (G).

STEP 1.

Outside

wall face

17mm

FLUE LENGTH

IMPORTANT

"BUTT FIT"

STEP 2.

Drill, screw 2 off

and tape the Air Duct

2 off

(G)

(A)

90mm

Flue

centre line

BOILER

(B)

25mm

(D)

FIXING

COLLAR

SEAL

11879

STEP 3.

(A)

(E)

EXTERNAL RUBBER

SEALING COLLAR

STEP 4.

(A)

(E)

STEP 5.

(D)

'O' RING

(G)

(A)

ELBOW

(H)

BOILER

2 off

(G)

4 off

(G)

GASKET

(F)

(D)

2 off

(D)

(E)

FIXING

COLLAR

(C)

Diagram 11.3

4000123944-2

12 Horizontal Top Flue Installation

12a.1 The Horizontal Top flue - kit 86285H

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.

SIDE FLUE

11886a

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.

11646

70mm

225mm

450 mm

20mm

* refer to diagram 6.1

Min. Clearance

65mm

Note : Top of boiler casing not front panel

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

REAR FLUE

70mm 232 mm

65mm

Note : Top of boiler casing not front panel

4000123944-2

Diagram 12a.2

12 Horizontal Top Flue Installation

17mm

90mm

cutting length

Air duct cutting length

X minus 90mm

plus 17mm =

Air duct

cutting length

25mm

check

dimension

(cut end)

Flue duct cutting length = air duct cutting length + 95mm

Air duct

Flue duct

Outside

wall face

Flue

centre line

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.

11643

Horizontal Top flue system

The maximum permissible length (L) is 3.5 m. For each 90° flue elbow used, (or two 45° elbows) the maximum permissible length (L) must be reduced by 1 metre.

Gasket

Diagram 12a.3

12061a

232

Diagram 12a.4

4000123944-2

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

CONTROLS PANEL REAR COVER

SECURING SCREW (3)

WIRE LINK(E)

11911

11985

4000123944-2

Diagram 13.1

Diagram 13.2

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 13.3. 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

10212

OILER

CONTROLS

INTERFACE PCB

3 2 

HEATIN CONTROLS

CONNECTION PLU

EXTERNAL

ROOM

DO NOT

CONNECT

MAINS VOL TAE

PRORAMMER

EXTERNAL

FROST

THERMOSTAT

INTERNAL PROGRAMMER

EXTERNAL 230V AC ROOM THERMOSTAT

EXTERNAL 230V AC FROST THERMOSTAT

TO MAIN PCB

CONNECTOR J5

HEATIN CONTROLS

REMOVE LIN

HEN EXTERNAL

CONTROLS ARE SE

EXTERNAL

JUNCTION BOX

DOUBLE POLE

ISOLATOR

STRAIN RELIEF

MAINS CABLE

EXTERNAL CONTROLS CABLE

Diagram 13.4

VOLTAE FREE

CONNECTION

ON CONTROLS

BOX COVER

ONOFF SITCH

3 AMP FUSE

LNE

230V~ 50Hz

PERMANENT

MAINS

SUPPLY

11983

EXTERNAL CONTROLS CABLE(MAINS VOLTAGE)

CONTROLS INTERFACE PCB

PLUG

Diagram 13.3

11974

OLER

INTERFACE PCB

EXTERNAL

FROST

THERMOSTAT

EXTERNAL

ROOM

THERMOSTAT

EXTERNAL

PRORAMMER

EXTERNAL PROGRAMMER/CLOCK

EXTERNAL 230V AC ROOM THERMOSTAT

EXTERNAL 230V AC FROST THERMOSTAT

DO NOT

CONNECT

MAINS VOL TAE

HEATIN CONTROLS

CONNECTION PLU

CONTROLS

3 2 

TO MAIN PCB

CONNECTOR J5

HEATIN CONTROLS

REMOVE LNK

HEN EXTERNAL

CONTROLS ARE SE

EXTERNAL

JUNCTION BOX

DOUBLE POLE

ISOLATOR

VOLTAE FREE

CONNECTION

ON CONTROLS

BOX COVER

ONOFF

SITCH

3 AMP FUSE

LNE

230V~ 50Hz

PERMANENT

MAINS

SUPPLY

Diagram 13.5

4000123944-2

11984

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

16. 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 1 to 8

Make sure that:

• The boiler is connected to the electrical supply.

