Glow-worm 30ci, 30si, 35ci Instructions For Use Installation And Servicing

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Instructions for Use

Installation and Servicing

To be left with the user

Fanned Flue

30ci

G.C. No. 47-047-20

30si

Combination Boiler

Fanned Flue

System Boiler

4000123923-2 07/03

G.C. No. 41-047-70

35ci

G.C. No. 47-047-28

Fanned Flue

Combination Boiler

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

30si shown

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

4000123923-2

General and Sales enquiries :

Tel. 00 44 (0)1773 824141

Fax. 00 44 (0)1773 820569

(0)

Contents

CONTENTS DESCRIPTION SECTION PAGE No.

Important Information 4 Draining and Filling 5

INSTRUCTION

FOR USE

INSTALLATION

INSTRUCTIONS

Appliance Introduction 5 Appliance Safety Devices 6 Maintenance and Servicing 6 User Controls and Lighting 7 Analogue Programmer 30ci Only 8 Digital Programmer 30ci Only 8

Technical Data 1 11 General Information 2 12 Heating System Design 3 13 Domestic Hot Water System Design (30ci/35ci) 4 15 Boiler Schematic 30ci/35ci 5 16 Boiler Schematic 30si 5a 16 Boiler Location, Flue and Ventilation 6 17 Fixing jig 7 18 Boiler Preparation and System Connections 8 19 Boiler Installation 9 20 Horizontal Rear Flue Installation 10 21 Horizontal Telescopic Top Flue Installation 11 23 Horizontal Top Flue Installation 12 25 Electrical Connection 13 27 Commissioning 14 29 Changing Gas Type 15 32 Bypass Settings 16 32

SERVICING

INSTRUCTIONS

Routine Cleaning and Inspection 17 33 Fault Finding 18 37 Wiring Diagram 30ci 19 43 Wiring Diagram 30si 19a 44 Wiring Diagram 35ci 19b 45 Replacement of Parts 20 46 Spare Parts 21 58

4000123923-2

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 or 1312.

Product/production certified by: Notified body 0049 or 1312.

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 60C.

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

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Draining and Filling

Caution: The boiler is installed as part of a sealed system

which must only be drained and filled by a competent person. If the mains electricity and gas are to be turned off for any long periods during severe weather, it is recommended that the whole system, including the boiler, refer to diagram 1, should be drained to avoid the risk of freezing. Make sure that, if fitted, the immersion heater in the cylinder is switched off. If in doubt, consult your servicing company.

30ci Only

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

and the boiler ON indicator (b) will flash red indicating a fault. Fill the system by the filling device (c) at the bottom of the boiler until the pressure gauge reads 1.0 bar. A mains pressure of 2.0 bar is required to reach a fill pressure of 1.0 bar. Reset boiler: refer to diagram 2, turn the On/Off switch to (0), wait for five seconds. Turn the On/Off switch to ( I ) to reset the appliance.

30si Only

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

and the running lamp (b) will flash red indicating a fault. Fill the system with the external filling device until the pressure gauge reads 1.0 bar. Reset boiler: refer to diagram 2, turn the On/Off switch to (0), wait for five seconds. Turn the On/Off switch to ( I ) to reset the appliance.

• Warning: Take care not to overfill the boiler. At a pressure of 2.5 bar or above indicating over pressure, the boiler ON indicator (b) will flash red indicating a fault. The pressure must be reduced to 1.0 bar by opening the drain valve, refer to diagram 1. If the fault continues call the relevant Servicing organisation or Glow-worm Service using the telephone number on the inside front cover of this literature.

(a)

9744

BOILER DRAIN VALVE

(b)

➜

(c)

Diagram 1

Appliance Introduction

The 30ci and 35ci boilers are wall mounted modulating boilers with electronic ignition providing central heating and hot water. The 30si boiler is wall mounted modulating boilers with electronic ignition providing central heating only.

The boiler is of the II (G20) as distributed in the United Kingdom, or Butane (G30), Propane (G31) with the appropriate conversion kit.

The boiler has a fan assisted balanced flue which both discharges the products of combustion to and draws the combustion air from the outside of the room. The central heating and domestic hot water (30ci Only) temperatures are user adjustable. Domestic hot water demand (30ci Only) 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

category for use with Natural Gas

2H3+

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. This boiler may be installed in any room, although particular attention is drawn to the installation of a boiler in a room containing a bath or shower where reference must be made to the relevant requirements. Any electrical switch or boiler control utilising mains electricity should be placed so that it cannot be touched by a person using the bath or shower. In GB this is the current I.E.E. WIRING REGULATIONS and BUILDING REGULATIONS. In IE reference should be made to the current edition of I.S.813 "Domestic Gas Installations" and the current ETCI rules. These instructions should be carefully followed for the safe and economical use of your boiler. The 'User Controls and Lighting' section describes how to safely use the boiler. Note: The boiler serial number is marked on the data label attached to the rear of the control box.

Accessories

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

4000123923-2

Appliance Safety Devices

Air flow rate safety device

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

Overheating safety

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

Electrical supply failure

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

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

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

Frost protection

The appliance has a built in frost protection device that protects the boiler from freezing. With the gas and electric supplies ON and irrespective of any room thermostat setting, the frost protection device will light the boiler when the temperature of the boiler water falls below 6°C.

When the temperature reaches 16°C, the boiler stops.

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

Heating safety valve

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

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

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

Maintenance and Servicing

Cleaning

WARNING: This appliance contains metal parts (components)

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

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

Do not use abrasive or solvent cleaners.

Maintenance and Servicing

To ensure the continued efficient and safe operation of the appliance it is recommended that it is checked and serviced as necessary at regular intervals but in general once a year should be enough, refer to guarantee registration on the inside front cover of this literature.

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

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

To obtain service, please call the relevant service organisation or 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: 00 44 (0)1256 372300.

Spare Parts

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

If a part or advice is required contact the relevant service organisation or 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.

4000123923-2

User Controls and Lighting

Central heating temperature selector

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

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

Domestic hot water temperature selector (30ci Only)

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

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

Boiler ON/RUNNING

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

On/Off switch

PROGRAMMER

30 ci/35 ci Only

11887

1. Lighting the boiler :

Make sure that:

• The boiler is connected to the electrical supply.

• The gas service cock is open.

• The room thermostat is calling for heat.

• Turn the On/Off switch to ON ( I )

• The boiler ON indicator will illuminate green.

2. Stop the boiler :

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

3. Domestic hot water adjustment

(30ci Only) :

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

ECO Maximum

recommended for constant use

Occasional use for water above approx. 50˚C

4. Heating temperature adjustment :

Winter: Set the

control knob anywhere between the 5

Summer: Set the control knob to (30ci Only)

segments

5. If a fault occurs (indicated by

red flashing light) :

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

6. Pressure gauge:

• The boiler pressure gauge will show a reading

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

Domestic hot water OFF

Diagram 2

4000123923-2

Programmer Instructions for Use

Analogue Programmer (30ci Only) Part

No. A20086. Fitted as standard.

Setting the time, see diagram 3

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

Note: The time is set in 24 hour format.

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

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

• Select the off times by pushing the black tappets to the inside.

To override or advance the programmer The clock has a manual on/off switch which operates as

follows: Upper position I : Heating on continuously

Middle position Lower position 0 : Heating off

To override or advance the programmer

: Heating on timed

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

KEYPAD DESCRIPTION

See diagram 4 for position of keypads as described below,

Time/Automatic Run Mode selection

Prog. Programme selection Res.* Reset clears all settings

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

±1h* Summer/Winter time setting

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

*Recessed keys; use a pen point to press

11460

OFF TIMES

ON TIMES

BLACK TAPPETS

INDICATOR ARROW

Diagram 4

LCD Display

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

Diagram 3

Programmes

The Digital Programmer will accept up to 20 events

Each event consists of:

1. An ON or OFF command

2. Time of day (Hour and Minute)

3. Single day or multiple days

An event is required for each ON and OFF.

