23c Installation & Service Manual Boilers - Glow-worm
Contents
1. 18 27 Automatic air vent refer to diagram 18 18 Before starting refer to the front of Section 18 Important information Remove the front panel refer to Section 15 3 Lower the control panel refer to Section 15 4 Drain down the boiler only refer to relevant part of diagram 18 1 Unscrew to remove automatic air vent After fitting replacement automatic air vent ensure the cap is open 18 28 Gas Control valve refer to diagram 18 19 Before starting refer to the front of Section 18 Important information e Remove the front panel refer to Section 15 3 Lower the control panel refer to Section 15 4 Disconnect gas supply pipe union nuts atthe gas control valve Disconnect injector supply pipe union nut at the gas control valve Slacken the union nut at the burner injector bar Remove gas control valve retaining clip from the underside of gas control valve Ease gas control valve forwards and disconnect electrical connections to gas control valve Note The washers must be kept for use on reassembly Withdraw gas control valve assembly After fitting replacement gas control valve test for gas soundness 18 29 Gas control valve stepper motor Before starting refer to the front of Section 18 Important information Remove the front panel refer to Section 15 3 Lower the control panel refer to Section 15 4 Disconnect the electrical connection from stepper motor see diagram 182. J Diagram 14 1 15 Routine Cleaning and Inspection REMEMBER when replacing a part on this appliance use only spare parts that you can be assured conform to the safety and performance specification that we require Do not use reconditioned or copy parts that have not been clearly authorised by Hepworth Heating To ensure the continued efficient and safe operation of the boiler it is recommended that it is checked and serviced at regular intervals The frequency of servicing will depend upon the particular installation conditions and usage but in general once a year should be enough It is the law that any servicing is carried out by a qualified registered person 15 1 Products of combustion check Note To obtain a products of combustion reading unscrew the left hand sampling point cap on the flue elbow located on top of boiler see diagram 15 1 Connect the analyser tube onto sampling point Refer to the combustion product values in Section 1 Technical Data Switch on the electrical supply and gas supply then operate the boiler On completion of the test switch off the electrical supply and the gas supply remove analyser tube and replace sampling point cap 15 2 Service Check and Preparation solate boiler from the gas and electrical supplies Drain the Domestic hot water circuit and the boiler refer to diagram 15 2 Oncompletion check all gas carrying parts for soundness with leak detection flui
3. Overheat thermostat reset button WATER Refer to section 18 10 to locate the overheat thermostat PRESSURE reset button SENSOR Depress the button to reset 45V GANT DE p gt td di CONTROL DE 2 5 BOARD PCB R1 R2 1kQ x T LE m T La d i FAULTY WATER PRESSURE SENSOR It is possible to replace the sensor with two 1k 2 EL zu THERMOSTAT resistors as shown in the diagram Diagram 16 1 RESET BUTTON Diagram 16 2 27 2000225000B 16 Fault Finding FAULT NO HEATING BUT HOT WATER AT TAPS Is the heating set hiah enouah The setting is too low or the boiler a is set to summer mode YES Turn the setting up by turning the central heating temperature control knob clockwise YES Is the room thermostat in demand Me Adjust the setting Check the thermostat the line Check by overriding the room thermostat YES the connections both at the connector Does the fault persist to the room thermostat and the control board PCB YES Check the electrical connections Is the system fitted with to the control board PCB a external sensor YES Unplug the sensor and test it individually YES If the problem persists fit a replacement control board PCB 2000225000B 28 16 Fault Finding FAULT NO HOT WATER BUT THE HEATING IS WORKING Is the cold water inlet tap fully open Open it YES Insuffic
4. Standard flue system side only The maximum permissible length L for the standard flue system is 3 0m For flue systems up to 1 5m the flue restrictor a must be fitted inside the fan outlet For longer flue systems the restrictor must be removed For each 90 flue elbow used or two 45 elbows the maximum permissible length L must be reduced by 1metre FLUE RESTRICTOR a Diagram 10 7 2000225000B 18 11 Electrical Connection Warning This boiler must be earthed All system components must be of an approved type Electrical components have been tested to meet the equivalent requirements of the BEAB Connection of the whole electrical system and any heating system controls to the electrical supply must be through a common isolator Isolation should preferably be by a double pole switched fused spur box having a minimum contact separation of 3 mm on each pole The fused spur box should be readily accessible and preferably adjacent to the boiler It should be identified as to its use A fused three pin plug and shuttered socket outlet may be used instead of a fused spur box provided that a They are not used in a room containing a fixed bath or shower b Both the plug and socket comply with the current issue of BS1363 The mains electrical supply must be maintained at all times in order to provide domestic hot water Do not interrupt the mains supply with a time switch or programmer WAR
5. Bypass fully shut e Open 1 4 turn e Open 1 2 turn open 1 turn O Open 2 turns heating supply and return lines c D E D Q o a o o o O o OQ 9 o gt lt 0 500 1000 10 kPa 1 m WG Flow rate through heating system l h Diagram 1 1 2 Dimensions The 23c is delivered in three separate packages The boiler The fixing jig and hanging bracket The flue system Net lift weight boiler only 36 kg Gross lift weight boiler and packaging 37 kg 1 ue 9l de Dese Optional electro mechanical clock timer shown fitted Diagram 2 1 9 2000225000B 3 Heating System Design The 23c is compatible with any type of installation Heating surfaces may consist of radiators convectors or fan assisted convectors Pipe sectional areas shall be determined in accordance with normal practices using the output pressure curve diagram 1 1 The distribution system shall be calculated in accordance with the output requirements of the actual system not the maximum output of the boiler However provision shall be made to ensure sufficient flow so that the temperature difference between the flow and return pipes be less than or equal to 20 C The minimum flow is 500 I h The piping system shall be routed so as to avoid any air pockets and facilitate permanent venting of th
6. 19 Remove the two screws securing stepper motor to the gas control valve see diagram 18 20 Fit replacement gas control valve stepper motor Note Take care not to damage the O ring 18 30 Discharge safety valve refer to diagram 18 21 Before starting refer to the front of Section 18 Important information Remove the front panel refer to Section 15 3 Lower the control panel refer to Section 15 4 Undo discharge pipe union nut Pull out slotted metal clip from valve body and remove valve 41 AUTOMATIC AIR VENT STEPPER MOTOR ELECTRICAL CONNECTION GAS CONTROL VALVE Diagram 18 19 STEPPER MOTOR GAS CONTROL VALVE Diagram 18 20 2000225000B 18 31 Igniter unit refer to diagram 18 22 18 Replacement of Parts Before starting refer to the front of Section 18 Important information Remove the front panel refer to Section 15 3 e Lower the control panel refer to Section 15 4 IGNITER For ease of access remove the left hand side panel refer to UNIT Section 15 6 B Disconnect electrical connections Remove ignition unit securing screw Pull upwards to release and remove the ignition unit from the retaining slot il 18 32 Expansion vessel refer to diagram t l 18 23 Before starting refer to the front of Section 18 Important information IMPORTANT With regards to the manual handling operations 1992 regulations the following operation e
7. ABOVE ADJACENT GROUND OR BALCONY LEVEL FROM SURFACE FACING THE TERMINAL FACING TERMINALS FROM OPENING DOOR WINDOW INCAR PORT INTO DWELLING 1200 VERTICAL FROM A TERMINAL 1500 HORIZONTALLY FROM A TERMINAL 600 C D E 300 300 300 600 1200 2000225000B 12 6 2 Terminal guard A terminal guard is required if persons could come into contact with the terminal or the terminal could be subject to damage If a terminal guard is required it must be positioned to provide a minimum of 50mm clearance from any part of the terminal and to be central over the terminal Terminal guard type K3 supplied by Tower flue components Ltd Morley road Tonbridge Kent TN9 1RA 6 3 Flue options There are various flue systems to choose from as follows Telescopic horizontal flue pack rear only Standard horizontal flue pack left or right only Standard horizontal extended flue pack for use with standard horizontal flue pack Vertical flue pack Twin flue pack Extensions 90 and 45 bends Flue options and accessories For detailed information refer to flue options guide for further information this is available from your nearest stockist 6 4 Cupboard or compartment ventilation The boiler can be fitted in a cupboard or compartment without the need for permanent ventilation Diagram 6 1 7 Fixing Jig Pack The fixing jig is made up as follows Other components within the fixing jig pack