• The gas service cock is open. 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.

BURNER PRESSURE POINT

GAS PURGE POINT

11445

Diagram 14.1

11547

• Open the three water isolating valves.

HEATING RETURN

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

DOMESTIC HOT WATER OUTLET

Note: Isolating valves are shown in the: OFF position

GAS SERVICE COCK

COLD WATER INLET

• Turn the switch ON ( I )

• Open the tap on the filling device

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

HEATING FLOW

11927

4000123944-2

11548

9792

➜

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

14 Commissioning

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

• If necessary repressurise the system, refer to procedure 4

➜

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

Ins 061a

11524

• Leave cap open on automatic air vent.

• Open various hot water taps to bleed system

11548

Ins 062a

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 from lighting. Refer to Data Label on electrical controls box. Should there be any doubt about the gas rate it should be checked at the meter.

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

• Refill system to a pressure of 1.5 bar and vent as before.

• Restart boiler and operate until a maximum temperature is reached. If necessary, refer to page 30 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.

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

Completion

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

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.

4000123944-2

14 Commissioning

Bypass

The boiler has a built-in bypass, see diagram 15.1. 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. and diagram 1.1. (turn clockwise to close the valve).

15 Boiler Settings

Boiler settings (for use by installers and Service Providers only)

Press the button and keep pressed for 10 seconds. This gives access to both the operating parameters and the fault history.

When the menu is shown on display, select code 96 using button + or -.

Press the button , to show the first menu to be adjust

: Heating ouput

2.0

bar

9718

Diagram 15.1

45°C

10 s

Note : The display will revert back to normal if no changes are

made after 1 minute or if the button is again pressed for more than 10 seconds.

Parameter 1 : Setting the heating output

The maximum heating output of the boiler is adjustable between the maximum and minimum values given in the Technical Data section.

• When flashing, press on if you want to adjust this menu.

• Use the heating + and - button to set the desired heating output in kW. Note : Adjustment of the heating output does not affect the hot water output.

For kW to Btu/hr conversion refer to table :

kW Btu/hr 10 34,120 12 40,940 14 47,770 16 54,590 18 61,420

Factory setting

kW Btu/hr 20 68,240 22 75,060 24 81,890 26 88,710 28 95,540

• Select a parameter between 0 and 10 according to the following table.

Flue parameters following maxi. flue length :

Setting Horizontal Horizontal Verticale Horizontal

TOP Flue REAR Flue TOP Flue TWIN Flue

0 0,3 m 0,3 m 1 m 1,7 m 1 0,6 m 0,5 m 1,7 m 3,9 m 2 0,9 m 0,8 m 2,4 m 6,8 m 3 1,3 m 1 m 3,1 m 9,7 m 4 1,6 m 1,3 m 3,8 m 12,6 m

Parameter 02 : Setting the flue parameters

This adjustment is made to ensure the boiler operates at maximum efficiency with longer flue lengths.

4000123944-2

Factory setting

5 1,9 m 1,5 m 4,5 m 15,5 m 6 2,2 m / 5,2 m 18,4 m 7 2,5 m / 5,9 m 21,3 m 8 2,9 m / 6,6 m 24,2 m 9 3,2 m / 7,3 m 27,1 m

10 3,5 m / 8 m 30 m

15 Boiler Settings

Parameter 3 : Setting the minimum heating temperature

This can be set to one of two values : 38°C or 50°C.

Parameter 4 : Setting the maximum heating temperature

This can be set to one of four values : 50°C, 73°C, 80°C and 87°C.

Parameter 5 : Pump operation

This can be set to one of three values : 1 - intermittent (with room thermostat)

2 - intermittent (with burner) 3 - permanently on

38°C

87°C

Factory setting

4000123944-2

16 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 suitably qualified engineer.