4000123923-2

Programmer Instructions for Use

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

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

Selecting AM/PM or 24 Hour Time

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

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

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

±1h key once.

±1h

Setting the Time

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

Press and hold the (If British Summer Time is in effect, press

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

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

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

key during the following:

±1h first)

key)

Day Key Selections

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

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

Manual GMT/BST Time Changeover

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

Programming 24 Hour or 7 Day Schedules

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

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

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

Three events need to be entered.

Press Prog. key only once. Display shows :

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

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

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

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

key once. ON symbol appears

key twice. OFF symbol appears

key to enter Run Mode

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

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

4000123923-2

Programmer Instructions for Use

Event Review

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

Manual Override

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

CONTINUOUS OPERATION: While in the Run Mode, press

the

Pressing the permanently.

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

key twice to turn the output to permanently ON.

symbol appears in display.

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

key until

Changing an Event

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

Hours and minutes can be changed with the h and m keys. Press Prog. or

key to store the new programme.

Deleting an Event

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

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

Press enter the Run Mode. Using the reset key will delete ALL events, the time of day, and day of the week.

key, display will flash for several seconds and then

Troubleshooting

PROBLEM: Days are flashing, pressing any key does nothing

except SOLUTION: Time of Day and Day of Week have not been set.

See "SETTING THE TIME"

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

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

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

SOLUTION: Current day of week was not set while holding

down

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

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

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

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

but it will not accept it and

SOLUTION: The ON of the program. ON or OFF must be selected.

key turns output ON and OFF.

key

the key. See "SETTING THE TIME"

and

symbols.

key (temporary

appears in display.

is flashing.

or OFF was not entered as part

4000123923-2

1 Technical Data

30ci 30si 35ci

Heating

Heat input (max) NET Q kW 32,6 32,6 37,8

Heat input (min) NET Q kW 13,3 13,3 12

Heat output (max) NET P kW 29,6 29,6 34,8

Heat output (min) NET P kW 10,8 10,8 10,2 Efficiency - Sedbuk D % 79,6 79,6 78,5

Maximum heating temperature °C87 8787 Expansion vessel effective capacity litres 8 8 8 Expansion vessel charge pressure bar 0,5 0,5 0,5 Maximum system capacity at 75°C litres 156 156 156 Safety valve, maximum service pressure bar 3 3 3

Hot water

Heat input (max) NET Q kW 32,6 / 37,8

Heat input (min) NET Q kW 13,3 / 12

Heat output (max) NET P kW 29,6 / 34,8

Heat output (min) NET P kW 10,8 / 10,2 Maximum hot water temperature °C60 / 60

Minimum hot water temperature °C38 / 38 Specific flow rate (for 35°C temp rise) litres/min. 12,1 / 14,3 Threshold flow rate litres/min. 1,7 / 1,7 Maximum supply pressure bar 10 / 10 Minimum supply pressure bar 0,5 / 0,5

BTU/H 111,231 111,231 128,973

BTU/H 45,380 45,380 40,944

BTU/H 100,995 100,995 118,739

BTU/H 36,849 36,849 34,803

BTU/H 111,231 / 128,973

BTU/H 45,380 / 40,944

BTU/H 100,995 / 118,739

BTU/H 36,849 / 34,803

Combustion

Products outlet diameter mm 60 60 60 Fresh air inlet diameter mm 100 100 100 Combustion products values CO (ppm) 40 40 30

CO2 (%) 7,6 7,6 6,3

NOx (ppm) 82 82 65

Electrical

Electrical supply V/Hz 230/50 230/50 230/50 Electrical rating (fused at 3A) W 130 130 130 Level of protection IPX4D IPX4D IPX4D Fuse rating mA 1,25 1,25 1,25

Natural Gas (G20)

Ø Burner injector mm 1,15 1,15 1,25 Inlet pressure mbar 20 20 20 Maxi. Burner pressure mbar 14,4 14,4 12 Mini. Burner pressure mbar 2,45 2,45 1,18 Gas rate maximum m3/h 3,45 3,45 4

Butane Gas (G30)

Ø Burner injector mm 0,73 0,73 0,77 Inlet pressure mbar 29 29 29 Maxi. Burner pressure mbar 25,5 25,5 24,2 Mini. Burner pressure mbar 3,73 3,73 2,35 Gas rate maximum kg/h 2,57 2,57 2,98

Propane Gas (G31)

Ø Burner injector mm 0,73 0,73 0,77 Inlet pressure mbar 37 37 37 Maxi. Burner pressure mbar 32,5 32,5 30,9 Mini. Burner pressure mbar 4,7 4,7 3 Gas rate maximum kg/h 2,53 2,53 2,93

4000123923-2

The 30ci, 35ci and 30si are delivered in two

separate packages:

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

• The flue system

Net lift weight (boiler only) 30ci 37 kg 30si 36 kg 35ci 38 kg

Gross lift weight (boiler, fixing jig and packaging) 30ci 43,5 kg 30si 42 kg 35ci 45,5 kg

1 Technical Data

11658

232

798

365

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).

450

Diagram 2.1

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

The Current I.E.E. Wiring Regulations. Where no specific instructions are given, reference should be

made to the relevant British Standard Code of Practice.

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

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

In GB the following Codes of Practice apply: BS4814, BS5440 Part 1 and 2, BS5449, BS5546 Part 1, BS6700,

BS6798, BS6891 and BS7074 Part 1 and 2, BS7478, BS7593, BS7671.

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

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

BSI Certification

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

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

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

4000123923-2

2 General Information

2.3 Gas Supply

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

In GB this is BS 6891.

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

The supply from the governed meter must be of adequate size to provide a steady inlet working pressure of 20mbar (8in wg) at the boiler.

3 Heating System Design

Bypass fully shut

Open 1/4 turn

Open 1/2 turn

Important Notice

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

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

They should only be kept outside.

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

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

11357

Open 1 turn

Open 2 turns

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

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

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

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

• The 30ci/35ci and 30si are for use with sealed central heating systems.

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

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

• The circulation pump is integral with the boiler.

• Pipe sectional areas shall be determined in accordance with normal practices, using the output/pressure curve (diagram 3.1). The distribution system shall be calculated in accordance with the output requirements of the actual system, not the maximum output of the boiler. However, provision shall be made to ensure sufficient flow so that the temperature difference between the flow and return pipes be less than or equal to 20°C. The minimum flow rate is shown in table 1.

Available pressure (kPa)

between heating supply and return

0 200 400 600 800 1000 1200 1400

(10 kPa = 1 m WG)

Flow rate through heating system l/h

Diagram 3.1

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

in diagram 3.2.

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

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

0.5 bar and allows a maximum system volume of 156 litres for an average temperature of 75°C and a maximum service pressure of 3 bar. This pressure setting can be modified at commissioning stage if the static head differs. An additional expansion vessel can be fitted to the system if required, see

diagram 3.2.

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

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

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

• In the case of an existing installation, it is ESSENTIAL that the system is thoroughly flushed prior to installing the new boiler, using a proprietary product from Fernox or Sentinel.

4000123923-2

TEMPORARY CONNECTION

HOSE

UNION

HOSE

UNION

SUPPLY

PIPE

CONTROL

VALVE

CONTROL

VALVE

DOUBLE

CHECK

VALVE

BOILER

RETURNFLOW

HEATING CIRCUIT

DRAIN POINT

SUPPLY

PIPE

AIR GAP

TUNDISH

CONTROL

VALVE

CONTROL

VALVE

TYPE CA BACKFLOW

PREVENTION DEVICE

BOILER

RETURNFLOW

HEATING CIRCUIT

DRAIN POINT

Method 1

Method 2

3 Heating System Design

D p

3.1 Bypass

•The boiler is fitted with an adjustable automatic bypass. Ensure that under no circumstances does the flow rate drop below the figure specified, see Table 1.

