Glow-worm 30ci Plus User Manual

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

+ 39 hidden pages