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

Adjusting the step pressure.

This setting is used to adjust step pressure which may be necessary after gas conversion or after changing the gas control valve.

Settings:- 2.9 mbar Natural gas G20

4.41 mbar Butane G30

5.4 mbar Propane G31 Lock the boiler at minimum power as follows. Press the mode button for about 10 seconds, Use + or - to

display code ‘96’, Press the mode button to confirm, The display idicates line 1 in the data menu, The figure on the left is the data, the one on the right is the setting for the data. Scroll through the data using + or - until you reach ‘8’, Press the mode button the figure on the right begins to flash, Change it to ‘1’ using + or -. Press the mode button to confirm. This mode will time out after 15 minutes.

Adjust the step pressure. The factory set value is noted on the data label.

Press the mode button for about 10 seconds, Use + or - to display code ‘35’, Press the mode button to confirm, The display idicates line 23 in the data menu, The figure on the left is the data, the one on the right is the setting for the data. Scroll through the data using + or - until you reach ‘24’, Press the mode button the figure on the right begins to flash, Change it to the required setting ‘0 to 199’ using + or -. Press the mode button to confirm.

Setting maximum burner pressure.

This setting is used only to reduce burner pressure at maximum setting, if the network pressure is constantly higher than normal pressure.

Settings:- 12.2 mbar Natural gas G20

23.2 mbar Butane G30

29.8 mbar Propane G31 Lock the boiler at maximum burner pressure as follows. Press the mode button for about 10 seconds, Use + or - to

display code ‘96’, Press the mode button to confirm, The display idicates line 1 in the data menu, The figure on the left is the data, the one on the right is the setting for the data. Scroll through the data using + or - until you reach ‘8’, Press the mode button the figure on the right begins to flash, Change it to ‘2’ using + or -. Press the mode button to confirm. This mode will time out after 15 minutes.

Adjust the maximum burner pressure setting.

Press the mode button for about 10 seconds, Use + or - to display code ‘35’, Press the mode button to confirm, The display idicates line 23 in the data menu, The figure on the left is the data, the one on the right is the setting for the data. Scroll through the data using + or - until you reach ‘25’, Press the mode button the figure on the right begins to flash, Change it to the required setting ‘0 to 199’ using + or -. Press the mode button to confirm.

4000123944-2

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 competent 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, unscrew the sampling point cap on the flue spigot, 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.

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

17.2 Service Check and Preparation.

• Isolate boiler from the gas and electrical supplies.

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

diagram 17.2.

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

• Remove boiler casing as follows:

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.

PRODUCTS SAMPLING POINT

SAMPLING POINT CAP

(view showing top of boiler)

Diagram 17.1

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.

9532

4000123944-2

17 Routine Cleaning and Inspection

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 isolating valves (e) and (a).

• Open the boiler drain valve (f).

BOILER DRAIN VALVE

11900

(f)

11927

(a)

HEATING FLOW

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

(b)

DOMESTIC HOT WATER OUT

(c)

GAS SERVICE COCK

9533

97999800

(d)

COLD WATER IN

(e)

HEATING RETURN

Diagram 17.2

9797

4000123944-2

Diagram 17.3

Diagram 17.4

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 Spark and Sense Gaps

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

17.6. Note: To gain access to spark and sense electrodes for removal, refer to Section, 20.12 and 20.13 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, 20.9.

17.10 Fan, refer to diagram 17.8

• Disconnect power supply leads and earth lead from fan.

• Disconnect the electrical plug from the fan sensor.

• 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

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

see diagram 20.29.

17.15 Combustion Chamber Insulation

Check the condition of the combustion chamber insulation. If renewing, refer to Section 20.15.

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.

98119816

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, 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 (c) on cold water inlet and test the Domestic Hot Water circuit for soundness.

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.