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

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

3.2 Filling the system 30ci/35ci

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

diagram 2 controls and lighting and diagram 3.1.

Additiona expansion vessel (if require

omestic

water

Hot water out

Cold supply in

Boiler

Filling device

3.3 Filling the system 30si

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

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

TABLE 1. FLOW RATE

Model Minimum flow rate 30ci 21.26 litres per minute 30si 21.26 litres per minute 35ci 24,98 litres per minute This is equal to 20°C differential at maximum heat input

9898

11593

30ci/35ci

Drain point

Control

valve

Drain point

Control

valve

Bypass

valve

'A'

Flow

Heating

circuit

Additional

Bypass valve (if required)

Return

Boiler

Bypass

valve

'A'

Additional

Bypass valve (if required)

Additiona expansion vessel (if require

10157

30si

4000123923-2

rain

oint

Flow

Heating

circuit

Return

Diagram 3.2

Diagram 3.3

4 Domestic Hot Water System Design. 30ci Only

General - All domestic hot water circuits, connections, fittings

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

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

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

• Copper tubing or plastic Hep hot water system. Unnecessary pressure losses should be avoided.

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

0 may be used for the domestic

• The flow restrictor, supplied in the document envelope, must be fitted as diagram 7.1, limiting the flow through the boiler to a maximum of 12 litres/min for 30 ci and 14 litres/min for 35 ci.

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

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

4.1 Hard Water Areas

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

4000123923-2

1 - Fan. 2 - Air pressure switch. 3 - Heat exchanger. 4 - Overheat thermostat. 5 - Combustion chamber. 6 - Expansion vessel. 7 - Ignition electrode. 8 - Burner. 9 - Flame sense electrode. 10 - Pump. 11 - Heating thermistor. 12 - Ignition unit. 13 - By-pass. 14 - Gas control valve. 15 - Loss of water sensor. 16 - Domestic heat exchanger 17 - 3 way valve 18 - Domestic water flow sensor 19 - Filter cold water inlet 20 - Filling system 21 - Discharge safety valve (3bar) 22 - Drain valve 23 - Heating filter

5 Boiler Schematic 30ci/35ci

9899

FITTED TO REAR OF APPLIANCE

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

1 - Fan. 2 - Air pressure switch. 3 - Heat exchanger. 4 - Overheat thermostat. 5 - Combustion chamber. 6 - Expansion vessel. 7 - Ignition electrode. 8 - Burner. 9 - Flame sense electrode. 10 - Pump. 11 - Heating thermistor. 12 - Ignition unit. 13 - By-pass. 14 - Gas control valve. 15 - Loss of water sensor. 16 - Heating filter. 17 - Discharge safety valve (3bar). 18 - Drain valve

5a Boiler Schematic 30si

11450

FITTED TO REAR OF APPLIANCE

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

4000123923-2

Diagram 5.1

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.

6.2 Terminal guard, see diagram 6.3.

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

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

A suitable terminal guard type K3 can be supplied by:

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

6.3 Flue options

There are various flue systems to choose from as follows:

Horizontal telescopic rear flue pack.

Horizontal telescopic top flue pack.

Horizontal top flue pack.

Horizontal extended flue pack.

Vertical flue pack.

Twin flue pack.

Extensions, 90° and 45° bends.

For detailed information refer to flue options guide. This is available from your nearest stockist.

6.4 Cupboard or compartment ventilation

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

300mm

50mm

above boiler

rear flue only)

20mm

5mm

25mm above elbow

11651

11508

MINIMUM SITING DIMENSIONS FOR THE POSITIONING OF FLUE TERMINALS MM

HORIZONTAL FLUES

A DIRECTLY BELOW, ABOVE OR

HORIZONTALLY TO AN OPENING, AIR BRICK, OPENING WINDOWS, AIR VENT, OR ANY

OTHER VENTILATION OPENING 300 B BELOW GUTTER, DRAIN/SOIL PIPE 75 C BELOW EAVES 200 D BELOW A BALCONY OR CAR PORT 200 E FROM VERTICAL DRAIN PIPES AND

SOIL PIPES 150 F FROM INTERNAL/EXTERNAL CORNERS

OR TO A BOUNDARY ALONGSIDE THE TERMINAL 300

G ABOVE ADJACENT GROUND OR

BALCONY LEVEL 300 H FROM SURFACE OR A BOUNDARY

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

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

VERTICAL FLUES

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

Diagram 6.2

*Note: It is permissible

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

600mm

450mm

300mm

Diagram 6.1

20mm

Diagram 6.3

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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 - 30ci Only Domestic hot water outlet. C - Gas service cock. D - 30ci Only 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: (30ci Only)

- 3 x 22mm Installation connection pipes

- 2 x 15mm Installation connection pipes

Bag containing: (30ci Only)

- 4 x 22mm boiler connection pipes

- 1 x 15mm boiler connection pipe

Bag containing : (30si only)

- 3 x 22mm Installation connection pipes

Bag containing : (30si only)

- 2 x 22mm boiler connection pipes

- 1 x 15mm boiler connection pipe

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)

11940a

Wall template

APPLIANCE HANGING BRACKET

FIXING JIG Inclusive Isolating Valves

Sealing Washers :

30ci/35ci 30si Description

V1 (1) 1 (1) 15 mm Gas valve Connection only*

W4 (5) 2 (5) 22 mm - smal bore

X3 (4) 1 (4) 15 mm

Y3 (4) 3 (4) 22 mm - large bore

Z4 (5) 2 (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

4000123923-2

Cold water inlet restrictor

30ci/35ci shown

Diagram 7.1

20mm*

min.

145

80 min

C.H. flow

Gas supply

Cold water in

D.H.W. hot out

C.H. return

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

KEY

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

REAR TOP FLUE OUTLET

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.

30ci/35ci shown

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".

4000123923-2

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.

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

diagram 7.1. Important Note. With regards to the manual handling

operations, 1992 regulations, the following operation exceeds the recommended weight for one man lift.

• Lift the boiler up and engage boiler onto the hanging bracket, refer to diagram 7.1.

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

KNURLED UNION NUT finger tighten only

11581

DISCHARGE SAFETY VALVE PIPE

Diagram 9.1

10088

FILLING DEVICE

9.3 Discharge safety valve (diagram 9.1)

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

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

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

9.4 Filling loop extension 30ci Only

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

9.5 Filling loop extension knob 30si

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

30ci Only

SPIGOT

FILLING LOOP EXTENSION

Diagram 9.2

SECURING SCREW (4)

Diagram 9.3

4000123923-2

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 10.4.

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.

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................................................................. H

Horizontal Rear Telescopic flue kit

Diagram 10.1

12060

10.2 Sealed chamber cover

• Unscrew and remove the two retaining screws from the sealed chamber cover, see diagram 10.3

• 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

9533

12007

Diagram 10.2

Pho 087

Diagram 10.3

Diagram 10.4

4000123923-2

10 Horizontal Telescopic Rear Flue Installation

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.

10.5 Flue Hood Outlet Restrictor, refer to diagram 10.7 (for 35 ci only)

Secure restrictor, supplied with flue pack, to the flue hood as shown in diagram 10.7.

10.6 Restrictor, refer to diagram 10.8

For flue systems less than 0.5m long, fit the flue restrictor supplied in document envelope into the fan outlet (30ci/30si only), see diagram 10.8.

10.7 Fan Securing, refer to diagram 10.5

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

Replace chamber cover and secure with screws previously removed.