8. Fault Finding Before trying to operate the boiler make sure that All gas supply cocks are open and that the gas supply has been purged of air The heating system pressure is at least 1 bar There is a permanent mains supply to the boiler The fuse on the PCB is intact WARNING Always isolate the boiler from the electrical supply before carrying out any electrical replacement work Always check for gas soundness after any service work Should there be any doubt about the voltage supply to any of the components it is possible to carry out a simple electrical test to ensure all is operational in that area To carry out the electrical test gain access to the main Printed Circuit Board PCB as described previously and measure the voltages according to table 2 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 Table 2 ET 7M value roe re point 230 230 Volt 230V 23VA Between Between terminals H8 1 and H amp 2 H8 1 and H8 2 24 Volt maximum 33V DC Between terminals J5 3 and J15 1 minimum 20V E an 18 18 Volt BVI 1V Between Between terminals J2 9 and J2 10 J2 9 and J2 10 Display 5V x 0 5V Between terminals J13 4 and J13 1 TYPE OF FAULT CHECK No domestic hot water or central heating 230V
9. NO S ChecddBe inennicicn tap down to reduce the flow rate T CD e Check that the flow restrictor on the cold water inlet is fitted e Check the rate of flow 31 2000225000B 16 Fault Finding FAULT THE FAN DOES NOT START Does the warning light flash 45 seconds after the start of the demand e Check the power from the room thermostat e Replace the interface board or control board PCB e Check the fan loose terminal connector windings burnt out e nterface board or control board PCB FAULT THE FAN RUNS BUT THERE ARE NO SPARKS Does the warning light flash 45 seconds after the start of the demand e The air flow switch is not operating or is unplugged e Thermistor e Control board PCB e Check the pressure drop on the flue pipe e s the plastic tube on the correct pressure connection of the air pressure switch Are the electrical connections in place CONNECTIONS TO THE AIR PRESSURE SWITCH Air flow switch take off Electrical contacts 2000225000B 32 17 Wiring Diagram 10016 Z1 bk AIR PRESSURE L SWITCH PLUG IGNITOR T IGNITION UNIT RODE f ELECTRODES ELECTRODE i CHASSIS EARTH g y L THERMOSTAT 2 INPUT g FROST STAT H THERMOSTAT CH 1 INPUT ROOM STAT MAINS VOLTAGE EXTERNAL CONTROLS CONNECTION PLUG 5 JJ PRESSURE OVERHEAT SENSOR THERMOS
10. Section 15 3 e Lower the control panel refer to Section 15 4 Drain down the boiler refer to relevant part of Section 18 1 JAG ooi Undo the union on the cold water inlet isolating tap 7n M s N ad 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 18 25 System water pressure sensor refer to diagram 18 16 Before starting refer to the front of Section 18 Important information Remove the front panel refer to Section 15 3 Lower the control panel refer to Section 15 4 Drain down the boiler refer to relevant part of Section 18 1 Remove electrical connections from water pressure sensor Pull off slotted metal clip and remove water pressure sensor 18 26 Bypass valve refer to diagram 18 17 Before starting refer to the front of Section 18 Important information e Remove the front panel refer to Section 15 3 e Lower the control panel refer to Section 15 4 PRESSURE l SENSOR Drain down the boiler refer to relevant part of Section 18 1 Pull out slotted metal clip and remove bypass valve Diagram 18 16 BYPASS i R VALVE P Diagram 18 17 2000225000B 40 18 Replacement of Parts
11. boiler If this cannot be achieved itis acceptable to pack out the service cock bracket to obtain the correct alignment Position the wall template see diagram 8 1 e Mark the position of the holes for the hanging bracket and jig Drill plug and fix the hanging bracket to the wall using suitable screws not supplied Check that the hanging bracket is level Drill plug and fix the fixing jig to the wall For horizontal flue system mark the position for the flue hole as follows 8 3 Flue to rear of boiler Mark correct position of hole from template 8 4 Flue to side of boiler e Mark the horizontal centre line for the hole on the rear wall Extend the horizontal centre line to the side wall and mark the vertical centre line of flue hole as shown in diagram 8 1 8 5 Cutting the flue hole Making allowance for the slope of the flue cut hole in external wall preferably using a core drill For installations with internal and external access use a 105 mm diameter core drill For installations with internal access only use a 125 mm diameter core drill Important When cutting the flue hole and when extending the flue centre line to a side wall remember that the flue system must have a fall of about 35 mm per metre of flue DOWNWARD towards the terminal There must NEVER be a downward incline towards the boiler 8 6 Water connection Connect the system pipework to the copper connections on the fixing jig obser
12. fitting may result in faulty operation If in doubt consult your installation service company 2000225000B 1 Technical Data Heating Electrical Heat input max NET Q 25 kW Electrical supply 230 V 50Hz 89 300 BTU H Electrical rating 122W fused at 3A Heat input min NET Q 10 4 kW Level of protection IPXAD 35 490 BTU H Fuse rating 125mA Heat output max NET P 23 kW 8 480 BTU H Heat output min NET P 8 7 kW 29 670 BTU H Natural Gas G20 Efficiency Sedbuk D 79 90 Burner injector 1 2 MM Maximum heating temperature 67 C Inlet pressure 20 mbar Expansion vessel effective capacity 5l Maxi Burner pressure 12 mbar Expansion vessel charge pressure 0 5 bar Mini Burner pressure mbar Maximum system capacity at 75 C 110 Gas rate maximum 2 64 m3 h safety valve maximum service pressure 3 bar Hot water Heat input max NET Q 25 kW 85 300 BTU H Heat input min NET Q 10 4 kW 35 490 BTU H Heat output max NET P 23 kW 8 480 BTU H Heat output min NET P 8 7 kW 29 670 BTU H Maximum hot water temperature 63 C Minimum hot water temperature oo C specific flow rate for 30 C temp rise 11L min Threshold flow rate 1 7 L min Maximum supply pressure 10 bar Minimum supply pressure 0 5 bar Combustion Products outlet diameter 60 mm Fresh air inlet diameter 100 mm Combustion products values CO 52 ppm CO2 6 4076 NOx 92ppm 2000225000B 1 Technical Data
13. in the countries of destination at the time of installation Manufacture s instructions supplied Manufacture s instructions must not be taken as overriding statutory requirements Note The boiler serial number is marked on the label attached to the inside of the drop down door Refer to the Introduction section for a description of the basic functions of the boiler The Users section describes how to safely operate the boiler Mandatory warning for CEE countries Warning This appliance is designed approved and inspected to meet the requirements of the market The identification plate located on the inside of the appliance certifies the origin where the product was manufactured and the country for which it is intended If you see any exception to this rule please contact your nearest Glow worm dealer Thank you in advance for your assistance CE Mark This boiler meets the requirements of Statutory Instrument No 3083 The boiler Efficiency Regulations and therefore is deemed to meet the requirements of Directive 92 42 EEC on the efficiency requirements for new hot water boilers fired with liquid or gaseous fuels Type test for purposes of Regulation 5 certified by Notified body 0063 Product production certified by Notified body 0063 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 7
14. not use a wire or sharp instrument Note Make sure that injector size marked on each injector is the same as that given in Section 1 Technical Data for the type of gas being used 35 gt a ai E r f E i A e 1 B bts me S i F h i r tz RETAINING CLIPS AIR PRESSURE SWITCH ELECTRICAL CONNECTORS Li F l r G J r i SENSING gt j TUBE t Diagram 18 3 FLOW RESTRICTOR UNION NUTS RETAINING WIRE Diagram 18 4 COLD WATER IN ISOLATING VALVE eee BURNER Eit INJECTOR BAR ESSI csi mue x y 7 m ET a E e eo00pUusus wt I d eo amp m x C DL ON i Diagram 18 5 2000225000B 18 Replacement of Parts 18 9 Burner injector assembly refer to diagram 18 6 Before starting refer to the front of Section 18 Important information Remove burner from boiler refer to Section 15 9 Undothe gas supply union nutfrom underthe 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 When refitting burner injector assembly ensure the gas connection locate
15. of e Check the 230V mains supply phase and neutral reversing phase and neutral on the electric plug will have no effect FAULT NOT FOUND e f the problem persists change the control board PCB flame detection module faulty FAULT THE BURNER DOES NOT LIGHT AT ALL BUT THERE IS AN IGNITION SPARK N Are the gas taps on 2 e Turn on the gas taps YES e s there 24Vdc at the NO e Check the wiring gas control valve e f the problem persists change the YES e est the gas control valve e Check resistance of safety valve coil control board PCB 2000225000B 30 16 Fault Finding FAULT THE RADIATORS ARE LUKE WARM Is the installation fitted with a YES p e The temperature of the radiators external sensor depend on the outside temperature If the room temperature is not sufficient adjust e s the installation fitted with a YES e he radiators will only be hot if the room thermostat thermostat is demanding heat If the room temperature is not sufficient turn the setting of the room thermostat up Z NO NO YES s the heating power adequate Check the adjustment of the by pass too far open Check the circulation in the radiators Check the thermistor f problem persists change the interface board or the control board PCB FAULT THE WATER AT THE TAPS IS LUKE WARM s the setting high enough T e s the temperature higher if you turn the