Diagram 17.5

3.5mm

11559

3.5mm

SPARK GAP

3.5 mm

SENSE GAP Diagram 17.6

4000123944-2

9812

17 Routine Cleaning and Inspection

BURNER RETAINING SCREWS

BURNER GUIDE

9818

9815

9742

AIR PRESSURE SWITCH SENSING TUBE

FLUE HOOD

9817

9825

FAN SENSOR PLUG

POWER SUPPLY LEADS

EARTH LEAD

Diagram 17.7

FAN RETAINING BOLTS

Diagram 17.8

HEAT EXCHANGER

DOMESTIC WATER INLET FILTER

11428

HOUSING

RETAINING CLIP

Diagram 17.9

CLIP

9822

FILTER

Diagram 17.10

11928

4000123944-2

11929

FLAT

FILTER

Diagram 17.11

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.

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

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

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

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 20.11 to locate the overheat thermostat reset button.

Depress the button to reset.

OVERHEAT THERMOSTAT

RESET BUTTON

9826

Diagram 18.1

TYPE OF FAULT CHECK

No display on control panel • 230V supply

• PCB fuse

• Connection between PCBs

No domestic hot water • Loose connections on control board (PCB) No central heating • Connections on air pressure switch (electrical or tubes) (warning light of fault code disconnected displayed on control panel) • Faulty control or interface board (PCB's)

• Water pressure, flashing pressure

• Shortage of air or gas

• Faulty temperature sensor

• Overheating

4000123944-2

18 Fault Finding

COMPONENT TESTING DATA

COMPONENT NORMAL MEASURE CHECK

Gas control valve Under demand during ignition sparks: If 0 Volt: the gas control valve Resistance of coil 116Ω 24V dc for 1 to 2 seconds, then is not faulty.

12Vdc (constant) at the gas control If 24 Volts and then 12 Volts valve electrical connection. but no gas at the burner:

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

Adjustment valve Close the gas inlet: If the valve does not move: (step motor) Dismantle the step motor (screw not Check the connections at both

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).

Three way valve. When heating is on: If voltages are different: 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. When hot water is on: Three way valve lead.

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).

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 spindle does not move before testing) plugged in. Replace the motor, or replace

When hot water is on: the spindle should the control board (PCB). pull in. When heating is on : the spindle should push out.

Domestic water flow To test: Use a new detector and

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

4000123944-2

18 Fault Finding

DISPLAY FAULT

spark' and 'F' and 'flashing red LED' Ignition fault (lockout) caused by no gas, no detection 'fan' and 'F' and 'flashing red led' Air fault, pressure switch, no power to fan

'05' and 'phone' and 'F' and 'flashing red LED' Overheat fault '06' and 'phone' and 'F' and 'flashing red LED' Central heating flow NTC fault

'08' and 'phone' and 'F' and 'flashing red LED' Micro accumulation vessel NTC fault '09' and 'phone' and 'F' and 'flashing red LED' Water pressure sensor fault '11' and 'phone' and 'F' and 'flashing red LED' No reception by the main board (MMI Lead) '12' and 'phone' and 'F' and 'flashing red LED' User interface or distant control panel fault '13' and 'phone' and 'F' and 'flashing red LED' Main board fault '14' and 'phone' and 'flashing red LED' Over temperature on primary water circuit

'15' and 'phone' and 'F' and 'flashing red LED' Stepper motor fault (gas valve) '16' and 'phone' and 'F' and 'flashing red LED' Gas safety value failure '17' and 'phone' and 'F' and 'flashing red LED' Power supply <170V

11669

'18' and 'phone' and 'F' and 'flashing red LED' Local user interface fault '19' and 'phone' and 'F' and 'flashing red LED' Central heating NTC not connected to pipe

'20' and 'phone' and 'F' and 'flashing red LED' User interface not compatible with boiler '0.5bar' flashing and 'F' and 'flashing red LED' Lack of water fault (<0.5b) '2.7bar' flashing and 'F' and 'flashing red LED' Upper water pressure (>2.7b)

FAULT: NO HEATING

Are the external heating

controls calling for heat?

Rectify fault on external controls.

YES

Is the polarity correct?

Rectify, check the 230V

controls board.

YES

Connect 1 and 2 on J10,

Faulty main PCB.

does boiler fire in central heating?

10301

YES

Faulty 230V controls board.