EARTH

9741

LEAD

FAN RETAINING BOLTS

POWER SUPPLY LEADS

Diagram 10.5

TWIST ANTI-CLOCKWISE & LOCK AT 90O POSITION

RESTRICTOR (35ci only)

FLUE HOOD

Diagram 10.7

NOTE: Please check orientation when engaging bayonet spigot

Diagram 10.6

10316

SEAL

RESTRICTOR (30ci/30si only)

FAN

Diagram 10.8

4000123923-2

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

11886a

70mm

65m

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

EAR 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

4000123923-2

11 Horizontal Telescopic Top Flue Installation

(

)

11.3 Installation of telescopic flue assembly

• For flue lengths less than 0.5m fit the restrictor (supplied in the document envelope) inside the fan outlet (30ci/30si only),

see diagram 11.3.

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

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

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

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

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

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

STEP 1.

Outside

wall face

17mm

FLUE LENGTH

IMPORTANT

"BUTT FIT"

STEP 2.

Drill, screw 2 off

and tape the Air Duct

2 off

(G)

STEP 3.

(A)

(D)

90mm

centre line

BOILER

(B)

25mm

ELBOW

(D)

Flue

FIXING

COLLAR

SEAL

4 off

11879

(A)

XTERNAL RUBBER

SEALING COLLAR

'O' RING

(H)

GASKET

(F)

BOILER

STEP 4.

11874

RESTRICTOR fitted for flue lengths less than 0.5m (30ci/30si only)

(E)

(A)

(G)

STEP 5.

(A)

(E)

FIXING

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

Diagram 11.3

COLLAR

(D)

2 off

(G)

(C)

Diagram 11.4

2 off

(D)

4000123923-2

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.

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

SIDE FLUE

70mm

225mm

450 mm

20mm

* refer to diagram 6.1

Min. Clearance

11886a

65m

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

EAR FLUE

70mm 232 mm

65mm

Note : Top of boiler casing not front panel

Diagram 12a.2

4000123923-2

12 Horizontal Top Flue Installation

F a

12a.4 Installation of horizontal top flue assembly

Important: If the flue has been cut, ensure that there are no

burrs that could damage the ‘O’ ring.

• For flue systems less than 0,5 m long, fit the flue restrictor (a) into the fan outlet, see diagram 10a.4.

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

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

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

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

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

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

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

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

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

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

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

Outside

all face

Flue

centre line

90mm

17mm

cutting length

Air duct cutting length

lue duct cutting length =

ir duct cutting length + 95mm

X minus 90mm

plus 17mm =

Air duct

cutting length

Flue du

Air duct

25mm

check

dimension

(cut end)

Diagram 12a.3

11643

Horizontal Top flue system

The maximum permissible length (L) is :

- 3.5 m for 30ci and 30si

- 2,5 m for 35ci For each 90° flue elbow used, (or two 45° elbows) the maximum permissible length (L) must be reduced by 1 metre. Warning : The flue restrictor (a) must be fitted inside the fan outlet of 30ci and 30si for flue lenghts less than 0,5 m.

FLUE RESTRICTOR

Gasket

232

10092a

Diagram 12a.4

4000123923-2

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 TERMINAL

CONTROLS PANEL REAR COVER

SECURING SCREW (3)

WIRE LINK(E)

11911

11994

Diagram 13.1

Diagram 13.2

4000123923-2

SUPPLY

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

➜

11659

BOILER

ci only

CONTROLS

INTERFACE PCB

3 2 1

HEATING CONTROLS

CONNECTION PLUG

EXTERNAL

ROOM

DO NOT

CONNECT

MAINS VOL TAGE

PROGRAMMER

EXTERNAL

FROST

THERMOSTAT

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

TO MAIN PCB

CONNECTOR J15

HEATING CONTROLS

REMOVE LINK

WHEN EXTERNAL

CONTROLS ARE USED

EXTERNAL

JUNCTION BOX

3 AMP FUSE

DOUBLE POLE

ISOLATOR

STRAIN RELIEF

MAINS CABLE

EXTERNAL CONTROLS CABLE

Diagram 13.4

VOLTAGE FREE

CONNECTION

(ON CONTROLS

BOX COVER)

ON/OFF

SWITCH

LNE

230V~ 50H

PERMANEN

MAINS

11992

The type of plug and orientation may be different to that illustrated but the wiring should always be as wiring diagrams

PLUG

4000123923-2

EXTERNAL CONTROLS CABLE(MAINS VOLTAGE)

CONTROLS INTERFACE PCB

Diagram 13.3

11974

si only

BOILER

INTERFACE PCB

EXTERNAL

FROST

THERMOSTAT

EXTERNAL

ROOM

THERMOSTAT

EXTERNAL

PROGRAMMER

EXTERNAL PROGRAMMER/CLOCK

EXTERNAL 230V AC ROOM THERMOSTAT

EXTERNAL 230V AC FROST THERMOSTAT

DO NOT

CONNECT

MAINS VOL TAGE HEATING CONTROLS CONNECTION PLUG

CONTROLS

3 2 1

TO MAIN PCB

CONNECTOR J15

HEATING CONTROLS

REMOVE LINK

WHEN EXTERNAL

CONTROLS ARE USED

EXTERNAL

JUNCTION BOX

DOUBLE POLE

ISOLATOR

VOLTAGE FREE

CONNECTION

(ON CONTROLS

BOX COVER)

ON/OFF SWITCH

3 AMP FUSE

LNE

230V~ 50H

PERMANEN

MAINS

Diagram 13.5

11993

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

15.

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

Filling the system

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

Make sure that:

• The boiler is connected to the electrical supply.

• The gas service cock is open.

Turn the switch OFF ( 0 )

Air in pipes

Important: A central heating system can not operate correctly

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

Bleed the air in the radiators and adjust the pressure if system requires. If the system requires filling to often this may be due to minor leaks or corrosion in the system.

BURNER PRESSURE POINT

GAS PURGE POINT

11898

30ci shown

Diagram 14.1

9796

• Open the three water isolating valves.

HEATING FLOW

30ci/35ci shown

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

DOMESTIC HOT WATER OUT

(30ci Only)

Note: Isolating valves are shown in the: OFF position

GAS SERVICE COCK

9810

COLD WATER IN

(30ci Only)

• Turn the switch ON ( I )

• 30ci Only Open the tap on the filling device

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

HEATING RETURN

11933

9792

➜

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

➜

4000123923-2

14 Commissioning

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

• If necessary repressurise the system, refer to

Ins 061a

procedure 4

➜

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

10217

14.1 Adjusting the Central heating output.

The central heating output is factory preset to approximately :

- 15 kW for 30ci/30si.

- 20 kW 35ci. If a different central heating output is required, proceed as follows :

• Leave cap open on automatic air vent.

• Open various hot water taps to bleed system

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

see diagram 13.3.

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

9810

Ins 062a

maxi

15 kW

max.

mini

POTENTIOMETER P3

234 1

ON DIP

POTENTIOMETER P6

USER INTERFACE BOARD

Diagram 14.2

the table below can be used to change the operation of the pump and maximum heating temperature of your boiler.

11890

MANOMETER

maxi

15 kW

P. max.

mini

SW1 DIP SWITCH

Factory set in "OFF" position

14.2 Dip Switches

The position of the SW1Dip Switch(es), see diagram 12.2, and

ON DIP

234 1

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

CONTINUOUS ON ON 53OCON ON

WITH BURNER ON OFF 87

C ON* OFF*

CONTINUOUS OFF ON 53OC OFF ON

WITH HEATING OFF* OFF* 73

C OFF OFF

DEMAND

FACTORY SETTING* GB/IE PREFFERED SETTING

4000123923-2

14 Commissioning

14.3 : Setting the flue parameters for 35ci

This adjustment is made to ensure the boiler operates at maximum efficiency with longer flue lengths. Note : This adjustment must be done when the burner is off.

• Insert a small flat edge screw driver into the arrowed slot in potentiometer P7 (shown in diagram 14.2) : the code A

will appear on the display

• Turn to adjust to the desired code according to the following table.

When all adjustments are completed :

• Adjust heating temperature to maximum.

Flue length (L) for 35ci

Setting Horizontal Rear Vertical flue (L) Vertical flue (L) Twin

flue (L) flue (L) Ø 100/60 mm Ø 125/80 mm flue (2xL)

(C12) (C12) (C32) (C32) (C52)

0 0,3 m 0,3 m / 1 m / 1 0,5 m 0,7 m / 1,6 m / 2 0,8 m 1,1 m 1 m 2,1 m 1 m 3 1,0 m 1,5 m 1,4 m 2,7 m 2,8 m 4 1,3 m / 1,7 m 3,2 m 4,8 m 5 1,5 m / 2,1 m 3,8 m 6,6 m 6 1,8 m / 2,4 m 4,3 m 8,4 m 7 2,0 m / 2,8 m 4,9 m 10,2 m 8 2,3 m / 3,1 m 5,4 m 12,2 m 9 2,5 m / 3,5 m 6 m 14 m

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

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

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

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

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

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

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

• Restart boiler and operate until a maximum temperature is reached. If necessary, refer to section 16 to adjust the bypass. Shut down boiler and vent heating system. If necessary, top up heating system and make sure that a pressure of at least 1 bar is indicated when system is COLD.

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

Completion

Adjust the boiler temperature control and any system controls to their required settings. For IE, it is necessary to complete a "Declaration of

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 heating system controls.

Advise the user on the use and maintenance of any scale reducer and pass on any relevant instructional documents. Advise that to ensure the continued efficient and safe operation of the boiler it is recommended that it is checked and serviced at regular intervals. The frequency of servicing will depend upon the installation conditions and usage, but in general, once a year should be enough.

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

4000123923-2

15 Changing Gas Type

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

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

Conversion natural gas (G20) to G30/G31 :

Part No. A2011900 for 30 ci and 30 si.

Part No. A2031800 for 35 ci.

Setting the step pressure.

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

Proceed as follows:

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

• Unclip the control box, see diagram 13.3.

• Run the appliance in heating mode.

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

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

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

14.2.

• Return the potentiometer P3 to its initial value.

16 Bypass Settings

Bypass

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

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. in section 3 (turn clockwise 'A' to close the valve).

30ci/35ci shown

9718

Diagram 16.1

4000123923-2

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 competant person.

17.1 Products of combustion check

Top Flue: To obtain a products of combustion reading, unscrew

the left hand sampling point cap on the flue elbow, located on top of boiler, see diagram 17.1.

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

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

Data.

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

PRODUCTS SAMPLING POINT

(view showing top of boiler)

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

SAMPLING POINT CAP

Diagram 17.1

17.2 Service Check and Preparation.

• Isolate boiler from the gas and electrical supplies.

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

diagram 17.2.

9532

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

• Close boiler isolating valve (d).

• Turn on one or more hot water taps.

• Open the domestic hot water circuit drain valve.

To Drain the boiler

• Close isolating valves (e) and (a).

• Open the boiler drain valve (f).

BOILER DRAIN VALVE

9839

(f)

11933

(a)

HEATING FLOW

30ci/35ci shown

(b)

DOMESTIC HOT WATER OUTLET

(30ci Only)

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

(c)

GAS SERVICE COCK

(d)

COLD WATER INLET

(30ci Only)

(e)

HEATING RETURN

Diagram 17.2

4000123923-2

17 Routine Cleaning and Inspection

• Drain the boiler, refer to diagram 17.2.

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

17.3 Front panel

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

• Remove front panel by lifting up and forward.

17.4 Control panel

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

17.5 Sealed chamber cover

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

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

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

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

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

• Unhook each panel from the front retaining tabs.

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

9533

Diagram 17.3

9799

9800

9797

4000123923-2

30ci shown

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 Ignition and Flame Sensing Gaps

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

Replacement of Parts.

17.9 Burner, refer to diagram 17.7

• Unscrew and remove the two burner retaining screws.

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

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

Note: To gain access to injectors for removal and cleaning, refer to Section, 20.8.

17.10 Fan, refer to diagram 17.8

• Disconnect power supply leads and earth lead from fan.

• Unscrew and remove the two fan retaining bolts.

• Ease the fan down and forwards to remove.

17.14 Sealed chamber cover seal check

Check the condition of the seal, replace as required.

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

diagram 20.25.

17.15 Combustion chamber insulation

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

17.16 Flue system

• Check externally to make sure that flue is not blocked

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

17.17 Reassembly of parts removed for servicing

All parts are replaced in reverse order to removal.

9811

17.11 Heat exchanger, refer to diagram 17.9

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

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

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

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

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

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

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

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

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

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

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

30ci shown

3.5mm

IGNITION GAP

Diagram 17.5

3.5mm

9752

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.

3.5 mm

9816

FLAME SENSING GAP

Diagram 17.6

4000123923-2

9812

17 Routine Cleaning and Inspection

BURNER RETAINING SCREWS

BURNER GUIDE

9742

9818

AIR PRESSURE SWITCH SENSING TUBE

FLUE HOOD

9817

9825

9815

EARTH

9741

LEAD

POWER SUPPLY LEADS

30ci/30si shown

11934

Diagram 17.7

FAN RETAINING BOLTS

Diagram 17.8

HEAT EXCHANGER

DOMESTIC WATER INLET FILTER HOUSING

Diagram 17.9

CLIP

9822

FILTER

Diagram 17.1030ci Only

11935

30ci shown

4000123923-2

FLAT

FILTER

RETAINING CLIP

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.

WARNING. Always isolate the boiler from the electrical supply before carrying out any electrical replacement work.

Always check for gas soundness after any service work.

Should there be any doubt about the voltage supply to any of the components, it is possible to carry out a simple electrical test to ensure all is operational in that area.

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

Overheat thermostat reset button

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

Depress the button to reset.

OVERHEAT THERMOSTAT

RESET BUTTON

30ci/ shown

9826

Diagram 18.1

DISPLAY FAULT

'01' and 'F' and 'flashing red LED' Ignition fault (lockout) caused by no gas, no detection '02' and 'F' and 'flashing red led' Air fault, pressure switch, no power to fan

'05' and 'F' and 'flashing red LED' Overheat fault '06' and 'F' and 'flashing red LED' Central heating flow NTC fault '09' and 'F' and 'flashing red LED' Water pressure sensor fault '11' and 'F' and 'flashing red LED' No reception by the main board (MMI Lead) '12' and 'F' and 'flashing red LED' User interface or distant control panel fault '13' and 'F' and 'flashing red LED' Main board fault '14' and 'flashing red LED' Over temperature on primary water circuit

'15' and 'F' and 'flashing red LED' Stepper motor fault (gas valve) '16' and 'F' and 'flashing red LED' Gas safety value failure '17' and 'F' and 'flashing red LED' Power supply <170V '18' and 'F' and 'flashing red LED' Local user interface fault

'19' and 'F' and 'flashing red LED' Central heating NTC not connected to pipe '20' 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)

4000123923-2

18 Fault Finding

TYPE OF FAULT CHECK

No display on control panel • 230V supply

• PCB fuse

• Connection between PCBs

No domestic hot water (30ci Only) • Loose connections on control board (PCB), No central heating • Connections on air pressure switch (electrical or tubes) (Red flashing warning light and flashing disconnected, fault code in display) • Faulty control or interface board (PCB's),

• Water pressure, flashing pressure

• Shortage of air or gas,

• Faulty temperature sensor,

• Overheating,

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).

(30ci Only)

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 motor axle 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.

(30ci Only)

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.

4000123923-2

18 Fault Finding

FAULT: NO HEATING

FAULT: NO HOT WATER, BUT THE HEATING IS WORKING

Are the external heating

controls calling for heat?

YES

Is the polarity correct?

YES

Connect 1 and 2 on J10,

does boiler fire in central heating?

YES

Faulty 230V controls board.

Rectify fault on external controls

Rectify, check the 230V

controls board.

Faulty main PCB.

30ci Only

Is the water pressure greater

than 0.5 bar ?

Is the water flow rate greater

YES

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.

4000123923-2

18 Fault Finding

F1 or F4 FAULT DISPLAYED

F1 FAULT DISPLAYED

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

The flame is not spreading across

the whole burner and is not reaching

the sensing electrode. Is the gas

pressure correct?

YES

• Clean the gas filter.

• Clean the burner.

• Check that the gas taps are fully open

• Check the gas pressure.

FAULT: THE BURNER LIGHTS, THEN GOES OUT.

The flame is spreading across the

whole burner, but not being detected.

CHECK THE MAINS

FAULT NOT FOUND

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

CHECK

THE

PROBE

With the power turned off, check the continuity between the flame sense electrode and terminal H2 . 4 on the control board (PCB). Check the connector on the end of the wire. Check that the spark electrode is pointing towards the flame. Check the spark electrode. Change it.

1187

4000123923-2

F1 FAULT DISPLAYED

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

18 Fault Finding

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

Are the gas taps on?

YES

Is there 24Vdc at the gas control valve? for testing see component testing data.

YES

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

Turn on the gas taps.

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

Is the room thermostat and or radiator

set high enough and calling for duty?

Turn up settings

Is the heating power adequate?

YES

Is the heating temperature on the boile set high enough?

YES

- Check set point P3. (Refer to Commissioning)

- Check the adjustment of the by-pass internal and external (If fitted). - 30ci/35ci Only Check the 3-way valve is not passing into the domestic hot water heat exchanger

4000123923-2

FAULT: THE FAN DOES NOT START.

FAULT: THE FAN RUNS BUT THERE ARE NO SPARKS.

18 Fault Finding

FAUL T: THE W A TER A T THE T APS IS LUKE-WARM.

30ci Only

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.

Is there 230V ac

at fan during demand?

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

11875

Check continuity of fan harness.

YES

Faulty fan, replace.

• CHECK CONTIUITY OF SPARK (ELECTRODES AND LEADS)

• CHECK POWER SUPPLY FROM PCB TO IGNITION UNIT

CONNECTIONS TO THE AIR PRESSURE SWITCH

YES

11876

Faulty PCB, replace.

11877

4000123923-2

Air flow switch take-off.

Electrical contacts.

19 Wiring Diagram 30ci

WATER PRESSURE SENSOR

FAN

OVERHEAT

THERMOSTAT

THERMISTOR

bg/y

bk bk

AIR PRESSURE SWITCH

IGNITION ELECTRODES

SENSE

ELECTRODE

GAS

CONTROL

PUMP

VALVE

pory

THREE-WAY

VALVE

MAINS VOLTAGE HEATING CONTROLS PLUG

230V SWITCHED LIVE FROM OPTIONAL FROST STAT.

230V SWITCHED LIVE FROM HEATING CONTROLS.

IGNITOR

UNIT

CHASSIS

EARTH

PLUG

g/y

10224

USER INTERFACE

FLOW SENSOR

PROGRAMMER

J10

J12

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

YELLOW

J15

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

J11

KEY

REMOVE VOLTAGE FREE LINK

CONTROLS INTERFACE

VOLTAGE FREE HEATING CONTROLS PLUG

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

J13

FUSE 125mAT

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

ON/OFF SWITCH

H5 H1

H3 H8

H6 H7

LINK

g/y

b br

b b

br g/y

br b

g/y

b br

230V~50Hz

PERMANENT

MAINS SUPPL

FUSED AT 3A

CHASSIS EARTH

g/y

4000123923-2

19a Wiring Diagram 30si

WATER PRESSURE SENSOR

FAN

OVERHEAT

THERMOSTAT

THERMISTOR

bg/y

bk bk

AIR PRESSURE SWITCH

IGNITION

SENSE

ELECTRODES

ELECTRODE

GAS

CONTROL

VALVE

PUMP CH

pory

IGNITOR

UNIT

MAINS VOLTAGE HEATING CONTROLS PLUG

230V SWITCHED LIVE FROM OPTIONAL FROST STAT.

230V SWITCHED LIVE FROM HEATING CONTROLS.

CHASSIS

EARTH

g/y

10298

PLUG

NOT USED

USER INTERFACE

J12

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

YELLOW

J15

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

J11

KEY

CONTROLS INTERFACE

J13J10

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

REMOVE VOLTAGE FREE LINK

VOLTAGE FREE HEATING CONTROLS PLUG

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

H5 H1

H3 H8

FUSE 125mAT

H6 H7

ON/OFF SWITCH

LINK

g/y

b br

g/y b br

CHASSI

EARTH

g/y

b br

230V~50Hz

PERMANENT

MAINS SUPPLY

FUSED AT 3A

4000123923-2

19b Wiring Diagram 35ci

FAN SENSOR

WATER PRESSURE SENSOR

FAN

OVERHEAT

THERMOSTAT

THERMISTOR

bg/y

bk bk

AIR PRESSURE SWITCH

IGNITION ELECTRODES

IGNITOR

SENSE

ELECTRODE

GAS

CONTROL

PUMP

VALVE

pory

THREE-WAY

VALVE

MAINS VOLTAGE HEATING CONTROLS PLUG

230V SWITCHED LIVE FROM OPTIONAL FROST STAT.

230V SWITCHED LIVE FROM HEATING CONTROLS.

PLUG

UNIT

CHASSIS

EARTH

1029-35kW8

g/y

USER INTERFACE

FLOW SENSOR

PROGRAMMER

J10

J12

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

YELLOW

J15

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

J11

KEY

CONTROLS INTERFACE

REMOVE VOLTAGE FREE LINK

VOLTAGE FREE HEATING CONTROLS PLUG

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

J13

FUSE 125mAT

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

ON/OFF SWITCH

H5 H1

H3 H8

H6 H7

LINK

g/y

b br

b b

br g/y

br b

g/y

b br

230V~50Hz

PERMANENT

MAINS SUPPLY

FUSED AT 3A

CHASSIS EARTH

4000123923-2

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).

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

• Close boiler isolating valve (d).

• Turn on one or more hot water taps.

To Drain the boiler

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

• Open the boiler drain valve (f).

BOILER DRAIN VALVE

9839

(f)

11933

(a)

HEATING FLOW

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

IMPORTANT INFORMATION WARNING: Before commencing the replacement of any

component, isolate appliance from electrical supply and turn off gas at service cock. Replacement of parts must be carried out by a competent person. When replacing components it may be necessary to renew sealing washers, gaskets and 'O' rings. If new ones are supplied with replacement components they must be used. All parts are replaced in reverse order to removal. If any gas-carrying components are disturbed, removed or replaced it will be necessary on completion of assembly to test for gas soundness and purge in accordance with the current issue of BS6891 or in IE, the current edition of I.S.813 "Domestic Gas Installations".

20.1 Central heating thermistor Before starting refer to the front of Section 20 Important information.

• Remove the front panel, refer to Section 17.3.

• Lower the control panel, refer to Section 17.4.

• Locate central heating thermistor on heating flow pipe on

(b)

DOMESTIC HOT WATER OUTLET

(30ci Only)

(c)

GAS SERVICE COCK

30ci shown

centre of boiler, see diagram 20.2.

• Unclip thermistor from pipe.

• Disconnect electrical connections from thermistor.

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

(d)

COLD WATER INLET

(30ci Only)

CENTRAL HEATING THERMISTOR

(e)

HEATING RETURN

Diagram 20.1

Diagram 20.2

10227

4000123923-2

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 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.

20.4 (30ci Only) Domestic water inlet filter

If the water flow rate through the appliance has reduced it may be necessary to clean or replace the water inlet filter. Before starting refer to the front of Section 20 Important

information.

• Remove the front panel, refer to Section 17.3.

• Lower the control panel, refer to Section 17.4.

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

RETAINING CLIPS

ELECTRICAL CONNECTORS

SENSING TUBE

UNION NUT

11939

9646

AIR PRESSURE SWITCH

Diagram 20.3

COLD WATER INLET RESTRICTOR

11932

20.5 Central Heating Filter

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

information.

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

17.13.

20.6 (30ci Only) Cold water inlet restrictor Before starting refer to the front of Section 20 Important information.

• Remove the front panel, refer to Section 17.3.

• Lower the control panel, refer to Section 17.4. Drain down domestic hot water circuit of boiler only, refer to relevant part of diagram 20.1.

• Remove the retaining wire.

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

• Clean and inspect restrictor, replace if necessary, see

diagram 20.4.

20.7 Burner, refer to Section 17.9. Before starting refer to the front of Section 20 Important information.

• Remove the front panel, refer to Section 17.3.

• Lower the control panel, refer to Section 17.4.

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

COLD WATER IN

30ci Only

• Remove the combustion chamber cover, refer to Section

17.7.

• Remove the burner, refer to Section 17.9.

20.8 Burner injectors, refer to diagram 20.5. Before starting refer to the front of Section 20 Important information.

• Remove the front panel, refer to Section 17.3.

• Lower the control panel, refer to Section 17.4.

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

• Remove the combustion chamber cover, refer to Section

17.7.

• Remove burner from boiler, refer to Section 17.9.

• Remove and replace injectors as required. Note: The injectors may be cleaned, remove injectors inspect and clean. Do not use a wire or sharp implement. 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.

ISOLATING VALVE

Diagram 20.4

4000123923-2

20 Replacement of Parts

20.9 Burner injector assembly, refer to diagram 20.6. Before starting refer to the front of Section 20 Important information.

• Remove the front panel, refer to Section 17.3.

• Lower the control panel, refer to Section 17.4.

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

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

• Remove burner from boiler, refer to Section 17.9.

• Undo the gas supply union nut from under the sealed chamber. Note: The fibre washer between the burner injector assembly and gas supply must be kept for use on reassembly.

• Undo and remove the sense and ignition electrode assemblies.

• Remove the burner injector assembly securing screws.

• Remove the burner injector assembly by lifting up, easing the gas connection through the grommet in the sealing chamber. Note: Take care not to damage the insulation.

• When refitting burner injector assembly ensure the gas connection locates correctly through the grommet. Note: Make sure that injector size, marked on each injector, is the same as that given in ‘Section 1 Technical Data’ for the type of gas being used.

BURNER INJECTOR

9819

9820

BAR

IGNITION ELECTRODE ASSEMBLY

9813

Diagram 20.5

GROMMET

GAS SUPPLY PIPE

SENSE ELECTRODE ASSEMBLY

9814

Diagram 20.6

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

• Remove the front panel, refer to Section 17.3.

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

• Locate overheat thermostat on heating flow pipe on 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.

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

• Remove the front panel, refer to Section 17.3.

• Lower the control panel, refer to Section 17.4.

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

• Remove the combustion chamber cover, refer to Section

17.7.

• Remove burner, refer to Section 17.9.

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

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

• Disconnect the electrical connections at the ignition unit,

see diagram 20.22. Note the routing of the cables.

20.12 Flame sense electrode

Before starting refer to the front of Section 20 Important

OVERHEAT THERMOSTAT

9826

CLIP

ELECTRICAL LEADS

PIPE SECURING CLIP 2 OFF

9825

HEAT EXCHANGER

Diagram 20.7

information.

• Remove the front panel, refer to Section 17.3.

• Lower the control panel, refer to Section 17.4.

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

• Remove the combustion chamber cover, refer to Section

17.7.

• Remove burner, refer to Section 17.9.

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

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

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

4000123923-2

20 Replacement of Parts

20.13 Heat exchanger, refer to diagram 20.7. Before starting refer to the front of Section 20 Important information.

• Remove the front panel, refer to Section 17.3.

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

• Remove the combustion chamber cover, refer to Section

17.7.

• Drain down central heating water circuit of the boiler only,

refer to relevant part of diagram 20.1.

• Remove the fan, refer to Section 17.10.

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

• Release both side panels, refer to section 17.6.

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

• Disconnect the electrical leads from the overheat thermostat.

• Remove the two pipe securing clips.

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

20.14 Combustion chamber insulation, refer to diagram

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

• Remove the front panel, refer to Section 17.3.

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

• Remove the combustion chamber cover, refer to Section

17.7.

• Remove the heat exchanger, refer to Section 20.13.

• Pull out side insulation panels from combustion chamber.

• Tilt rear insulation panel forwards and out.

• Fit replacement insulation in reverse order to removal.

information.

• Remove the front panel, refer to Section 17.3.

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

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

• Remove the two user inter face board retaining screws.

• Remove the user inter face board.

20.17 230V Controls board, refer to diagram 20.10. Before starting refer to the front of Section 20 Important information.

• Remove the front panel, refer to Section 17.3.

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

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

• Remove the 230V controls board retaining screw.

• Remove the 230V controls board.

20.18 Mains switch, refer to diagram 20.10. Before starting refer to the front of Section 20 Important information.

• Remove the front panel, refer to Section 17.3.

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

• Remove the mains switch.

• Disconnect the electrical connections from the mains switch.

20.15 Printed circuit board (PCB), refer to diagram 20.9. Before starting refer to the front of Section 19 Important information.

• Remove the front panel, refer to Section 17.3.

• Lower the control panel, refer to Section 17.4.

• Gain access to rear of control panel.

• Undo and remove the two front retaining screws.

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

• Carefully pull off electrical connections to PCB.

• Unclip and lift out PCB.

• Fit replacement PCB in reverse order to removal. Be careful not trap any of the cables. Make sure that PCB connections are fully pushed onto replacement PCB.

20.16 User interface board, refer to diagram 20.10.

Before starting refer to the front of Section 20 Important

INSULATION

9824

Diagram 20.8

4000123923-2

10021

CONTROL BOARD COVER

20 Replacement of Parts

PCB (CONTROL BOARD)

10001

230V CONTROLS BOARD

➜

CONTROL PANEL

30ci shown

PROGRAMMER

➜

Diagram 20.9

➜

11659

30ci shown

4000123923-2

➜

USER INTERFACE BOARD

11660

➜

MAINS SWITCH

Diagram 20.10

20 Replacement of Parts

20.19 (30ci Only) Analogue Programmer, refer to diagram 20.10. Before starting refer to the front of Section 20 Important information.

• Remove the front panel, refer to Section 17.3.

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

• Disconnect the electrical connections from the programmer.

• Undo the two securing screws and remove the programmer.

20.20 Central heating pump head, refer to diagram

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

• Remove the front panel, refer to Section 17.3.

• Lower the control panel, refer to Section 17.4.

• Drain down central heating water circuit of the boiler only, refer to relevant part of diagram 20.1. Note: it is not necessary to drain down the entire heating system to carry out this work.

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

• Undo four head fixing screws and remove pump head.

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

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

• Connect electrical connection to replacement pump head.

• Fit replacement pump head.

HEX HEAD SCREW (4 OFF)

30ci shown

REDUCED PRESSURE ZONE VALVE (RPZ)

➜

9823

PUMP ELECTRICAL CONNECTION BOX

PUMP HEAD

Diagram 20.11

11936

➜

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

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

• Remove the front panel, refer to Section 17.3.

• Lower the control panel, refer to Section 17.4.

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

• Pull of the filling loop tap extension.

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

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

20.22 (30ci Only) Reduced pressure zone valve (RPZ), refer to diagram 20.12. Before starting refer to the front of Section 20 Important information.

• Remove the front panel, refer to Section 17.3.

• Lower the control panel, refer to Section 17.4.

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

• Pull out slotted metal clip securing pipe to RPZ.

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

➜

30ci Only

➜

FILLING TAP

Diagram 20.12

4000123923-2

20 Replacement of Parts

20.23 Boiler drain point, refer to diagram 20.13. Before starting refer to the front of Section 20 Important information.

• Remove the front panel, refer to Section 17.3.

• Lower the control panel, refer to Section 17.4.

• Drain down the boiler only, refer to relevant part of diagram 20.1. Pull out slotted metal clip securing boiler drain valve into housing, remove boiler drain valve.

➜

9841

BOILER DRAIN VALVE

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

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

• Remove the front panel, refer to Section 17.3.

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

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

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

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

• Remove domestic water inlet filter housing.

• Remove electrical connections from water flow sensor.

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

20.25 System water pressure sensor, refer to diagram

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

• Remove the front panel, refer to Section 17.3.

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

• Remove electrical connections from water pressure sensor.

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

➜

30ci Only

➜

9847

➜

Diagram 20.13

9846

➜

WATER FLOW SENSOR

➜

Diagram 20.14

4000123923-2

30ci shown

➜

9833

SYSTEM WATER PRESSURE SENSOR

➜

Diagram 20.15

20 Replacement of Parts

20.26 Bypass valve, refer to diagram 16.1. Before starting refer to the front of Section 20 Important information.

• Remove the front panel, refer to Section 17.3.

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

• Remove the igniter unit, refer to Section 20.33. Pull out slotted metal clip, ease out bypass valve from bypass valve housing.

9810

CAP

AIR VENT

20.27 Automatic air vent, refer to diagram 20.16. Before starting refer to the front of Section 20 Important information.

• Remove the front panel, refer to Section 17.3.

• Lower the control panel, refer to Section 17.4.

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

• Unscrew to remove automatic air vent.

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

20.28 Gas Control valve, refer to diagram 20.17. Before starting refer to the front of Section 20 Important information.

• Remove the front panel, refer to Section 17.3.

• Lower the control panel, refer to Section 17.4.

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

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

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

• Ease gas control valve forwards and disconnect electrical connections to gas control valve. Note: Use the new washers supplied with the gas control valve.

• Fit gas valve resistor to replacement gas control valve.

• Withdraw gas control valve assembly.

• 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.

30ci shown

➜

30ci shown

10018

➜

Diagram 20.16

➜

11936

GAS CONTROL VALVE

9842

➜

Diagram 20.17

GAS CONTROL VALVE

STEPPER MOTOR

➜

Diagram 20.18

4000123923-2

20 Replacement of Parts

20.30 Discharge safety valve, refer to diagram 20.19. Before starting refer to the front of Section 20 Important information.

• Remove the front panel, refer to Section 17.3.

• Lower the control panel, refer to Section 17.4.

• Drain down the boiler only. Refert to relevant part of diagram

20.1.

• Undo discharge pipe union nut.

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

20.31 (30ci Only) Three-way valve head, refer to diagram 20.20. Before starting refer to the front of Section 20 Important information.

• Remove the front panel, refer to Section 17.3.

• Lower the control panel, refer to Section 17.4.

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

• Remove electrical plug from valve head.

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

• Fit replacement valve head. Note :

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

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

➜

30ci shown

➜

9794

PRESSURE RELIEF VALVE

➜

Diagram 20.19

10230

20.32 (30ci Only) Three-way valve actuator, refer to diagram 20.21. Before starting refer to the front of Section 20 Important information.

• Remove the front panel, refer to Section 17.3.

• Lower the control panel, refer to Section 17.4.

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

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

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

• Remove the three way valve actuator, see diagram 20.21

30ci Only

➜

THREE WAY VALVE HEAD

10229

Diagram 20.20

THREE WAY VALVE/ BYPASS HOUSING

THREE WAY VALVE

➜

ACTUATOR

9785

4000123923-2

30ci Only

Diagram 20.21

20 Replacement of Parts

20.33 Ignition unit, refer to diagram 20.22. Before starting refer to the front of Section 20 Important information.

• Remove the front panel, refer to Section 17.3.

• Lower the control panel, refer to Section 17.4.

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

Section 17.6.

• Disconnect electrical connections.

• Remove ignition unit securing screw.

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

20.34 (30ci Only) Domestic hot water plate to plate heat exchanger Before starting refer to the front of Section 20 Important information.

• Remove the front panel, refer to Section 17.3.

• Lower the control panel, refer to Section 17.4.

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

• Unclip the central heating thermistor.

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

see diagram 20.23.

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

• Remove plate to plate heat exchanger from boiler.

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

➜

DOMESTIC HOT WATER PLATE TO PLATE HEAT EXCHANGER

➜

10231

IGNITION UNIT

Diagram 20.22

11598

➜

30ci Only

11599

Diagram 20.23

4000123923-2

20 Replacement of Parts

20.35 Expansion vessel

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

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

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

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

• Remove the front panel, refer to Section 17.3.

• Lower the control panel, refer to Section 17.4.

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

• Disconnect the flue system.

• Disconnect the fixing jig connection pipes at the boiler.

• Disconnect the pressure relief valve discharge pipe.

• Disconnect the mains cable and any external controls cables.

• Lift up to remove the boiler from the wall.

• Remove sealed chamber cover, refer to Section 17.4.

• Remove the combustion chamber cover, refer to Section

17.5.

• Remove the fan, refer to Section 17.10.

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

• Release both side panels, refer to Section 17.6.

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

• Remove the expansion vessel retaining screw.

• From the rear of the boiler.

• Undo pipe coupling on expansion vessel.

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

‘Section 1 Technical Data’.

EXPANSION VESSEL

11600

30ci shown

11640

PIPE COUPLING

20.36 Sealed chamber cover seal, refer to diagram

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

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11582

SECURING SCREW

Diagram 20.24

20 Replacement of Parts

• Remove the front panel, refer to Section 17.3.

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

• Remove the old seal, thoroughly clean the casing. Fit the new seal, it is supplied to the correct length. Note: Ensure the seal is fitted correctly giving an air tight seal.

FRONT CASING PANEL

10063

SEALED CHAMBER COVER

SEAL

Diagram 20.25

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21 Spare parts

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

Short parts list

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

1 Central heating thermistor 801935 E91-959 2 Fan 801860 E92-062 3 Air pressure switch 801862 E92-063 4 30ci Only Domestic water flow sensor 801910 E84-014 5 Printed circuit board - Main 801915 E91-904 6 Pump head (50W) 801857 E92-064 7 System water pressure sensor 801911 E83-997 8 Gas control valve (G20) 801891 E91-945 9 Gas control valve (G30) 801978 E92-058 10 Discharge safety valve 801904 E84-000 11 Overheat thermostat 801913 E91-949 12 Ignition electrode 801888 E91-917 13 Flame sense electrode 801887 E91-922 14 230V controls board 801923 E84-018 15 User interface PCB 801922 E91-954 16 Stepper motor (G20) 801892 E91-924 17 Stepper motor (G30) 801979 E92-059 18 Ignition unit 801936 E91-960 19 30ci Only Three way valve head 801912 E88-839 20 Three way valve cartridge 801903 E88-838 21 Heat exchanger 30ci/30si only 801853 E92-054 22 Burner/17 blades 30ci/30si only 801854 E92-057 23 Heat exchanger 35ci only 2000802471 24 Burner/18 blades 35ci only 2000802475

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

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Glow-worm 30ci, 30si, 35ci Instructions For Use Installation And Servicing

Specifications and Main Features

Frequently Asked Questions

User Manual