16. supply No flashing warning light on control panel e Is fuse blown Loose connections on control board PCB e Faulty control or interface board PCB s No domestic hot water or central heating Water pressure A flashing warning light on control panel e Shortage of air or gas Faulty temperature sensor Overheating Wrong flue length Connections on air pressure switch electrical or tubes disconnected No hot water but central heating ok Loose connections at hot water flow sensor Faulty hot water flow sensor e Faulty control board PCB 2000225000B 26 16 Fault Finding COMPONENT NORMAL MEASURE CHECK Gas control valve Under demand during ignition sparks If O Volt the gas control valve Resistance of coil 116Q 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 stepper 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 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
17. switch tube from sensing probe on fan Disconnect air pressure switch electrical connections Unclip to remove air pressure switch 18 4 Domestic water inlet filter Before starting refer to the front of Section 18 Important information If the water flow rate through the appliance has reduced it may be necessary to clean or replace the water inlet filter refer to section 15 12 18 5 Central Heating Filter Before starting refer to the front of Section 18 Important information It may be necessary to clean or replace the central heating filter refer to section 15 13 18 6 Cold water inlet restrictor Before starting refer to the front of Section 18 Important information Remove the front panel refer to Section 15 3 Lower the control panel refer to Section 15 4 Drain down domestic hot water circuit of boiler only refer to relevant part of diagram 18 1 Remove the retaining wire Undo union nuts from boiler cold water in isolating valve Clean and inspectrestrictor replace if necessary see diagram 18 4 18 7 Burner refer to Section 15 9 Before starting refer to the front of Section 18 Important information 18 8 Burner injectors refer to diagram 18 5 Before starting refer to the front of Section 18 Important information e Remove burner from boiler refer to Section 15 9 Remove and replace injectors as required Note The injectors may be cleaned remove injectors inspect and clean Do
18. 3 23 EEC on the harmonization of the Laws of the Member States relating to the electrical equipment designed for use within certain voltage limits 3 Directive 89 336 EEC on the approximation of the Laws of the Member States relating to electromagnetic compatibility Substances Hazardous to Health Under section 6 of the Health and Safety at Work Act 1974 we are required to provide information on substances hazardous to health The adhesives and sealants used in this appliance are cured and give no known hazard in this state INSULATION PADS CERAMIC FIBRE GLASSYARN MINERAL WOOL These can cause irritation to skin eyes and the respiratory tract If you have a history of skin complaint you may be susceptible to irritation High dust levels are usual only if the material is broken Normal handling should not cause discomfort but follow normal good hygiene and wash your hands before eating drinking or going to the lavatory If you do suffer irritation to the eyes or severe irritation to the skin seek medical attention The insulation is composed of non combustible material Spare Parts REMEMBER When replacing a part on this appliance use only spare parts that you can be assured conform to the safety and performance specification that we require Do not use reconditioned or copy parts that have not been clearly authorised by Hepworth Heating Ltd Manual Handling Guidance During the appliance installation it will be necessary to employ
19. A Heating return fitting with isolating valve v F Hanging bracket B Cold water inlet fitting with isolating valve m G wall template The cold water inlet restrictor supplied with boiler is H copper connections fitted when the boiler is installed Refer to Section 9 J sealing washers and screws C Heating flow fitting with isolating valve q D Domestic hot water outlet E Gas fitting LEFT HAND SUPPORT BRACKET COPPER CONNECTIONS AND WASHERS 5 OFF ISOLATING VALVE 1 Heating systems connections Pipe diameter 22mm 2 Hot water system connections Pipe diameter 15mm 3 Gas connection Pipe diameter 15mm RIGHT HAND SUPPORT BRACKET THE FIXING JIG SHOWN ASSEMBLED Diagram 7 1 13 2000225000B 8 Piping System Installation 8 1 Fixing jig see diagram 7 1 Remove the contents of the fixing jig pack e Secure the left and right hand support brackets to the isolating valve plate with the securing screws 2 OFF supplied Connect the five copper connections and sealing washers to the isolating valves 1 Heating system connections Pipe diam 22mm 2 Hot water system connections Pipe diam 15mm 3 Gas connection Pipe diam 15mm 8 2 Wall template Remove the wall template follow the instructions given on the wall template Note It is important the hanging bracket and service cock bracket are fitted to a flat and true wall area for correct alignment with the
20. Controls board refer to diagram 18 11 Before starting refer to the front of Section 18 Important information Unclip control panel user interface and hinge forward Do not strain the cables Disconnect the electrical connection from the 230V controls board and the electrical connection from printed circuit board PCB Remove the 230V controls board retaining screw Remove the 230V controls board 18 Replacement of Parts 18 20 Central heating pump head refer to PUMP diagram 18 12 ELECTRICAL Before starting refer to the front of Section 18 Important CONNECTION information BOX Remove the front panel refer to Section 15 3 Lower the control panel refer to Section 15 4 PUMP HEAD Drain down central heating water circuit of the boiler only refer to relevant part of diagram 18 1 Note itis not necessary to drain down the entire heating system to carry out this work For ease of access if required remove the right hand side panel refer to Section 15 6 Undo four fixing screws and remove pump head Gain access to the pump electrical connection box and remove Diagram 18 12 cover Disconnect pump cable from pump avoid straining cables REDUCED PRESSURE ZONE VALVE RPZ Connect electrical connection to replacement pump head Fit replacement pump head in reverse order to removal Check for leaks 18 21 Filling system tap refer to diagram 18 13 Before starting re
21. EE Regulations Connection of the boiler and system controls to the mains supply must be through a common isolator and must be fused 3A maximum This method of connection must be by a fused double pole isolating switch with a minimum contact separation of 3mm on both poles The switch should be readily accessible and preferably adjacent to the appliance It should supply the appliance only and be easily identifiable as so doing Alternatively an unswitched shuttered socket outlet and 3A fused 3 pin plug both to the current issue of BS1363 may be used provided that they are not used in a room containing a bath or shower Wiring to the boiler must be PVC 85 C insulated cable not less than 0 75mm 24 0 20mm Gas safety Installation and use Regulations In your interests and that of gas safety it is the law that ALL gas appliances are installed and serviced by a qualified registered person in accordance with the above regulations Gas leak or fault If agas leak or fault exists or is suspected turn the boiler off and consult the local gas supply company or your installation service company Air in the heating system Persistent air in the heating system may indicate leaks in the system or corrosiontaking place Call your Installation Servicing company Overheating safety In the event of a problem the overheating safety devices cause safety shutdown of the boiler If this happens call your Installation Servicing compan
22. NING UNDER NO CICUMSTANCES MUST ANY MAINS VOLTAGE BE APPLIED TO ANY OF THE TERMINALS ON THE VOLTAGE FREE HEATING CONTROLS CONNECTION PLUG Warning This appliance must be wired in accordance with these instructions Any fault arising from incorrect wiring cannot be put right under the terms of the Glow worm guarantee Important If a replacement supply cable is required it must be purchased Part No S1008600 11 1 External controls Voltage Free This boiler will operate on heating as supplied provided that the wire link E fitted between the two terminals of the heating controls conection plug is left in place see diagram 11 1 External controls e g room thermostat frost thermostat etc should be fitted in accordance with the rules in force WARNING UNDER NO CICUMSTANCES MUST ANY MAINS VOLTAGE BE APPLIED TO ANY OF THE TERMINALS ON THE VOLTAGE FREE HEATING CONTROLS CONNECTION PLUG If mains voltage controls are required see section 11 2 Refer to the wiring diagram Section 17 11 2 External controls Mains Voltage Remove the MAINS VOLTAGE HEATING CONTROLS CONNECTION PLUG from the fittings pack and install on the 230V interface control board as shown on the instruction sheet also provided in the fittings pack and diagram 11 2 Gain access to the 230V interface by unclipping the control panel and hinge forward The wire link E must be removed from the voltage free heating controls connection plug External con
23. TAT GAS CONTROL THERMISTOR gn 230V CONTROLS b VOLTAGE FREE E HEATING eon CONTROLS IT CONNECTION wjf gn I CHASSIS EARTH Ee ay g y REMOVE BLUE LINK IF USING w 230V EXTERNAL CONTROLS bk BLACK br BROWN r RED hf br 230V 50Hz_ LIL w WHITE b BLUE or ORANGE e MA NSISUBPLY g y GREEN p PINK gn GREEN ON OFF NL FUSED AT 3A YELLOW g GREY y YELLOW SWITCH d 2000225000B 18 Replacement of Parts To Drain the central heating circuit Open drain valve fitted at the lowest point in the system BOILER DRAIN VALVE Allow air into the system by opening a radiator bleed screw or the boilers drain valve a To Drain the Domestic hot water circuit Close boiler isolating valve c Turn on one or more hot water taps To Drain the boiler Close isolating screws on the isolating valves b c and d turn from vertical to horizontal to close Open the boiler drain valve a Turn on one or more hot water taps NO 5 o o HEATING FLOW Note Isolating cocks water and gas COLD HEATING are shown in the OFF position QQ WATER IN RETURN Diagram 18 1 IMPORTANT INFORMATION CENTRAL HEATING WARNING Before commencing the replacement of any THERMISTOR component isolate appliance from electrical supply and turn off gas at service cock Replacement of parts must be carried out
24. The Building Standards Regulations Scotland The Health and Safety at Work Act 9 2 Sheet metal parts WARNING When installing or servicing this boiler care should be taken when handling the edges of sheet metal parts to avoid the possibility of personal injury 9 3 Installing the boiler Prior to starting work the system must be thoroughly flushed using a propriety cleanser such as Sentinel X300 to eliminate any foreign matter and contamination e g metal filings solder particles oil grease etc Note Solvent products could cause damage to the system The boiler pack consists of the boiler and a document envelope and fittings pack which contain literature self adhesive wiring diagram label magnetic user instruction label external controls connector guarantee return form sealing washers screws flue restrictor cold water inlet restrictor filling loop extension discharge safety valve pipe IMPORTANT With regards to the manual handling operations 1992 regulations the following operation exceeds the recommended weight for one man lift e Stand the boiler upright Remove all packaging from around the boiler Remove the transit plate from the fan outlet on top of the boiler secured with two screws 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 If applicable remove the self adhesive wiring diagram label f
25. aws the combustion air from the outside of the room The boiler is suitable for top outlet flue connection only but can be fitted with horizontal flue vertical flue or twin pipe flue Refer to flue options guide for further information this is available from your nearest stockist Both the central heating and domestic hot water temperature are user adjustable from the boiler control panel Domestic hot water demand always has priority over heating demand The pump expansion vessel and associated safety devices are all fitted within the boiler The boiler can be installed against either an external wall or on an adjacent inside wall that is the flue system will pass directly to the rear or to either side to the terminal fitted on the outside wall face The installation must be carried out by a qualified registered person in accordance with the relevant requirements of The Building Regulations The Water Byelaws The Building Standards Scotland Regulations and any applicable local regulations These instructions should be carefully followed for the safe and economical use of your boiler Electrical Supply WARNING This boiler must be earthed All system components shall be of an approved type and shall be connected in accordance with the current issue of BS7671 and any applicable local regulations All external wiring between the appliance and the electrical supply and earthing requirements shall comply with the current I
26. bstruct any access 6 1 Clearances The position of the boiler must be such that there is adequate space for servicing The recommended clearances are 20 mm either side of the boiler 600 mm at the front of the boiler 300 mm below the boiler 25 mm above the flue elbow Note The boiler must be mounted on a flat wall which is sufficiently robust to take its weight when full that is 36 kg If in doubt expert advice should be obtained in the event of the wall being found not suitable Note Itis permissible to install the boiler with smaller clearances than those quoted above PROVIDING that adequate consideration is given for Servicing Repairs at a later date If any doubt exists contact the Glow worm s Technical Helpline 01773 828300 The minimum acceptable spacings from the terminal to obstructions and ventilation openings are shown in diagram 6 1 The boiler must be installed so that the terminal is exposed to the external air Should any doubt exist as to the permissible position of the terminal contact the Glow worm s Technical Helpline 01773 828300 MINIMUM SITING DIMENSIONS FOR THE POSITIONING OF FLUE TERMINALS MM A DIRECTLY BELOW ABOVE OR HORIZONTALLY TO AN OPENING AIR BRICK OPENING WINDOWS AIR VENT OR ANY OTHER VENTILATION OPENING 300 B BELOW GUTTER DRAIN SOIL PIPE 75 BELOW EAVES 200 BELOW A BALCONY OR CAR PORT 300 FROM VERTICAL DRAIN PIPES AND SOIL PIPES FROM INTERNAL CORNERS AND EXTERNAL CORNERS
27. by a competent person When replacing components it may be necessary to renew sealing washers gaskets and O rings If new ones are OVERHEAT supplied with replacement components they must be used THERMOSTAT All parts are replaced in reverse order to removal If any gas carrying components are disturbed removed or replaced it will be necessary on completion to check for gas soundness with leak detection fluid 18 1 Central heating thermistor Before starting refer to the front of Section 18 Important information e Remove the front panel refer to Section 15 3 Disconnect electrical connections from thermistor Lower the control panel refer to Section 15 4 Remove the thermistor from the heat exchanger Remove the sealed chamber cover refer to Section 15 5 Fit replacement thermistor Locate central heating thermistor on the top left hand side of Refit electrical connections the heat exchanger see diagram 18 2 2000225000B 34 18 Replacement of Parts 18 2 Fan refer to Section 15 10 Routine Cleaning and Inspection 18 3 Air pressure switch Before starting refer to the front of Section 18 Important information Remove the front panel refer to Section 15 3 Lower the control panel refer to Section 15 4 Remove the sealed chamber cover refer to Section 15 5 e Locate air pressure switch situated inside combustion chamber on top left hand side see diagram 18 3 Remove air pressure
28. 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 2000225000B 2 Contents CONTENTS INSTRUCTION FOR USE INSTALLATION INSTRUCTIONS SERVICING INSTRUCTIONS DESCRIPTION Important Information Introduction Controls and Lighting Clock timer Optional Draining Safety Devices servicing and Maintenance Technical Data Dimensions Heating System Design Domestic Hot Water System Design Boiler Schematic Boiler Location flue and ventilation Fixing jig pack Piping System Installation Boiler installation Flue Installation telescopic and standard Electrical Connection Commissioning Settings Routine Cleaning and Inspection Fault Finding Wiring Diagram Replacement of Parts Spare Parts SECTION o 0O NOORA UOUN 15 16 17 18 19 PAGE No 00 BD 10 10 11 12 13 14 15 16 19 20 22 22 27 34 44 2000225000B Introduction The 23c boiler is a wall mounted modulating combination boiler with electronic ignition providing central heating and instantaneous hot water The boiler is of the I2H category for use with Natural Gas G20 as distributed in the United Kingdom The boiler has a fan assisted balanced flue which both discharges the products of combustion to and dr
29. d Remove boiler casing as follows 2000225000B PRODUCTS SAMPLING POINT Diagram 15 1 15 3 Front panel Unscrew and remove the two retaining screws from the bottom of the front panel Remove front panel by pulling forward and lifting up 15 4 Control panel Lower forwards to gain access to lower part of boiler 15 5 Sealed chamber cover Unclip the two toggle clips holding the sealed chamber cover see diagram 15 3 Lift cover up and off pins on the top of the boiler 15 Routine Cleaning and Inspection To Drain the Domestic hot water circuit Close boiler isolating valve c Turn on one or more hot water taps To Drain the boiler Close isolating screws on the isolating valves b c and d turn from vertical to horizontal to close Open the boiler drain valve a Turn on one or more hot water taps ad d a a c b HEATING Note Isolating cocks water and gas COLD FLOW are shown in the OFF position dali p m WATER IN RETURN Diagram 15 2 Diagram 15 3 Diagram 15 4 23 2000225000B 15 Routine Cleaning and Inspection 15 6 Side panels for ease of access if required refer to diagram 15 4 Support the side panels as you remove them Unscrew and remove the three retaining screws from front of each side panel Left hand side panel only disconnect the control panel retaining strap at the control panel Pull each panel forward from the rear retai
30. e the fixing collar can only be fitted one way due to the different diameters of the flue elbow and air duct Take hold of the flue duct pipe and push gently onto the elbow outlet taking care not to tear the O ring Open fixing collar D and locate between elbow and air duct pipe A Close fixing jig Engage the two fixing clips E onto the collar D and press down to lock into position Secure clips with screws provided Important If the flue has been cut ensure that there are no burrs that could damage the O ring 17 For flue systems less than 1 5 m long fit the restrictor a in the fan outlet see diagram 10 7 Remove the backing from the self adhesive gasket H and carefully fit gasket to base of flue elbow Fit elbow onto boiler and secure with the four screws I The flue kit A2004500 is 659 5 mm long and comprises Telescopic flue assembly External rubber sealing collar Telescopic flue kit Diagram 10 3 The flue kit 86285 is 1000 mm long and comprises Air duct pipe Fue duct pipe Flue elbow Fixing collar Locking clips External rubber sealing collar Internal flange Diagram 10 4 2000225000B 10 Flue Installation Telescopic flue system rear and side The maximum permissible length L for the telescopic flue system is 659 5mm The restrictor a must be fitted to inside the fan outlet FLUE RESTRICTOR GASKET Diagram 10 6
31. e installation Bleed fittings must be provided at every high point of the system and on all radiators The total volume of water permitted for the heating system depends amongst other things on the static head in the cold condition The expansion vessel on the boiler is pressurised at 0 5 bar and allows a maximum system volume of 110 litres for 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 8 2 Provision shall be made for a drain valve at the lowest point of the system Where thermostatic radiator valves are fitted not all radiators must be fitted with this type of valve and in particular where the room thermostat is installed In the case of an existing installation itis ESSENTIAL that the system is thoroughly flushed prior to installing the new boiler using a proprietary product such as Fenox or Sentinel Contact the product manufacturers for specific details 3 1 Filling the system A filling device is fitted to the boiler to initially fill the system and replace water lost during servicing see the relevant parts of diagram 2 controls and lighting and diagram 8 2 4 Domestic Hot Water System Design e Copper tubing or plastic Hep 0 may be used for the domestic hot water system Unnecessary pressure losses sho
32. e 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 Replace the filter into its housing and replace the securing Clip Open isolating valve c on cold water inlet and test the Domestic Hot Water circuit for soundness 2000225000B 24 15 13 Central Heating Filter refer to diagram 15 11 Remove the filter retaining clip and filter clean or renew if necessary Hefitthe filter ensuring the correct orientation The flat and hole in the filter as shown Secure with retaining clip 15 14 Reassembly of parts removed for servicing All parts are replaced in reverse order to removal 15 15 Flue system Check externally to make sure that flue is not blocked Inspect flue system to make sure that all fittings are secure L ME OO E i E yi sr EC Tae oe Br m i a A EE f i a ye a af f IN i y F n m Li inisa S UM M enr Tu SPARK GAP P lagram 15 6 SENSE GAP AIR PRESSURE SWITCH SENSING TUBE FAN RETAINING SCREW 15 Routine Cleaning and Inspection BURNER RETAINING SCREWS EELT f BURNER Giat EUN HEAT EXCHANGER DOMESTIC WATER INLET FILTER HOUSING PULLDOWN Diagram 15 8 FILTER RETAINING CLIP FILTER 25 Diagram 15 9 Diagram 15 10 Diagram 15 11 2000225000B 16
33. eful not to trap any of the cables Make sure that PCB connections are fully pushed onto replacement PCB ELECTRICAL LEAD CENTRAL HEATING THERMISTOR OVERHEAT THERMOSTAT ELECTRICAL LEADS HEAT EXCHANGER Diagram 18 8 RIGHT HAND INSULATION FRONT INSULATION RETAINING TABS LEFT HAND SHOWN LEFT HAND INSULATION Diagram 18 9 2000225000B 18 Replacement of Parts CONTROL BOARD COVER y 3 S CONTROL PANEL 18 17 User interface board refer to diagram 18 11 Before starting refer to the front of Section 18 Important information Remove the front panel refer to Section 15 3 e Lower the control panel refer to Section 15 4 Unclip control panel user interface and hinge forward Do not strain the cables e Disconnect the electrical connections from the user inter face board Remove the two user inter face board retaining screws e Remove the user inter face board 18 18 Mains switch see diagram 18 11 Before starting refer to the front of Section 18 Important information Remove the front panel refer to Section 15 3 e Lower the control panel refer to Section 15 4 2000225000B PCB CONTROL BOARD MAINS SWITCH USER INTERFACE BOARD Diagram 18 11 Unclip control panel user interface and hinge forward Do not strain the cables e Disconnect the electrical connections from the mains switch Remove and replace the mains switch 18 19 230V
34. er to diagram 18 8 Disconnect the four union nuts Lift to remove the heat exchanger taking care not to damage the insulation 18 15 Combustion chamber insulation refer to diagram 18 9 Before starting refer to the front of Section 18 Important information Remove the front panel refer to Section 15 3 Lower the control panel refer to Section 15 4 e Remove the sealed chamber cover refer to Section 15 5 Remove the combustion chamber cover refer to Section 15 7 Remove the heat exchanger refer to Section 18 14 Carefully bend back side insulation retaining tabs pull out side and front insulation panels from combustion chamber Tilt rear insulation panel forwards slide up and out Fit replacement insulation 18 16 Printed circuit board PCB refer to diagram 18 10 Before starting refer to the front of Section 18 Important information Remove the front panel refer to Section 15 3 e Lower the control panel refer to Section 15 4 Gain access to rear of control panel Undo and remove the two cover retaining screws This will disconnect the metal plate heat reflector e 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 e Carefully pull off electrical connections to PCB Unclip and lift out PCB Fit replacement PCB in reverse order to removal Be car
35. ervicing company or Heatcall Glow worm s own service organisation using the telephone number on the front cover ie EB of this literature gt pu B 6 Installation filling If the boiler loses water the pressure gauge a and fault display b will flash Fill the system by the filling device c at the bottom of the boiler until the pressure gauge reads 1 5 bar e Warning Take care not to overfill the boiler Ata pressure of 2 5 bar or above indicating over pressure the fault display b will flash The pressure must be reduced to 1 5 bar by bleeding a radiator If the fault continues call your Installation Servicing company or Heatcall Glow worm s own service organisation using the telephone number on the front cover of this literature 2000225000B Clock timer instructions for use Optional Clock timers inclusive of installation and user instructions These are available from your nearest stockist Electro Mechanical Part No 4000122022 Digital Part No 4000120494 Draining Protection against freezing The boiler has a built in frost protection programme as long as the electricity and gas are left switched on If the temperature within the appliance falls to 3 C the burner and system pump are activated When the temperature inside the appliance reaches 10 C the burner will shut down and after a short period the pump will stop This device primarily protects t
36. fer to the front of Section 18 Important information Remove the front panel refer to Section 15 3 Lower the control panel refer to Section 15 4 Drain down the boiler only refer to relevant part of diagram 18 1 Pull out slotted metal clip securing tap into housing remove tap Pull out slotted metal clip and remove pipe from tap 18 22 Reduced pressure zone valve RPZ refer to diagram 18 13 FILLING TAP Before starting refer to the front of Section 18 Important Diagram 18 13 information Remove the front panel refer to Section 15 3 e Lower the control panel refer to Section 15 4 e Drain down the boiler only refer to relevant part of diagram BOILER 18 1 DRAIN Pull out slotted metal clip securing pipe to RPZ Pull out slotted metal clip securing RPZ into housing remove HPZ 18 23 Boiler drain point refer to diagram 18 14 Before starting refer to the front of Section 18 Important information Remove the front panel refer to Section 15 3 Lower the control panel refer to Section 15 4 Drain down the boiler only refer to relevant part of diagram 18 1 Pull out slotted metal clip securing boiler drain valve into housing remove boiler drain valve Diagram 18 14 39 2000225000B 18 Replacement of Parts 18 24 Water flow sensor refer to diagram 18 15 Before starting refer to the front of Section 18 Important information Remove the front panel refer to
37. he boiler Any other exposed areas of the system should be protected by a seperate frost thermostat If the boiler is to be out of use for any long periods during severe weather conditions it is recommended that the whole system including the boiler be drained to avoid the risk of freezing If in doubt consult your servicing company Draining and filling Caution The boiler is installed as part of a sealed system which must only be drained and filled by a competent person 2000225000B 6 Safety Devices The 23c incorporates a visual fault display that indicates certain fault conditions red flashing light should they occur EB 4 Should the boiler fail to operate during Commissioning the most likely fault is that the gas supply to the boiler has not been turned on or purged sufficiently or that there is no pressure inthe heating system General safety devices Air flow rate safety device If an obstruction even partial of the flue occurs for any reason whatsoever the built in safety system of the boiler will turn the boiler OFF the red light will flash and the fan will continue to run The boiler will be ready to operate when the fault has been cleared Heating safety valve CAUTION A heating safety valve with a discharge pipe is fitted to this boiler The valve MUST NOT BE TOUCHED except by a qualified registered person If the valve discharges at any time switch the boiler off and isolate i
38. ient water pressure Is the water pressure greater The appliance will not operate than 0 5 bar Find out why the pressure is so low YES Check the cold water inlet filter for dirt Is the cold water tap fully open Check the heat exchanger for scaling Is the water flow rate greater than 1 7l min threshold figure Change or clean it Is flow detector operating Check the connectors on the sense electrode and the control board PCB If the fault persists fit a relplacement control board PCB 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 e Check that the gas taps are fully open the sensing electrode Is the gas e Check the gas pressure pressure correct e Adjust the low flow setting of the gas control valve e Clean the gas filter e Clean the burner 29 2000225000B 16 Fault Finding FAULT THE BURNER LIGHTS THEN GOES OUT The flame is spreading across the e With the power turned off check the whole burner but not being detected CHECK resistance between the spark electrode THE and terminal H23 on the control board PROBE PCB Check the connector on the end of the wire e Check that the spark electrode is CHECK THE MAINS pointing towards the flame e Check the spark electrode Change it e Check the earth no power and neutral Note the boiler is independent
39. 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 Controls and Lighting 1 On Off switch 2 Central heating temperature selector 3 Domestic hot water temperature selector 4 Pressure gauge bar and temperature gauge C 5 Fault display faults indicated by a red flashing light 6 Clock timer Optional 1 Lighting the boiler Make sure that The boiler is connected to the electrical supply The gas service cock is open Turn the switch ON 1 2 Stop the boiler Turn the switch OFF 0 the electrical supply is OFF Turn the gas supply OFF at the gas service cock if the boiler is to be out of use for a long time 3 Domestic hot water adjustment Position 0 Domestic hot water OFF Position 1 and ECO Domestic hot water between approx 35 C and 50 C e ECO Maximum recommended for constant use Between ECO and maxi Occasional use for water above approx 50 C Diagram 2 Diagram 1 4 Heating temperature adjustment Winter Set the control knob between 1 and 5 e Summer Set the control knob to 5 If a fault occurs indicated by red flashing light e Reset boiler Turn the On Off switch to O wait for five seconds Turn the On Off switch to 1 the boiler is reset If the fault continues call your Installation S
40. lectrical controls box Should there be any doubt about the gas rate it should be checked at the meter On reaching maximum temperature the boiler should be turned off and the system drained as rapidly as possible whilst still hot Refill system to a pressure of between 1 and 2 bar and vent as before Restart boiler and operate until a maximum temperature is reached Shutdown boiler and ventheating system If necessary top up heating system and make sure that a pressure of at least 1 bar is indicated when system is COLD Flush the domestic hot water system by opening the hot water taps for several minutes Remove the magnetic lighting instructions label from the document envelope and position it on the surface of the boiler casing 21 6 Leave cap on automatic air vent on top of pump open em 8 Ensure the display indicates a system pressure of 1 5 bar adjust if necessary 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 installatio
41. lectrical supply Lo TN TEST POINT The gas service cock is open e 7 Turn the switch OFF 0 Diagram 12 1 E Open the three boiler isolating valves The slot of the screw corresponds to flow direction To unscrew turn anti clockwise Fully open valves by turning anti clockwise HEATING HEATING FLOW WATER IN RETURN 3 4 Undo cap on automatic air vent on top of pump Turn the switch ON 1 and leave undone Open the tap on the filling device and fill the system until the pressure indicated on the display is 2 bar Close filling device o l e e 2000225000B 20 12 Commissioning 5 Bleed each radiator to remove air ensure all bleed screws are re tightened If necessary repressurise the system refer to procedure 4 T Open various hot water taps to bleed system Adjust heating temperature to maximum Check that any external controls if fitted are calling for heat set room thermostat to maximum Allow the temperature to rise to the maximum value with all radiator valves open The temperature rise will cause release of the gases contained in the water of the central heating system Gases driventowards the boiler will be automatically released through the automatic air vent The gases trapped at the highest point of the system must be released by bleeding the radiators Check the burner gas rate required ten minutes from lighting Refer to Data Label on e
42. low worm 2000225000B 02 02 Quality through design Instructions for Use Installation and Servicing Tobeleftwiththe user 23c Fanned Flue Combination Boiler G C No 47 047 18 C benchmark The mark of quality for domestic heating This is a Cat L Appliance e optional electro mechanical clock timer shown fitted The instructions consist of three parts User Installation and Servicing Instructions which includes the Guarantee Registration Card The instructions are an integral part of the appliance and must to comply with the current issue of the Gas Safety Installation and Use Regulations be handed to the user on completion of the installation Guarantee Registration Thank you for installing a new Glow worm appliance in your home Glow worm appliances are manufactured to the very highest standard so we are pleased to offer our customers a Comprehensive Guarantee This product is guaranteed for 24 months from the date of installation or 30 months from the date of manufacture whichever is the shorter for parts In addition this product is guaranteed for 12 months from the date of intallation or 18 months from the date of manufacture whichever is the shorter for labour The second year of the parts guarantee from the beginning of the 13th month onwards after installation or manufacture is conditional upon the boiler having been serviced by a CORGI registered gas installer in accordance with the manufactu
43. mistor Fan Air pressure switch Domestic water flow sensor Printed circuit board Main Pump head System water pressure sensor Gas control valve Discharge safety valve Overheat thermostat Ignition electrode Flame sense electrode 230V controls board User interface PCB Stepper motor Ignitor unit Pressure releif valve Heat exchanger Burner Part No 801933 801926 801928 801910 801915 801896 801911 801911 801904 801927 801888 801887 801914 801892 801094 G C No 43 2000225000B Notes Because of our constant endeavour for improvement details may vary slightly from those in the instructions 2000225000B 44
44. n conditions and usage but in general once a year should be enough Draw attention if applicable to the current issue of the Gas Safety Installation and Use Regulations Section 35 which imposes a duty of care on all persons who let out any property containing a gas appliance It is the Law that any servicing is carried out by a competent person Advise the user of the precautions necessary to prevent damage to the system boiler and the building in the event of the heating system being out of use during frost or freezing conditions Advise the user that the permanent mains electrical supply SHOULD NOT be switched off as the built in frost protection and pump saver program would not be operable Reminder leave these instructions and the Benchmark logbook with the user 2000225000B 14 Settings Bypass The 23c boiler has a built in bypass This must be adjusted according to the requirements of the system refer to the flow rate pressure curve diagram 1 1 The boiler is supplied with the built in bypass open a half a turn Itis adjusted by turning the bypass screw a see diagram 14 1 Turn the screw clockwise to close the bypass When using thermostatic radiator valves TRV s on all of the radiators it is essential that a separate adjustable bypass of 15 mm minimum diameter is fitted between the flow and return of the heating circuit see diagram 8 1 Any bypass must be fitted before system controls
45. ning pins to remove 15 7 Combustion chamber cover Unscrew and remove the four screws securing combustion chamber cover to combustion chamber see diagram 15 5 e Remove combustion chamber cover from boiler Take care not to damage the insulation 15 8 Spark and Sense Gaps Check that the spark and sense gaps as shown in diagram 15 6 Note To gain access to spark and sense electrodes for removal refer to Section 18 12 and 18 13 in Replacement of Parts 15 9 Burner refer to diagram 15 7 Unscrew and remove the two burner retaining screws Remove burner from boiler by easing it forward off the two burner guides Clean burner by washing in soapy water Dry thoroughly before refitting Note To gain access to injectors for removal and cleaning refer to Section 18 8 in Replacement of Parts 15 10 Fan refer to diagram 15 8 Disconnect power supply leads and earth lead from fan Remove air pressure switch sensing tube from the side of the fan Unscrew and remove the fan retaining screw e Ease the fan down and forwards to remove 15 11 Heat exchanger refer to diagram 15 9 Remove the two flue hood retaining screws to remove the flue hood Use a soft brush or vacuum clean the heat exchanger DO NOT USE ANY TOOL LIKELY TO DAMAGE PAINTED FINISH OF HEAT EXCHANGER 15 12 Domestic water inlet filter refer to diagram 15 10 If the water flow rate through the appliance has reduced it may b
46. ny burrs or sharp edges on the cut ends of the pipes Outside Flue wall face centre line n X minus 160mm plus 17mm Air duct cutting length weite cutting length Flue duct Air duct cutting h Air duct y m Flue duct cutting 95mm air duct cutting length 152mm check dimension cut end Diagram 10 2 10 Flue Installation Telescopic and Standard 10 5 Installation of telescopic flue assembly The elbow must be removed from the air and flue duct pipes Extend the telescopic flue assembly approximately 10 cm If the telescopic flue is pulled apart care must be taken not to damage the O ring on the flue duct when re assembling Remove the 2 securing screws on either side of the air elbow end of the air duct pipe carefully pull the air duct pipe off the air elbow taking care not to disconnect the telescopic flue duct pipes Remove the 2 securing screws on either side of the flue elbow to release the flue duct pipe pull the flue duct pipe out of the flue elbow note the O ring inside the flue elbow Fitrubber sealing collar B see diagram 10 3 into groove at the outer end of the air duct pipe A Fit air flue duct pipe assembly A into wall from the outside with rubber sealing collar to the outside Pull pipe assembly inwards to bring rubber sealing collar hard up against external wall see diagram 10 5 Fit O ring E into the underside of the flue elb
47. o Section 15 6 Undo and remove screw securing electrode assembly to the burner injector assembly see diagram 18 6 Disconnect the electrical connections at the igniter unit see diagram 18 21 Note the routing of the cables 2000225000B 36 18 13 Flame sense electrode Before starting refer to the front of Section 18 Important information Remove burner refer to Section 15 9 Remove the right hand side panel refer to Section 15 6 Undo and remove screw securing sense assembly to the burner injector assembly see diagram 18 6 Disconnectthe electrical connection from the inline connector Note the routing of the cable GROMMET GAS SUPPLY PIPE SENSE ELECTRODE ASSEMBLY IGNITION DOMESTIC HOT WATER THERMISTOR Diagram 18 7 18 Replacement of Parts 18 14 Heat exchanger refer to diagram 18 8 Before starting refer to the front of Section 18 Important information Remove the front panel refer to Section 15 3 e Lower the control panel refer to Section 15 4 Remove the sealed chamber cover refer to Section 15 5 Remove the combustion chamber cover refer to Section 15 7 Drain down central heating water circuit and domestic hot water cuircuit of the boiler only refer to relevant part of diagram 18 1 Remove the fan refer to Section 15 10 Remove the flue hood retained by two screws lift up and off Remove the electrical leads from the overheat thermostat ref
48. o the filling device on off knob this is a push fit see diagram 9 2 f DISCHARGE SAFETY VALVE 3 bar Diagram 9 1 FILLING DEVICE FILLING LOOP EXTENSION Diagram 9 2 2000225000B 10 Flue Installation Telescopic and Standard The Telescopic flue adjustable without cutting is suitable for installations that require a flue length from 425 minimum to 659 5 maximum There are no extensions or bends available for this flue The Standard flue suitable for side only adjustable by cutting is suitable for installations that require a flue length from 300 minimum to 930 maximum without extensions Note Additional 1 metre extentions 90 and 45 bends are available The maximum extended flue is 3m The use of flue bends requires the flue lengths to be reduced by 1m for 90 and 0 5m for 45 The boiler is only suitable for top outlet flue connection 10 1 Top outlet flue Telescopic kit A2004500 Standard kit 86285 10 2 Flue systems rear Telescopic Flue Extend to suit flue length required Max Std flue length 930mm Min Std flue length 300mm as Min Clearance 75mm Min Wall Thickness SIDE FLUE Diagram 10 1 2000225000B 10 3 Flue systems side Telescopic Flue Extend to suit flue length required Standard Flue Refer to diagram 10 1 10 4 Flue cutting Telescopic Flue The telescopic flue cannot be cut Standard Flue refer to diagram 10 2 Important Do not leave a
49. ow Apply a small amount of silicone grease to the O ring when fitting Remove the backing from the self adhesive gasket C and carefully fit gasket to base of flue elbow Leave the restrictor a fitted inside the fan outlet see diagram 10 6 Ensure transit plate has been removed from the fan outlet on top of the boiler Fit elbow onto boiler and secure with the four screws D Re fit the telescopic flue duct pipe to the flue elbow taking care not to tear the O ring fit the 2 securing screws Re fit the telescopic air duct pipe to the air elbow fit the 2 securing screws 10 6 Installation of standard flue assembly Ensure transit plate has been removed from the fan outlet on top of the boiler Fit rubber sealing collar F see diagram 10 4 into groove at the outer end of pipe A Fit air duct pipe A into wall with groove to the outside Pull pipe inwards to bring rubber sealing collar hard up against external wall see diagram 10 5 Fit internal plastic flange G onto air duct pipe Push along the pipe until engaged against internal wall From inside insert flue duct pipe B into air duct pipe Fitboth O rings J into the flue elbow C one atthe inlet one at the outlet By necessity they are a loose fit apply a small amount of silicone grease to each O ring when fitting Fixing collar D over air duct pipe A and elbow C ensuring itis the correct way round Not
50. rer s recommendations We strongly recommend regular servicing of your gas appliance but where the condition is not met any chargeable spare parts or components issued within the applicable guarantee period still benefit from a 12 month warranty from the date of issue by the manufacturer We recommend you complete and return as soon as possible your guarantee registration return literature supplied in the document envelope If your guarantee registration return literature is missing you can obtain a copy or record your registration by telephoning the Heatcall Customer Service number 01773 828100 REGISTER YOUR GLOW WORM APPLIANCE CALL 0208 247 9857 T Hepworth Heating Ltd Customer Services Nottingham Road Belper Derbyshire DE56 1JT Tel 01773 828100 General Sales enquiries One Contact Local Service Fax 01773 828070 Tel 01773 824141 Fax 01773 820569 Important Information Testing and Certification This boiler is tested and certificated for safety and performance It is therefore important that no alteration is made to the boiler without permission in writing from Hepworth Heating Ltd Any alteration not approved by Hepworth Heating Ltd could invalidate the certification boiler warranty and may also infringe the current issue of the Statutory Requirements The requirements are The installation of this boiler must be carried out by a competent person in accordance with the current rules in force
51. rom the document envelope Fit the self adhesive wiring diagram label to the inside of the front panel put front panel in a safe place to avoid damaging it Ensure the plastic plugs are removed from water and gas pipes NOTE There will be some spillage of water Fit water flow restrictor into cold water inlet isolating valve see diagram 18 4 Lift the boiler up and engage boiler upper part onto the hanging bracket Fit the washers between the boiler pipes and the inlet and outlet fittings on the fixing jig and connect the various couplings between the boiler and jig 15 9 4 Discharge safety valve refer to diagram 9 1 WARNING It must not discharge above an entrance or window or any type of public access area A short discharge pipe is supplied inthe fittings pack when fitted to the safety valve it will end below the boiler The discharge pipe must be extended using not less than 15 mm o d pipe to discharge in a visible position outside the building facing downward preferably over a drain Note Fit a compression fitting to facilitate service of the appliance The pipe must have a continuous fall and be routed to a position sothatany 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 5 Filling loop extension Remove the filling loop extension knob from the fittings kit Fit t
52. s correctly through the grommet Note Make sure that injector size marked on each injector is the same as that given in Section 1 Technical Data for the type of gas being used 18 10 Overheat thermostat Before starting refer to the front of Section 18 Important information e Remove the front panel refer to Section 15 3 Lower the control panel refer to Section 15 4 Remove the sealed chamber cover refer to Section 15 5 Locate overheat thermostat on left hand side of heat exchanger see part of diagram 18 8 Disconnect electrical connections from thermostat Unclip thermostat from heat exchanger Whenrefitting electrical connections to replacement thermostat the polarity is not important 18 11 Domestic hot water thermistor Before starting refer to the front of Section 18 Important information Remove the front panel refer to Section 15 3 Lower the control panel refer to Section 15 4 Locate domestic hot water thermistor on domestic hot water pipe to the left of centre of the boiler see part of diagram 18 7 Disconnect electrical connections from thermostat Unclip thermostat from flow pipe to the heat exchanger Whenrefitting electrical connections to replacement thermostat the polarity is not important 18 12 Ignition electrode Before starting refer to the front of Section 18 Important information Remove burner refer to Section 15 9 Remove the left hand side panel refer t
53. t from the electrical supply Contact your installation service company In case of power supply failure The boiler no longer operates As soon as power supply is restored the boiler will be automatically restarted If the gas supply is interrupted The boiler switches over to safety mode the red light will flash Call a qualified service engineer or Heatcall Glow worm s own service organisation using the telephone on the front cover of this literature Air in pipes Important A central heating system can not operate correctly unless itis filled with water and air bled from the system If these conditions are not met the system may be noisy Bleed the air in the radiators and adjust the pressure if system requires If the system requires filling to often this may be due to minor leaks or corrosion in the system Call a qualified service engineer or Heatcall Glow worm s own service organisation using the telephone number on the front cover of this literature Frost protection The 23c has a built in frost protection device that protects the boiler from freezing If the boiler is to be left and there is a risk of frost ensure that the gas and electrical supplies are left connected The frost protection device will light the boiler when the temperature of the boiler water falls below 6 C When the temperature reaches 16 C the boiler stops Note This device works irrespective of any room thermostat setting and will protect
54. the complete heating system Servicing and Maintenance To ensure the continued efficient and safe operation of the appliance it is recommended that it is checked and serviced as necessary at regular intervals The frequency of servicing will depend upon the particular installation conditions and usage but in general once a year should be enough If this appliance is installed in a rented property there is a duty of care imposed on the owner of the property by the current issue of the Gas Safety Installation and Use Regulations Section 35 Servicing maintenance should be carried out by a competent person in accordance with the rules in force in the countries of destination To obtain service please call your installer or Heatcall Glow worm s own service organisation using the telephone number behind the controls cover door Please be advised that the Benchmark logbook should be completed by the installation engineer on completion of commissioning and servicing All CORGI Registered Installers carry a CORGI ID card and have a registration number Both should be recorded in your boiler Logbook You can check your installer is CORGI registered by calling CORGI direct on 01256 372300 Cleaning The boiler casing can be cleaned with a damp cloth followed by a dry cloth to polish Do not use abrasive or solvent cleaners Boiler casing CAUTION Do not remove or adjust the casing in any way as incorrect
55. trols e g room thermostat frost thermostat etc should be fitted in accordance with the rules in force Refer to the wiring diagram Section 17 11 3 Testing Electrical Checks to ensure electrical safety must be carried out by a competent person After installation of the system preliminary electrical system checks as below should be carried out 1 Test insulation resistance to earth 2 Test earth continuity and short circuit of all cables 3 Test the polarity of the mains The installer is requested to advise and give guidance to the user of the controls scheme used with the boiler Note For further information see the building regulations 1991 Conservation of Fuel and Power 1995 edition appendix G Table 4b E Wire link VOLTAGE FREE HEATING CONTROLS pi CONNECTION n F PLUG Diagram 11 1 ines ee Sea VOLTAGE fy EXTERNAL CONTROLS S CONNECTION PLUG 230V CONTROLS BOARD CONTROL PANEL Diagram 11 2 19 2000225000B 12 Commissioning Please ensure the Benchmark logbook is completed and left with the user The commissioning and first firing of the boiler must only be done by a qualified registered person Gas installation It is recommended that any air is purged from the supply at the gas inlet test point on the gas valve see diagram 12 1 Filling the system 1 to 8 Make sure that wa 7 GAS INLET The boiler is connected to the e
56. uld be avoided The flow restrictor must be fitted limiting the flow through the boiler to a maximum of 10 l min The boiler will operate with a minimum supply pressure of 0 6 bar but under reduced flow rate Best operating comfort will be obtained from a supply pressure of 1 bar 4 1 Hard Water Areas In areas where the water is hard more than 200mgllitre it is recommended that a proprietary scale reducer is fitted in the cold water supply to the boiler 2000225000B 10 5 Boiler Schematic 9321 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 4 12 Ignition module 13 By pass 14 Gas valve 15 Loss of water sensor 16 Domestic hot water thermistor 17 Automatic air vent 18 Domestic water flow sensor 19 Filter cold water inlet 20 Filling system 21 Discharge safety valve 3bar 22 Heating filter 23 Drain valve 11 SOUS RRS A Heating flow B Domestic hot water outlet C Gas D Cold water inlet E Heating return 9720 Diagram 5 1 2000225000B 6 Boiler Location Flue and Ventilation If the appliance has to be stored for any length of time before installation it should be kept in a safe place where it will not be a hazard to persons or o
57. ving the correct flow and return format as shown in diagram 8 2 Do not subject the isolating valves to heat 8 7 Gas connection The supply from the governed gas meter must be of adequate size to provide a constant inlet working pressure of 20 mbar 8 in W g 2000225000B 14 Refer to Section 14 Boiler Filling device 9 Diagram 8 1 Additional expansion vessel if required Domestic sed nd D Cold supply in Hot water out Diagram 8 2 8 Piping System Installation To avoid low gas pressure problems itis recommended that the 15 mm gas supply on the boiler is connected to using 22 mm pipe as close as possible to the boiler within 1 metre On completion the gas installation must be tested using the pressure drop method and purged in accordance with the current issue of BS6891 Gas Safety Installation and use Regulations In your interests and that of gas safety it is the law that ALL gas appliances are installed and serviced by a competent person in accordance with the above regulations 9 Boiler Installation 9 1 Statutory requirements The installation of this boiler must be carried out by a qualified registered person in accordance with the relevant requirements of the current issue of The Gas Safety Installation and Use Regulations The Building Regulations The local water company Byelaws
58. xceeds the recommended weight for one man lift Diagram 18 22 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 referto the installation instructions Remove the front panel refer to Section 15 3 Lower the control panel refer to Section 15 4 Disconnect the mains cable and any external controls cables Drain down the boiler only refer to relevant parts of diagram Y 18 1 E EXPANSION For this operation the boiler must be removed from the wall VESSEL Disconnect the flue system Disconnect the union connections at the fixing jig Disconnect the pressure relief valve discharge pipe Lift up to remove the boiler from the wall From the rear of the boiler Undo pipe coupling on expansion vessel Undo and remove expansion vessel retaining nut Slide expansion vessel up to remove Note Check that expansion vessel pressure is correct see Section 1 Technical Data DISCHARGE SAFETY VALVE 3 bar gt L Diagram 18 23 Diagram 18 21 2000225000B 42 19 Spare Parts When ordering spare parts quote the part number and description stating the appliance model number and serial number from the data badge Short parts list OnDnDNARWNDH 2 e Description Central heating ther
59. y Boiler controls The control panel located at the lower front of the boiler casing see diagram 1 allows the boiler to be started shut down controlled and monitored during use Flue Do not obstruct the outside terminal of the flue Ancillary equipment A range of flue accessories are available including vertical flues twin pipe flues bends etc For further information contact your supplier Controls and lighting Your 23c boiler has been factory configured to operate at the heart of an existing installation However because many installations are specially designed do not hesitate to contact your installer who will be able to ensure that you get the best performance from your installation by adjusting the heating circuits maximum output or temperature Once these settings have been made you can still adjust the temperature to suit your needs Central heating adjustment The selector switch enables you to vary the temperature of the water in the central heating circuit from the minimum setting approx 38 C up to the maximum temperature set by your installer Most of the time the mid position will meet your needs but the selector should be moved nearer to the maximum setting in very cold weather when your home is not reaching the required temperature 2000225000B Domestic hot water The selector switch can be adjusted from a temperature of approx 35 C up to 60 C or more The ECO setting
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