4000123944-2

18 Fault Finding

FAULT: NO HOT WATER, BUT THE HEATING IS WORKING

996111797

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).

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.

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

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

pressure correct?

YES

Is the boiler actuall designed for the gas being used.

Change the gas tpe for the boiler gas conersion kit.

YES

Clean the gas filter. Clean the burner.

4000123944-2

18 Fault Finding

FAULT: THE BURNER LIGHTS, THEN GOES OUT.

The flame is spreading across the

whole burner, but not being detected.

CHECK THE MAINS

CHECK

THE

PROBE

With the power turned off, check the continuity between the spark electrode and terminal H24 on the control board (PCB). Check the connector on the end of the wire. Check that the spark electrode is

FAULT NOT FOUND

pointing towards the flame. Check the spark electrode. Change it.

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

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

Are the gas taps on?

Turn on the gas taps.

11798

YES

s there c at the gas control valve? or testng see coponent testng ata.

hec the rng.  the prole perssts change the control oar .

YES

Test the gas control valve. hec resstance o saet valve col.

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?

YES

Is the heating temperature on the boiler set high enough?

YES

11799

11899p

Turn up settings

Is the heating power adequate?

- Check the adjustment of the by-pass internal and external (If fitted).

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

4000123944-2

18 Fault Finding

F AUL T: THE WA TER A T THE T APS IS LUKE-WARM.

9966p9968p

Is the temperature higher if you reduce

the flow through the taps?

YES

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

FAULT: THE FAN DOES NOT START.

Is there 230V ac

at fan during demand?

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

Check continuity of fan harness.

YES

Faulty fan, replace.

Faulty C, 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

2 1

4000123944-2

Air flow switch take-off.

11877

Electrical contacts.

19 Wiring Diagram

11561a

4000123944-2

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).

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 valves (a), (d) and (e).

• Open the boiler drain valve (f).

• Turn on one or more hot water taps.

BOILER DRAIN VALVE

11900

(f)

11927

(a)

HEATING FLOW

(b)

DOMESTIC HOT WATER OUTLET

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

(c)

GAS SERVICE COCK

IMPORTANT INFORMATION

WARNING: Before commencing the replacement of any

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

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

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

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

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

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.

(d)

COLD WATER INLET

CENTRAL HEATING THERMISTOR

• 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.

(e)

HEATING RETURN

Diagram 20.1

Diagram 20.2

10227

4000123944-2

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 Fan sensor, refer to diagram 17.8

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.

• Disconnect the electrical plug.

• Remove the 2 fan sensor retaining screws.

• Remove the fan sensor.

20.4 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.

20.5 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.

20.6 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.

20.7 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.

9646

RETAINING CLIPS

AIR PRESSURE SWITCH

ELECTRICAL CONNECTORS

SENSING TUBE

Diagram 20.3

UNION NUTS

COLD WATER INLET RESTRICTOR

11941

COLD WATER IN ISOLATING VALVE

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

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

20.4.

Diagram 20.4

20.8 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.

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

• Remove the combustion chamber cover, refer to Section17.7.

• Remove the burner, refer to Section 17.9.

20.9 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 Section17.7.

• 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. Do not use a wire or sharp instrument. 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.

11929

4000123944-2

20 Replacement of Parts

20.10 Burner injector assembly, refer to diagram 20.5 and 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 Section17.7.

• 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.

BURNER INJECTOR BAR

9820

IGNITION ELECTRODE ASSEMBLY

9813

9819

Diagram 20.5

GROMMET

GAS SUPPLY PIPE

SENSE ELECTRODE ASSEMBLY

9814

Diagram 20.6

20.11 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 right 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.

20.12 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 the burner, refer to Section 17.9.

• Remove the right 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.

20.13 Flame sense electrode

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

4000123944-2

OVERHEAT

9826

THERMOSTAT

ELECTRICAL LEADS

PIPE SECURING CLIP 2 OFF

9825

HEAT EXCHANGER

Diagram 20.7

• 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 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.

CLIP

20 Replacement of Parts

20.14 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.

20.15 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 20.14.

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

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.

• 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

10021

CONTROL BOARD COVER

11391

PCB (CONTROL BOARD)

➜

Diagram 20.8

➜

Diagram 20.9

4000123944-2

20 Replacement of Parts

➜

CONTROL PANEL

20.17 User interface board, refer to diagram

20.10.

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

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

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

• Remove the user inter face board retaining screw .

• Remove the user inter face board.

➜

USER INTERFACE BOARD

230V CONTROLS BOARD

➜

10212

➜

MAINS SWITCH

Diagram 20.10

PUMP ELECTRICAL CONNECTION BOX

PUMP HEAD

11424

9823

20.18 230V Controls board, refer to diagram

20.10.

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

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

• Disconnect the electrical connection from the 230V controls board.

• Remove the 230V controls board retaining screw.

• Remove the 230V controls board.

20.19 Mains switch, refer to diagram 20.10.

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

• 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.

20.20 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.

HEX HEAD SCREW (4 OFF)

• 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.

Diagram 20.11

20.21 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 down 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.

4000123944-2

20 Replacement of Parts

20.22 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.

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 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 hot water circuit, 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.

REDUCED PRESSURE ZONE VALVE (RPZ)

➜

11930

➜

FILLING TAP

Diagram 20.12

9841

BOILER DRAIN VALVE

Diagram 20.13

9846

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.

➜

9847

WATER FLOW SENSOR

➜

Diagram 20.14

4000123944-2

20 Replacement of Parts

20.26 Bypass valve, refer to diagram 15.1.

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

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

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

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

• Withdraw gas control valve assembly.

• Fit gas restrictor to replacement gas control valve

• Fit replacement gas control valve. If the step pressure requires adjusting, refer to Section 15

Changing Gas Type.

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.

➜

9833

SYSTEM WATER PRESSURE SENSOR

➜

Diagram 20.15

CAP

11548

AIR VENT

Diagram 20.16

➜

11930

GAS CONTROL VALVE

➜

9842

➜

Diagram 20.17

4000123944-2

20 Replacement of Parts

20.30 Heating safety valve (3 bar RED), 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.

• Drain down the boiler only refer to section 20.1

• Undo discharge pipe union nut.

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

20.31 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.

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

Section 17.6.

• Remove electrical plug from valve head.

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

• Fit replacement valve head in reverse order to removal. 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.

10018

GAS CONTROL VALVE

➜

STEPPER MOTOR

➜

Diagram 20.18

11581

PRESSURE RELIEF VALVE

➜

20.32 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.

20.33 Ignition unit, refer to diagram 20.22.

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

• For ease of access remove the left hand side panel, refer to Section 17.6.

• Disconnect electrical connections.

• Remove ignition unit securing screw.

➜

Diagram 20.19

10230

➜

THREE WAY VALVE HEAD

Diagram 20.20

4000123944-2

20 Replacement of Parts

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

20.34 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 and hot water circuit ,refer to relevant parts of diagram 20.1.

• Remove the water flow sensor, refer to Section 20.24.

• Unclip the central heating thermistor.

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

• Remove the system water pressure sensor, refer to Section

20.25.

• 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 in reverse order to removal using new seals, supplied.

Note: Plate to plate heat exchanger mounting screws are offset to ensure correct fitting.

20.35 Domestic safety valve (10 bar BLUE), refer to diagram 20.24.

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 hot water circuit only ,refer to relevant parts of diagram 20.1.

DOMESTIC HOT WATER PLATE TO PLATE HEAT EXCHANGER

➜

10229

THREE WAY VALVE/ BYPASS HOUSING

THREE WAY VALVE

➜

ACTUATOR

Diagram 20.21

11587

➜

9785

9850

Diagram 20.23

10231

DISCHARGE PIPE

➜

4000123944-2

➜

IGNITION UNIT

Diagram 20.22

11925

DOMESTIC SAFETY VALVE (10 BAR BLUE)

➜

11398

➜

Diagram 20.24

20 Replacement of Parts

• Undo discharge pipe union nut.

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

20.36 Micro accumulator vessel thermistor, refer to diagram 20.25.

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

• Locate micro accumulator vessel thermistor, on top of the micro accumulation vessel.

• Disconnect the inline electrical connection plug to the micro accumulator vessel thermistor.

• Pull out to remove the thermistor.

20.37 Micro accumulator vessel, refer to diagram 20.26.

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.

• Drain down the boiler and hot water ,refer to relevant parts

of diagram 20.1. Note: It is not necessary to drain down entire heating system to

carry out this work.

• Disconnect the flue system.

• Disconnect the boiler pipes at the fixing jig.

• Disconnect the pressure relief valve discharge pipes.

• Disconnect the mains cable and any external controls cables.

• Lift up to remove the boiler from the wall.

• From the rear of the boiler.

• Disconnect the inline electrical connection plug to the micro accumulator vessel thermistor.

• Remove the slotted metal clips to disconnect pipes from the bottom of the micro accumulator vessel. Note: Take care there will be a loss of water.

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

• Bend back securing tab to release vessel from boiler frame.

• Remove the vessel from the boiler, taking care not to strain the heating element electrical cable.

• Pull out slotted metal clip and pull to remove heating element from micro accumulator vessel.

• Disconnect the electrical connection plug to the micro accumulator vessel heating element at the control board PCB connection H4, see diagram 20.9.

• Release the micro accumulator vessel heating element cable from the securing clips, note the routing of the cable for reassembly.

• Pull out micro accumulator vessel thermistor securing clip and remove thermistor from heating element.

20.39 Expansion vessel, refer to diagram

20.28.

Renewal of the expansion vessel requires the boiler to be removed from the wall. As an alternative, a separate expansion

11575

MICRO ACCUMULATOR THERMISTOR

Diagram 20.25

Bend back

11576

securing tab to release micro accumulator vessel

MICRO ACCUMULATOR VESSEL

11566

20.38 Micro accumulator vessel heating element, refer to diagram 20.27.

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

• Drain hot water circuit only.

• Remove the micro accumulatior vessel, refer to Section

20.37.

• Lower the control panel, refer to Section 17.4.

• Gain access to rear of control panel, see diagram 20.9.

➜

Diagram 20.26

4000123944-2

20 Replacement of Parts

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.

11577

SLOTTED METAL CLIP

• Disconnect the boiler pipes at the fixing jig.

• 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’.

11582

MICRO ACCUMULATOR VESSEL HEATING ELEMENT

MICRO ACCUMULATOR VESSEL

SLOTTED METAL CLIP

11565

EXPANSION VESSEL SECURING SCREW

EXPANSION VESSEL

11567

11568

➜

4000123944-2

Diagram 20.27

➜

Diagram 20.28

FRONT CASING PANEL

20 Replacement of Parts

20.40 Sealed chamber cover seal, refer to diagram 20.29

9771

Before starting refer to the front of Section 20 Important

information.

SEALED CHAMBER COVER

SEAL

Diagram 20.29

• 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.

4000123944-2

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 Fan 802037 E94-796 2 Air pressure switch 801862 E92-063 3 Domestic water flow sensor 801910 E84-014 4 Printed circuit board - Main 801915 E91-904 5 Pump head 801857 E92-064 6 System water pressure sensor 801911 E83-997 7 Gas control valve (G20) 801891 E91-945 8 Gas control valve (G30) 801978 E92-058 9 Discharge safety valve 801904 E84-000 10 Overheat thermostat 801913 E91-949 11 Ignition electrode 801888 E91-917 12 Flame sense electrode 801887 E91-922 13 230V controls board 801923 E84-018 14 PCB 802038 E94-797 15 Stepper motor (G20) 801892 E91-924 16 Stepper motor (G30) 801979 E92-059 17 Ignition unit 801936 E91-960 18 Three way valve head 801912 E88-839 19 Three way valve cartridge 801903 E88-838 20 Heat exchanger 801853 E92-054 21 Burner 801854 E92-057 22 Micro accumulator vessel 802026 E94-802 23 Micro accumulator vessel resistor 802027 E94-801

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

4000123944-2

Glow-worm 30ci Plus User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual