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30ci Plus Installation & Service Manual Boilers - Glow-worm

1. 17 Routine Cleaning and Inspection BURNER RETAINING gt SCREWS we e BURNER a lon r a A GUIDE ET i 7 FR AIR PRESSURE T FLUE HOOD ih aia ni i Ih Hii Ait i Pi nth iin Ne a i lhl LN Hh wH HEAT EXCHANGER Diagram 17 7 Diagram 17 9 FAN RETAINING BOLTS r N DOMESTIC WATER INLET FILTER HOUSING FILTER Diagram 17 10 FILTER bd Diagram 17 11 4000123944 2 36 18 Fault Finding Before trying to operate the boiler make sure that e All gas supply cocks are open and that the gas supply has been purged of air e The heating system pressure is at least 1 bar Overheat thermostat reset button Refer to Section 20 11 to locate the overheat thermostat reset button Depress the button to reset e There is apermanent mains supply to the boiler and thatthe polarity is correct e The fuse on the PCB is intact WARNING Always isolate the boiler from the electrical Supply before carrying out any electrical replacement work a OVERHEAT Always check for gas soundness after any service work THERMOSTAT Should there be any doubt about the voltage supply to any of the components itis 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 RESET connections the continuity polarity short circuit and resistance to
2. e Remove the fan refer to Section 17 10 e Remove air pressure switch sensing tube from the side of the flue hood see diagram 17 9 e Release both side panels refer to section 17 6 e Remove the flue hood lift up and off When refitting ensure the rear of the flue hood locates in the tabs e Disconnect the electrical leads from the overheat thermostat e Remove the two pipe securing Clips e Liftto remove the heat exchanger taking care not to damage the insulation 20 15 Combustion chamber insulation refer to diagram 20 8 Before starting refer to the front of Section 20 Important information e Remove the front panel refer to Section 17 3 e Remove the sealed chamber cover refer to Section 17 5 e Remove the combustion chamber cover refer to Section 17 7 e Remove the heat exchanger refer to Section 20 14 e Pull out side insulation panels from combustion chamber e Tilt rear insulation panel forwards and out e Fit replacement insulation in reverse order to removal CONTROL BOARD COVER 20 Replacement of Parts 20 16 Printed circuit board PCB refer to diagram 20 9 Before starting refer to the front of Section 20 Important information e Remove the front panel refer to Section 17 3 e Lower the control panel refer to Section 17 4 e Gain access to rear of control panel e Undo and remove the two front retaining screws e Hinge up the control panel cover and ease forwards from the rear re
3. SCREW ATV EXPANSION VESSEL Diagram 20 28 20 Replacement of Parts SEALED CHAMBER COVER CASING PANEL Diagram 20 29 55 20 40 Sealed chamber cover seal refer to diagram 20 29 Before starting refer to the front of Section 20 Important information e Remove the front panel refer to Section 17 3 e Remove the sealed chamber cover refer to Section 17 5 e Remove the old seal thoroughly clean the casing Fitthe new Seal it is supplied to the correct length Note Ensure the seal is fitted correctly giving an air tight seal 4000123944 2 21 Spare parts When ordering spare parts quote the part number and description stating the appliance model number and serial number from the data label Short parts list No Description 1 Fan 2 Air pressure switch 3 Domestic water flow sensor 4 Printed circuit board Main 5 Pump head 6 System water pressure sensor 7 Gas control valve G20 8 Gas control valve G30 9 Discharge safety valve 10 Overheatthermostat 11 Ignition electrode 12 Flame sense electrode 13 230V controls board 14 PCB 15 Stepper motor G20 16 Stepper motor G30 17 Ignition unit 18 Three way valve head 19 Three way valve cartridge 20 Heat exchanger 21 Burner 22 Micro accumulator vessel 23 Micro accumulator vessel resistor Because of our constant endeavour for improvement details may vary slightly from those i
4. 15 mm DOMESTIC WATER 22mm GAS SUPPLY C H flow lt c Gas supply gt Cold water in gt c C H return gt Cf Diagram 8 1 8 5 Gas connection Gas Safety Installation and use Regulations In your interests and that of gas safety itis the law that ALL gas appliances are installed and serviced by acompetent person in accordance with the above regulations e The whole of the gas installation including the meter should be inpected tested for soundness and purged in accordance with the current issue of BS 6891 and in IE the current edition of S 813 Domestic Gas Installations 4000123944 2 9 Boiler Installation 9 1 Sheet metal parts WARNING When installing orservicing this boiler careshould 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 e 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 e Remove the self adhesive wiring diagram label from the KNURLED DISCHARGE document envelope Fit the self adhesive wiring diagram label UNION NUT SAFETY VALVE fi
5. 29 6 e Leave cap open on automatic air vent we te r 8 Ins 062a 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 Instructand demonstrate the lighting procedure and advise the user on the safe and efficient operation of the boiler Instructon and demonstrate the operation of any heatingsystem controls Advise the user on the use and maintenance of any scale reducer and pass on any relevant instructional documents Advise thatto ensure the continued efficientand safe operation of the boiler it is recommended that it is checked and serviced atregularintervals The frequency of servicing willdepend 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 Advisethe userofthe precautions necessary to preventdamage 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
6. CONNECTION WIRE LINK E Diagram 13 1 4000123944 2 13 1 Mains Cable Important If a replacement supply cable is required it must be purchased Part No S 1008600 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 BOILER TO MAIN PCE CONNECTOR J165 CONTAOLS INTERFACE PCB 00 NOT CONNECT VOLTAGE FREE HEATING CONTROLS CONNECTION OM CONTROLS Bok COVER OMWOFF F HF CS ji A MF T E ji Wil e G H 3 Ahir EXTERNAL HEATING j CONTRO POLE P b i SOLATOR L H ES DOUBLE 4 230v 50Hz PERMANENT MAINS INTERNAL PROGRAMMER SUPPI Y EXTERNAL POTENTIAL FREE ROOM THERMOSTAT Diagram 13 2 13 Electrical Connection 13 3 Mains Voltage External Controls WARNING UNDER NO CIRCUMSTANCES MUST ANY MAINS VOLTAGE BE APPLIED TO ANY OF THE TERMINALS ON THE VOLTAGE FREE HEATING CONTROLS CONNECTION TERMINAL When mains voltage external controls are used remove the MAINS VOLTAGE HEATING CONTROLS CONNECTION PLUG from the fitti
7. Please check orientation J when engaging bayonet spigot 10 3 Fan Removal refer to diagram 10 5 Diagram 10 6 e Disconnect power supply leads and earth lead from fan e Unscrew and remove the two fan retaining bolts e 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 8 Secure restrictor Supplied with flue pack to the flue hood as Shown in diagram 10 8 10 6 Fan Securing refer to diagram 10 5 Ensure fan outlet seal is in position see diagram 10 7 then fit the fan into the flue duct and secure to the flue collector with screws previously removed Replace chamber cover and secure with screws previously Diagram 10 7 removed RESTRICTOR Diagram 10 8 21 4000123944 2 11 Horizontal Telescopic Top Flue Installation The Horizontal Telescopic Top Flue Kit No O tO A2004500 o9 m Suitable for installations that require a flue length L from 430 SIDE FLUE 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 L cut this flue but use the horizontal top flue 86285H Note Additional 1 metre extensions 90 and 45 bends are m 0mm available The maximum extended flue is 3 5m The use
8. current temperature setting flashes e Press or to seta temperature between 38 c to 65 c e The display will default to normal after 5 seconds if no buttons are pressed 4000123944 2 Controls and lighting 4 Central heating temperature adjustment e Press button W twice a HH is displayed and the current temperature setting flashes e Press or to seta temperature between 38 c to 87 c e The display will default to normal after 5 seconds if no buttons are pressed 5 Heating Mode select e Press button ry three times MODE is displayed and 4 will flash along side the current mode setting e Press or to setas required e The display will default to normal after 5 seconds if no buttons are pressed 6 Long absence Holiday mode i This mode protects the boiler against frost 4000123944 2 7 If a fault occurs e The green running light will change to a red flashing light and the display will flash the letter F with the type of fault e Reset the boiler Switch the boiler OFF 0 wait for five seconds Switch the boiler ON 1 the boiler is reset If the fault continues call your Installation Servicing company or Glow worm Service using the telephone number on the inside front cover of this literature cl Ignition fault shown 8 Installation filling If the boiler
9. e Pull out the two slotted metal clips retaining the domestic water inlet filter housing e Remove domestic water inlet filter housing e Remove electrical connections from water flow sensor e 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 e Remove the front panel refer to Section 17 3 e Lower the control panel refer to Section 17 4 Drain down the boiler refer to relevant part of Section 20 1 e Remove electrical connections from water pressure sensor Pull off slotted metal clip and remove water pressure sensor a d WATER i FLOW SENSOR Diagram 20 14 49 4000123944 2 20 26 Bypass valve refer to diagram 15 1 20 Replacement of Parts Before starting refer to the front of Section 20 Important information e Remove the front panel refer to Section 17 3 e Lower the control panel refer to Section 17 4 Fii e 4 hai pe gra SYSTEM Drain down the boiler refer to relevant part of Section 20 1 i I WATER Pull out slotted metal clip ease out bypass valve from bypass b eee PRESSURE valve housing F l SENSOR 20 27 Automatic air vent refer to diagram 20 16 Before starting refer to the front of Section 20 Important information e Remove the front panel refer to Section 17 3 e Lower the control panel refer to Section 17 4 e Drain down
10. iq Q Q 79 O a i ab lt oO oO z _ oO ne T A x lt Nr D D V O i a a ro amp gt lt L Open 2 turns 1200 1400 10 kPa 1 m WG Diagram 3 1 3 1 Bypass Boiler Filling device Additional expansion vessel if required eThe 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 TABLE 1 FLOW RATE Domestic water 30ci plus 21 26 litres per minute This is equal to 20 C differential at maximum heat input Cold supply Bypass If required Return Heating circuit Drain point Diagram 3 2 control valve e A bypass is not required on the central heating circuit unless the system controls could allow the boiler to operate when there is no flow e Where a bypass has to be fitted the bypass must be placed at least 1 5 metres from the appliance see diagram 3 2 3 2 Filling the system A filling device is fitted to the boiler to initially fill the system and replace water lost during servicing see the relevant parts of diagram 2 controls and lighting and diagram 3 2 4 Domestic Hot Water System Design e Copper tubing or plastic Hep 0 may be used forthe domestic hot water system Unecessary pressure losses should be avoided e Provision shall be made for a drain valve at the lowest points of the system
11. pressure correct Check that the gas taps are fully open Check the gas pressure 11797 YES s the boiler actuall designed for the e Change the gas tpe for the boiler gas being used gas conersion kit YES e Clean the gas filter e Clean the burner 4000123944 2 40 9961 18 Fault Finding FAULT THE BURNER LIGHTS THEN GOES OUT The flame is spreading across the whole burner but not being detected CHECK CHECK ie THE MAINS PROBE of the wire e Check that the spark electrode is pointing towards the flame e Check the spark electrode Change it e With the power turned off check the continuity between the spark electrode and terminal H24 on the control board PCB Check the connector on the end FAULT NOT FOUND e f the problem persists change the 11798 control board PCB flame detection module faulty FAULT THE BURNER DOES NOT LIGHT AT ALL BUT THERE IS AN IGNITION SPARK Are the gas taps on me Turn on the gas taps YES s there c at the gas control valve NO hec the rng or testng see coponent testng ata the prole perssts change the YES e Test the gas control valve hec resstance o saet valve col FAULT THE ROOM TEMPERATURE IS INADEQUATE AND RADIATORS ARE LUKE WARM Is the room thermostat and or radiator set high enough and calling for duty NO s the heating power adequate Check the adjustment of the by pass internal and exte
12. 25 e 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 e Remove plate to plate heat exchanger from boiler e Fitreplacement plate to plate heat exchanger in reverse order to removal using new Seals supplied THREE WAY VALVE BYPASS HOUSING THREE WAY VALVE ACTUATOR Diagram 20 21 IGNITION UNIT Diagram 20 22 4000123944 2 Note Plate to plate heat exchanger mounting screws are offset to ensure correct fitting 20 35 Domestic safety valve 10 bar BLUE refer to diagram 20 24 Before starting refer to the front of Section 20 Important information e Remove the front panel refer to Section 17 3 e Lower the control panel refer to Section 17 4 e Drain down the hot water circuit only refer to relevant parts of diagram 20 1 DOMESTIC HOT WATER PLATE TO PLATE HEAT EXCHANGER DISCHARGE PIPE 11398 DOMESTIC SAFETY VALVE 10 BAR BLUE Diagram 20 24 20 Replacement of Parts e Undo discharge pipe union nut e Pullout slotted metal clip from valve body and remove valve 20 36 Micro accumulator vessel thermistor refer to diagram 20 25 Before starting refer to the front of Section 20 Important information e Locate micro accumulator vessel thermistor on top of the micro accumulation vessel e Disconnect the inline electrical connection plug to the micro accumulator ve
13. 29 mbar Maxi Bumer pressure 32 5 mbar Mini Bumer pressure 4 7 mbar Gas rate maximum 2 53 kg h 4000123944 2 10 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 acompetent person in accordance with the rules in force in the countries of destination Manufacturer s instructions must not be taken as overriding statutory requirements 2 1 Sheet Metal Parts WARNING When installing the appliance care should be taken to avoid any possibility of personal injury when handling sheet metal parts 2 2 Statutory Requirements The appliance is suitable only for installation in GB and IE and should be installed in accordance with the rules in force In GB the installation of the boiler MUST be carried out by a competent person as discribed in the following regulations Manufacturer s instructions supplied The Gas Safety Installation and Use Regulations The appropriate Building Regulations either The Building Regulations The Building Regulations Scotland The building Regulations Nothern Ireland The Water Fittings Regulations or Water Bylaws in Scotland The Health and Safety at Work Act Control of Substances Hazardous to Health COSHH The Current I E E Wiring Regul
14. 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 suitable lubricant to each O ring when fitting E e Fit elbow onto boiler and secure with the four screws l i 17mm X minus 90mm e Fitrubbersealing collar F into groove atthe outerend of pipe plus 17mm A cutting length Air duct cutting length Insertflue duct pipe B into innerend ofairduct pipe A rotate flue duct pipe to locate into groove inside air duct pipe e Fit air flue duct pipe assembly through the wall with rubber Y sealing collar to the outside fo Uf 7A e Fit internal plastic flange G onto air duct pipe A Ul Flue duct Air duct cutting length Air duct e Fitthe fixing collar seal D onto the flue duct pipe B ensuring it is the correct way round the larger diameter onto the pipe e Pullair flueduct pipe assembly inwards to bring rubbersealing 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 e Fit the fixing collar E around the fixing collar seal D and Flue duct cutting length secure with 2 screws provided air duct cutting length 95mm e Push the internal plastic flange G along the air duct pipe A l l until engaged against internal wall dimension cut en
15. Kingdom or Butane G30 Propane G31 with the appropriate conversion kit Theboilerhas a fan assisted balanced flue which both discharges the products of combustion to and draws the combustion air from the outside of the room Both the central heating and domestic hot water temperature are user adjustable Domestic hot water demand always has priority over heating demand The boiler is designed for use as part of a Sealed water central heating system with fully pumped circulation The pump expansion vessel and associated safety devices are all fitted within the boiler The boiler can be installed against either an external wall or on an adjacent inside wall thatis 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 thatit cannot be touched bya 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 1 S 813 Domestic Gas Installations and the current ETCI rules These instructions should be carefully followed forthe safe and economicaluseof your boiler The
16. Please quote the name of the appliance this infomation will be on the name badge on the front of the appliance If in doubt seek advice from the local gas company or Glow worm Service using the telephone number on the inside front cover of this booklet Controls and lighting Central heating adjustment The temperature of the water in the central heating circuit can be set between approx 38 C and 87 C Itis supplied factory set to 38 C 73 C Domestic hot water The temperature can be adjusted from approx 38 C up to 65 C 012 3 4 5 6 7 8 9 1011 12 13 14 15 16 17 18 19 20 21 22 23 24 EHEHE EEEE EEE 1 0 bar OFF ON switch 2 Display G Programing buttons 4 Running lamp illuminated green when boiler is ON flashing red when fault indicated 1 Lighting the boiler Make sure that e The boiler is connected to the electrical Supply e The gas service cock is open Switch ON I The running lamp will illuminate green 2 Stop the boiler e Switch to OFF 0 the electrical supply is OFF Bann 1234567 15 35 20 iti Timed central heating and f instantaneous domestic hot water iti A Central heating and domestic hot water A Domestic hot water only Central heating only Long absence Holiday mode and Appliance frost protection Diagram 2 3 Domestic hot water temperature adjustment OY once 1 e Press button once f is displayed and the
17. S PUMP CH RS A bk oly lt Sssq K ruel rit YL S LN T THERMISTOR CH CHASSIS EARTH nara THREE WAY J VALVE g VOLTAGE FREE HEATING CONTROLS PLUG CONTROLS BOARD p L REMOVE THE LINK IF FITTING g W VOLTAGE FREE OR 230V EXTERNAL CONTROLS IF THE LINK IS NOT REMOVED ees THE BOILER WILL RUN CONTINUOUSLY Ww FLOW SENSOR 10 J15 is E DB m es 2 eee E Le ot PE o j OO CCC ieee el eee J1 E E fe E M E D E E E E E a eee D ee ee eee D es ee ee eee CHASSIS bk BLACK br BROWN r RED w WHITE b BLUE or ORANGE ry br 230V 50Hz g y GREEN p PINK gn GREEN HH PERMANENT USER INTERFACE YELLOW g GREY y YELLOW N MAINS SUPPLY ON OFF aa FUSED AT 3A Remove the link if fitting voltage free or SWITCH 230V external controls If the link is not removed the boiler will run continuously 43 4000123944 2 11561a 20 Replacement of Parts To Drain the central heating circuit e Open drain valve fitted at the lowest point in the system Allow airinto the system by opening a radiator bleed screw orthe boilers drain valve f To Drain the Domestic hot water circuit BOILER DRAIN VALVE e Close boiler isolating valve d e Turn on one or more hot water taps To Drain the boiler e Close Isolating valves a d and e e Open the boiler drain valv
18. UserControls and Lighting section describes how to safely use the boiler Note The boiler serial number is marked on the data label attached to the rear of the control box Flue options There are various flue systems to choose from for detailed information refer to flue options guide which is available from your nearest stockist Accessories A range of accessories are available For further information contact your supplier 4000123944 2 Appliance Safety Devices Air flow rate safety device Ifthe flue is obstructed even partially the builtin 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 itis 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
19. and electric supplies ON and irrespective of any room thermostat setting the frost protection device will light the boiler when the temperature of the boiler water falls below 6 C When the temperature reaches 16 C the boiler stops Any other exposed areas of the system should be protected by a separate frost thermostat Heating safety valve CAUTION A heating safety valve with a discharge pipe is fitted to this boiler The valve MUST NOT BE TOUCHED except by a competent person If the valve discharges at any time switch the boiler off and isolate itfrom the electrical supply Contact yourinstallation service company Domestic Hot Water safety valve CAUTION A domestic hot water safety valve witha discharge pipe is fitted to this boiler The valve MUST NOT BE TOUCHED except by a competent person If the valve discharges at any time switch the boiler off and isolate itfrom the electrical supply Contact yourinstallation 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 boilercasing 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 i
20. carried out by a suitably qualified engineer Conversion natural Gas G20 to G30 G31 PartNo A2011900 Adjusting the step pressure This setting is used to adjust step pressure which may be necessary after gas conversion or after changing the gas control valve Settings 2 9 mbar Natural gas G20 4 41 mbar Butane G30 5 4 mbar Propane G31 Lock the boiler at minimum power as follows Press the mode button for about 10 seconds Use or to display code 96 Press the mode button to confirm The display idicates line 1 in the data menu The figure on the left is the data the one on the right is the setting for the data Scroll through the data using or until you reach 8 Press the mode button the figure on the right begins to flash Change it to 1 using or Press the mode button to confirm This mode will time out after 15 minutes Adjust the step pressure The factory set value is noted on the data label 4000123944 2 32 Press the mode button for about 10 seconds Use or to display code 35 Press the mode button to confirm The display idicates line 23 in the data menu The figure on the left is the data the one on the right Is the setting for the data Scroll through the data using or until you reach 24 Press the mode button the figure on the right begins to flash Change it to the required setting 0 to 199 using or Press the mode button to confirm Setting maximum burner p
21. e The flow restrictor must be fitted limiting the flow through the boiler to a maximum of 12 l min 4000123944 2 12 e The boiler will operate with a minimum supply pressure of 0 5 bar at reduced flow rate Best operating comfort willbe obtained from a supply pressure of 1 bar 4 1 Hard Water Areas In areas where the water is hard more than 200mg litre it is recommended that a proprietary scale reducer is fitted in the cold water supply to the boiler 5 Boiler Schematic WO CON DU BWN FE m 11 12 13 Fan Air pressure switch Heat exchanger Overheat thermostat Combustion chamber Expansion vessel Flame sense electrode Burner Ignition electrode Pump Heating thermistor Ignition unit By pass A Heating flow B Domestic hot water outlet C Gas D Cold water inlet E Heating return LLL LLL LLL LLL 13 Gas valve Loss of water sensor Domestic heat exchanger 3 way valve Domestic water flow sensor Filter cold water inlet Filling system Discharge safety valve 3bar Drain valve Heating filter Domestic safety valve 10 bar Micro accumulator vessel thermistor Micro accumulator vessel Heating element Q iA FITTED TO REAR OF APPLIANCE Diagram 5 1 4000123944 2 6 Boiler Location Flue and Ventilation 6 1 Boiler Location The recommended clearances are shown in diagram 6
22. earth checks must be repeated using a Suitable BUTTON multimeter Diagram 18 1 TYPE OF FAULT CHECK e 230V supply e PCB fuse e Connection between PCBs No display on control panel e Loose connections on control board PCB e Connections on air pressure switch electrical or tubes disconnected e Faulty control or interface board PCB s e Water pressure flashing pressure e Shortage of air or gas e Faulty temperature sensor e Overheating No domestic hot water No central heating warning light of fault code displayed on control panel 37 4000123944 2 18 Fault Finding COMPONENT TESTING DATA COMPONENT NORMAL MEASURE CHECK Gas control valve Under demand during ignition sparks If 0 Volt the gas control valve Resistance of coil 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 adjustment valve Adjustment valve Close the gas inlet If the valve does not move step motor Dismantle the step motor Screw not Check the connections at both sealed in Trigger a demand and check motor and control board PCB that the valve opens during the ignition Change the motor Replace the control board PCB Three way valve When heating is on If voltages are different Electrical supply to motor 230V ac between 1 and 2 of th
23. has been converted to use L P G Propane the following note applies Propane cylinders are under pressure and should never be stored or used indoors residentially They should only be kept outside Under no circumstances should L P G Propane cylinders be fitted or stored in basement areas or boiler houses On completion test the gas installation for soundness using the pressure drop method and suitable leak detection fluid purge in accordance with the above standard 3 Heating System Design e The 30ci plus is for use with sealed central heating systems e Heating surfaces may consist of radiators convectors or fan assisted convectors e The safety valves are an integral part of the boiler and cannot be adjusted e The circulation pump is integral with the boiler e 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 ofthe actual system not the maximum output of the boiler However provision shall be made to ensure sufficient flow so that the temperature difference between the flow and return pipes be less than or equal to 20 C The minimum flow is shown in Table 1 The system can be fitted with a lockable balancing valve if necessary in the main flow or return pipes shown as valve A in diagram 3 2 e The piping system shall be routed so as to av
24. loses water The green running light will change to a red flashing light and the display will flash the letter F with the low system water pressure fault and the Current system pressure e Fill the system by the filling device at the bottom of the boiler until the pressure gauge reads 1 0 bar vl Warning Take care not to overfill the boiler At a pressure of 2 5 bar or above the high system water pressure fault will be displayed The pressure must be reduced to 1 0 barby opening the drain valve see diagram 1 If the fault continues call your Installation Servicing company or Glow worm Service using the telephone number on the inside front cover of this literature Programmer instructions for use Setting the time Make sure there is an electrical supply to the boiler and the boiler is switched ON I Press button W four times O is displayed and the time will flash press or to set the correct time 24hr clock 11530 Setting the day Press button W five times is displayed and the current day setting will flash press or to set the correct day 1 MON 2 TUE 3 WED 4 THU 5 FRI 6 SAT 7 SUN O mM LA m m Setting the programmer Press button W six times PROG is displayed N mM LA m m press and ON PROG and the will be displayed along with 0 to 24 hour ON OFF settings and 1 to 7 days of the week Set ON OFF times at 30min interval
25. not affect the hot water output For kW to Btu hr conversion refer to table kW Btu hr kW Btu hr 10 34 120 20 68 240 12 40 940 22 75 060 14 47 110 24 81 890 16 54 590 26 88 710 18 61 420 28 95 540 Parameter 02 Setting the flue parameters This adjustment is made to ensure the boiler operates at maximum efficiency with longer flue lengths 4000123944 2 Factory setting 2 BEvVE20 2 B N e Select a parameter between and 12 according to the following table Flue parameters following maxi flue length Setting Horizontal Horizontal Verticale Horizontal TOP Flue REAR Flue TOP Flue TWIN Flue Lem 12 6 m T 155m 0 9m 23m 6m om 18 4 m 25m 2m 2m 0m 26m 55m 84m 25m am 71m 0m 15 Boiler Settings Parameter 3 Setting the minimum heating temperature This can be set to one of two values 38 C or 50 C Factory setting Parameter 4 Setting the maximum heating temperature This can be set to one of four values 50 C 73 C 80 C and 87 C oiL Factory setting Parameter 5 Pump operation This can be set to one of three values 1 intermittent with room thermostat 2 intermittent with burner 3 permanently on Factory setting 31 4000123944 2 16 Changing Gas Type Should it be necessary to change the gas type a conversion kit with instructions will be required This modification must only be
26. protection and pump saver program would not be operable Reminder leave these instructions and the Benchmark logbook with the user 4000123944 2 14 Commissioning Bypass The boiler has a built in bypass see diagram 15 1 The boiler is supplied with the bypass open half a turn It should not be necessary to adjust the bypass but if required ensure that under no circumstances does the flow rate fall below the figures specified refer to Table 1 and diagram 1 1 turn clockwise to close the valve Diagram 15 1 15 Boiler Settings Boiler settings for use by installers and Service Providers only Press the button hy and keep pressed for 10 seconds This gives access to both the operating parameters and the fault history D When the menu tis shown on display select code 96 using button or Press the button ty to show the first menu to be adjust Heating ouput Note The display will revert back to normal if no changes are made after 1 minute or if the button thy is again pressed for more than 10 seconds Parameter 1 Setting the heating output The maximum heating outputofthe boileris adjustable between the maximum and minimum values given in the Technical Data section Factory setting e When 1 flashing press on hy if you want to adjust this menu e Use the heating and button to set the desired heating Output in kW Note Adjustment of the heating output does
27. removed from the wall e IMPORTANT With regards to the manual handling operations 1992 regulations the following operation exceeds the recommended weight for one man lift e Remove the front panel refer to Section 17 3 e Lower the control panel refer to Section 17 4 e Drain down the boiler only refer to relevant parts of diagram 20 1 e Disconnect the flue system SLOTTED METAL CLIP MICRO ACCUMULATOR VESSEL HEATING ELEMENT SLOTTED METAL MICRO ACCUMULATOR VESSEL Diagram 20 27 4000123944 2 20 Replacement of Parts e Disconnect the boiler pipes at the fixing jig e Disconnect the pressure relief valve discharge pipe e Disconnectthe mains cable and any external controls cables Lift up to remove the boiler from the wall e Remove sealed chamber cover refer to Section 17 4 e Remove the combustion chamber cover refer to Section 17 5 e Remove the fan refer to Section 17 10 e Remove air pressure switch sensing tube from the side of the flue hood see diagram 17 9 e Release both side panels refer to Section 17 6 e Remove the flue hood lift up and off to release from rear location tabs e Remove the expansion vessel retaining screw From the rear of the boiler e Undo pipe coupling on expansion vessel e Lift to remove expansion vessel Note Check that expansion vessel pressure is correct see Section 1 Technical Data EXPANSION n VESSEL SECURING
28. than 15mm od to discharge in a visible position outside the building facing downward preferably over a drain IMPORTANT NOTE To facilitate servicing of the appliance the discharge pipe MUST ONLY be extended using the compression fittings supplied The pipes must have a continuous fall and be routed to a position so that any discharge of water possibly boiling or steam cannotcreate any dangerto persons damage to property or external electrical components and wiring Tighten all pipe connection joints 9 4 Filling loop extension The filling loop extension knob is supplied in the discharge Safety valve pipe connection pack Fitto the filling device on off knob this is a push fit see diagram 9 2 a E p p Finger tighten the knurled union nut Diagram 9 4 19 4000123944 2 10 Horizontal Telescopic Rear Flue Installation 10 1 Horizontal Telescopic Rear flue kit No A2018000 refer to diagram 10 1 Suitable for installations that require a flue length L 193 510mm For flue lengths less than 328mm the duct will need to be cut see diagram 10 2 To make a neat finish to the flue outlet a flue collar kit part No 900850 with instructions is available see diagram 10 3 Flue and Air Duct preparation Extend the telescopic flue to the required length making sure that the minimum overlap is no less than 25mm see diagram 10 2 and thatthe flue terminal projects 15mm minimum beyond the wall face Car
29. 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 1 S 813 Domestic Gas Installations The boiler must be installed so that the terminal is exposed to the external air 4000123944 2 14 300mm 50mm above boiler 600mm 450mm vote It is permissible to install the boiler with smaller clearances than those quoted PROVIDING that consideration is given for Servicing Repairs Diagram 6 1 6 Boiler Location Flue and Ventilation 6 2 Terminal guard see diagram 6 3 A terminal guard is required if persons could come into contact with the terminal or the terminal could be subject to damage If a terminal guard is required it must be positioned to provide a minimum of 50mm clearance from any partofthe 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 fl
30. 17 7 Combustion chamber cover e Unscrew and remove the two screws securing combustion chamber cover to combustion chamber see diagram 17 5 e Remove combustion chamber cover from boiler 17 8 Spark and Sense Gaps e Check that the spark and sense gaps as shown in diagram 17 6 Note To gain access to spark and sense electrodes for removal referto Section 20 12 and 20 13 in Replacement of Parts 17 9 Burner refer to diagram 17 7 e Unscrew and remove the two burner retaining screws e Remove burner from boiler by easing it forward off the two burner guides taking care not to damage the insulation e Clean burner by washing in soapy water Dry thoroughly before refitting Note To gain access to injectors for removal and cleaning refer to Section 20 9 17 10 Fan refer to diagram 17 8 e Disconnect power supply leads and earth lead from fan e Disconnect the electrical plug from the fan sensor e Unscrew and remove the two fan retaining bolts e Ease the fan down and forwards to remove 17 11 Heat exchanger refer to diagram 17 9 e Removeair pressure switch sensing tube from the side of the flue hood e Unscrew and remove the two retaining screws from front of each side panel e Unhook each panel from the front retaining tabs and ease outwards e Remove the flue hood When refitting ensure the rear of the flue hood locates in the tabs e Use a soft brush or vacuum clean the heat exchanger DO NOT USE ANY TOO
31. 4000123944 2 07 03 Instructions forUse InstallationandServicing To be left with the user 30ci plus G C No 4 7 047 22 Fanned Flue Combination Boiler low worm Quality through design Hepworth Heating Ltd Nottingham Road Belper Derbyshire DE56 1JT Guarantee Registration Thank you for installing a new Glow worm appliance in your home Glow worm appliances are manufactured to the very highest standard so we are pleased to offer our customers a Comprehensive Guarantee This product is guaranteed for 24 months from the date of installation or 30 months from the date of manufacture whichever is the shorter for parts In addition this product is guaranteed for 12 months from the date of installation or 18 months from the date of manufacture whichever is the shorter for labour The second year of the parts guarantee from the beginning of the 13th month onwards after installation is conditional upon the boiler having been serviced by a CORGI registered gas installer in accordance with the manufacturer s recommendations We strongly recommend regular servicing of your gas appliance but where the condition is not met any chargeable spare parts or components issued within the applicable guarantee period still benefit from a 12 month warranty from the date of issue by the manufacturer We recommend you complete and return as soon as possible your guarantee registration return literature Supplied in the document env
32. 7 3 Front panel e Unscrew and remove the two retaining screws from the bottom of the front panel e Remove front panel by lifting up and forward PRODUCTS SAMPLING alee SAMPLING POINT CAP wr view showing top of boiler Diagram 17 1 17 4 Control panel e Lower forwards to gain access to lower part of boiler 17 5 Sealed chamber cover e Unscrew and remove the two retaining screws from the sealed chamber cover see diagram 17 3 e 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 e Unscrew and remove the two retaining screws from front of each side panel e Left hand side panel only disconnect the control panel retaining strap at the control panel e Unhook each panel from the front retaining tabs e Pull each panel forward from the rear retaining tabs to remove 4000123944 2 17 Routine Cleaning and Inspection To Drain the Domestic hot water circuit es BOILER DRAIN VALVE e Close boiler isolating valve d i e Turn on one or more hot water taps To Drain the boiler e Close isolating isolating valves e and a e Open the boiler drain valve f my SA HEATING DOMESTIC HOT GAS SERVICE ace 7 HEATING FLOW WATER OUT COCK RETURN Note Isolating cocks water and gas are shown in the OFF position Diagram 17 2 Diagram 17 3 Diagram 17 4 4000123944 2 34 17 Routine Cleaning and Inspection
33. Fan refer to Section 17 10 Before starting refer to the front of Section 20 Important information e Remove the front panel refer to Section 17 3 e Remove the sealed chamber cover refer to Section 17 5 e Remove the fan refer to Section 17 10 20 3 Fan sensor refer to diagram 17 8 Before starting refer to the front of Section 20 Important information e Remove the front panel refer to Section 17 3 e Lower the control panel refer to Section 17 4 e Remove the sealed chamber cover refer to Section 17 5 e Disconnect the electrical plug e Remove the 2 fan sensor retaining screws e Remove the fan sensor 20 4 Air pressure switch Before starting refer to the front of Section 20 Important information e Remove the front panel refer to Section 17 3 e Remove the sealed chamber cover refer to Section 17 5 e Locate air pressure switch situated at the top right hand side see diagram 20 3 e Remove air pressure switch tube from sensing probe on flue hood Note Do not fit tube until the air pressure switch is in position e Disconnect air pressure switch electrical connections e Unclip to remove air pressure switch 20 5 Domestic water inlet filter If the water flow rate through the appliance has reduced it may be necessary to clean or replace the water inlet filter Before starting refer to the front of Section 20 Important information e Remove the front panel refer to Section 17 3 e Lower the con
34. L LIKELY TO DAMAGE PAINTED FINISH OF HEAT EXCHANGER 17 12 Domestic water inlet filter refer to diagram 17 10 If the water flow rate through the appliance has reduced it may be necessary to clean or replace the domestic water inlet filter e 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 e Open isolating valve c on cold water inlet and test the Domestic Hot Water circuit for soundness 17 13 Central Heating Filter refer to diagram 17 11 Remove the filter retaining clip and filter clean or renew if necessary Push the filter fully into its housing ensuring the correct orientation The flat and hole in the filteras shown Secure with retaining clip 35 17 14 Sealed Chamber Cover Seal Check Check the condition of the seal replace as required To replace remove the old seal thoroughly clean the casing Sufaces Fit the new seal it is supplied to the correct length see diagram 20 29 17 15 Combustion Chamber Insulation Check the condition of the combustion chamber insulation If renewing refer to Section 20 15 17 16 Flue system e Check externally to make sure that flue is not blocked e 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 SENSE GAP 4000123944 2
35. NTERFACE PCB VOLTAE FREE HEATIN CONTROLS CONNECTION ON CONTROLS BOX COVER REMOVE LIN HEN EXTERNAL CONTROLS ARE SE ONOFF SITCH EXTERNAL FROST THERMOSTAT MAINS VOLTAE HEATIN CONTROLS CONNECTION PLU PRORAMMER EXTERNAL ROOM THERMOSTAT i EXTERNAL bese JUNCTION BOX L _ _ INTERNAL PROGRAMMER EXTERNAL 230V AC ROOM THERMOSTAT EXTERNAL 230V AC FROST THERMOSTAT DOUBLE POLE ISOLATOR L N eS 230V 50Hz PERMANENT MAINS SUPPLY TO MAIN PCB CONNECTOR J5 CONTROLS INTERFACE PCB VOLTAE FREE HEATIN CONTROLS CONNECTION ON CONTROLS BOX COVER 4 EXTERNAL MAINS VOLTAE HEATIN CONTROLS EXTERNAL CONNECTION PLU Room THERMOSTAT REMOVE LNK HEN EXTERNAL CONTROLS ARE SE ONOFF EXTERNAL JUNCTION BOX EXTERNAL PROGRAMMER CLOCK DOUBLE POLE ISOLATOR EXTERNAL 230V AC ROOM THERMOSTAT LN et 230V 50Hz EXTERNAL 230V AC FROST THERMOSTAT PERMANENT MAINS SUPPLY Diagram 13 5 4000123944 2 Important The commissioning and firstfiring of the boiler must only be done by a competant person Gas installation If conversion from G20 to 30 or 31 Is required refer to section 16 Itis recommended that any air is purged from the supply at the gas purge point on the gas valve see diagram 14 1 Filling the system 1 to 8 l Make sure that e The boiler is connected to the electrical supply e The gas service cock is open Switch OFF 0 2 e
36. Open the three water isolating valves HEATING RETURN HOT WATER OUTLET 3 e Undo cap on automatic air vent on top of pump and leave undone Otte ee et E 4000123944 2 DOMESTIC GAS SERVICE COCK 14 Commissioning Air in pipes Important A central heating system can not operate correctly unless itis filled with water and air bled from the system Ifthese conditions are not met the system may be noisy Bleed the air in the radiators and adjust the pressure if system requires Ifthe system requires filling to often this may be due to minor leaks or corrosion in the system BURNER PRESSURE POINT GAS PURGE POINT COLD WATER INLET HEATING FLOW 4 e Turn the switch ON 1 e Open the tap on the filling device e Fill the system until the pressure indicated on the display is 1 bar Close filling device i NOTE On initial fill there may be a small discharge of water from the Reduced Pressure Zone valve 14 Commissioning 5 e Bleed each radiator to remove air ensure all bleed screws are re tightened e If necessary repressurise the system refer to procedure k F 4 i Ins O0O61la 7 e Ensure the display indicates a system pressure of 1 0 bar adjust if necessary Adjust heating temperature to maximum e 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 a
37. ations 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 1 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 Lid could invalidate the warranty and could also infringe the current issue of the Statutory Requirements 2 3 Gas Supply The gas installation must be in accordance with the relevant standards In GB this is BS 6891 In IE this is the current edition of 1 813 Domestic gas installation The supply from the governed meter must be of adequate size to provide a steady inlet working pressure of 20mbar 8in wg at the boiler Important Notice If your boiler
38. d Diagram 12a 3 Horizontal Top flue system The maximum permissible length L is 3 5 m For each 90 flue elbow used or two 45 elbows the maximum permissible length L must be reduced by 1 metre Diagram 12a 4 25 4000123944 2 13 Electrical Connection WARNING This appliance must be earthed This appliance must be wired in accordance with these instructions Any fault arising from incorrect wiring cannot be putrightunderthe terms of the Glow worm guarantee Allsystem components must be of an approved type Electricalcomponents 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 commonisolator Isolation should preferably be by a double pole switched fused Spurbox having a minimum contactseparation of 3mm on each pole The fused spur box should be readily accessible and preferably adjacentto the boiler Itshould 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 RETAINING SLOTS CONTROLS PANEL REAR COVER gH SECURING SCREW 3 Il Pi VOLTAGE FREE HEATING CONTROLS
39. d forsome time coverthe hole in the wall 8 2 Rear Flue Internal Installation Only Referto Horizontal Telescopic RearFlue 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 e 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 e 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 notsubjectthe isolating valves to heat from blowlamp when making connection Connectthe system pipework to the fixing jig connection pipes and the fixing jig isolating valves observing the correctflow and return as shown in diagram 8 1 REAR TOP FLU OUTLET E 145 J a80 min REAR FLUE OUTLET NOTE MINIMUM CLEARANCES refer diagram 6 1 1 S D H W hot out lt 0 O 22 mm CENTRAL HEATING
40. d remove pipe from tap 20 Replacement of Parts l 20 22 Reduced pressure zone valve RPZ REDUCED PRESSURE refer to diagram 20 12 ZONE VALVE RPZ Before starting refer to the front of Section 20 Important information e Remove the front panel refer to Section 17 3 e Lower the control panel refer to Section 17 4 Drain down the boiler only refer to relevant part of diagram 20 1 e Pull out slotted metal clip securing pipe to RPZ e Pull outslotted metal clip securing RP Z into housing remove 20 23 Boiler drain point refer to diagram 20 13 Before starting refer to the front of Section 20 Important a information FILLING TAP e Remove the front panel refer to Section 17 3 Diagram 20 12 e Lower the control panel refer to Section 17 4 e 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 ik BOILER DRAIN Fave 20 24 Water flow sensor refer to diagram 20 14 Before starting refer to the front of Section 20 Important information e Remove the front panel refer to Section 17 3 e Lower the control panel refer to Section 17 4 Diagram 20 13 Drain down the hot water circuit refer to relevant part of Section 20 1 e Undo the union nut on the cold water inlet isolating valve e Pull out slotted metal clip securing filling system tap into housing swing the tap forwards
41. e f e Turn on one or more hot water taps b c d HEATING DOMESTIC HOT GAS SERVICE COLD WATER HEATING FLOW WATER OUTLET COCK INLET RETURN Note Isolating cocks water and gas are shown in the OFF position 9 9 P Diagram 20 1 IMPORTANT INFORMATION WARNING Before commencing the replacement of any component isolate appliance from electrical supply and turn off gas at service cock wom CENTRAL HEATING THERMISTOR Replacement of parts must be carried out by a competent person When replacing components it may be necessary to renew sealing washers gaskets and O rings If new ones are Supplied with replacement components they must be used All parts are replaced in reverse order to removal If any gas carrying components are disturbed removed or replaced it will be necessary on completion to check for gas soundness with leak detection fluid 20 1 Central heating thermistor Before starting refer to the front of Section 20 Important information Diagram 20 2 e Remove the front panel refer to Section 17 3 e Unclip thermistor from pipe e Lower the control panel refer to Section 17 4 e Disconnect electrical connections from thermistor e Locate central heating thermistor on heating flow pipe on Fit electrical connections to replacement thermistor and fit centre of boiler see diagram 20 2 thermistor to pipe The polarity is not important 4000123944 2 44 20 Replacement of Parts 20 2
42. e motor Connections 0Q between 1 and 3 About 25V ac to 35V ac between 2 and 3 Control board PCB 9 6kQ between 1 and 2 When hot water Is on Three way valve lead 9 6kQ between 1 and 3 230V ac between 2 and 3 of the motor 1 2 and 3 marked on About 25V ac to 35V ac between 1 and 2 the motor Thrust action of the motor Unfasten the clip YES no risk of water If electrical Supply is OK remove gas control valve leak pull out the motor and leave it but the spindle does not move before testing plugged in Replace the motor or replace When hot water is on the spindle should the control board PCB pull in When heating is on the spindle Should push out Domestic water flow To test Use a new detector and connect it electrically in place of the faulty one Blow through to Simulate a demand for water 4000123944 2 38 18 Fault Finding spark and F and flashing red LED Ignition fault lockout caused by no gas no detection fan and F and flashing red led 05 and phone and F and flashing red LED 06 and phone and F and flashing red LED 08 and phone and F and flashing red LED 09 and phone and F and flashing red LED 11 and phone and F and flashing red LED 12 and phone and F and flashing red LED 13 and phone and F and flashing red LED 14 and phone and flashing red LED 15 and phone and F and flashi
43. efully drill though air duct pilot hole and secure with self tapping screw provided in fittings pack Seal the joint with the tape provided Fitthe self adhesive foam Seal provided in the flue pack around the airduct ata 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 notstick outinto the room Do notpush the flue assembly too far into the hole as it has to be pulled back into the boiler and secured Now continue with Fixing Jig and system connections see section 8 then complete the flue installation as described in the following paragraphs 10 2 to 10 6 10 2 Sealed chamber cover e Unscrew and remove the two retaining screws from the sealed chamber cover see diagram 10 4 e Lift cover up and off pins on top of boiler The flue kit No A2018000 compnises Telescopic flue assembly Foam seal Screws 6 off Restrictor flue hood outlet Horizontal Rear Telescopic flue kit Diagram 10 1 4000123944 2 NOTE If itis necessary to cutthe flue length make sure that the overlaps are as follows air duct 25mm flue duct 50mm L FLUE LENGTH Y WALL THICKNESS 133mm FOAM SEAL Diagram 10 2 Pho 087 10 Horizontal Telescopic Rear Flue Installation TWIST avre cvockmise D OSITION a POWER SUPPLY LEADS NOTE
44. elope 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 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 1 T Glow worm IE Ireland Tel 00 353 0 1630575 7 Fax 00 353 0 16305 24 C amp F Quadrant Ltd Quadrant House Chapelizod Dublin 20 Technical Advice Line Tel 00 44 0 1773 828300 General and Sales enquiries Tel 01773 824141 Fax 01773 820569 CE 4000123944 2 2 The code of practice for the installation commissioning amp servicing of gas central heating Contents CONTENTS INSTRUCTION FOR USE INSTALLATION INSTRUCTIONS SERVICING INSTRUCTIONS DESCRIPTION Important Information Draining and Filling Appliance Introduction Appliance Safety Devices Maintenance and Servicing Controls and Lighting Programmer instructions for use Technical Data General Information Heating System Design Domestic Hot Water System Design Boiler Schematic Boiler Location Flue and Ventilation Fixing J ig Boiler Preparation and System Connections Boiler Installation Horizontal Telescopic Rear Flue Installation Horizontal Telescopic Top Flue Installation Horizontal Top Flue Installation Electrical Connection C
45. embly to the burner injector assembly see diagram 20 6 e Disconnect the electrical connections at the ignition unit see diagram 20 22 Note the routing of the cables 20 13 Flame sense electrode Before starting refer to the front of Section 20 Important information 4000123944 2 46 ae BURNER INJ ECTOR skis BAR Diagram 20 5 GROMMET GAS SUPPLY PIPE SENSE ELECTRODE IGNITION ELECTRODE SPEME ASSEMBLY OVERHEAT THERMOSTAT ELECTRICAL LEADS PIPE SECURING CLIP 2 OFF EXCHANGER p Diagram 20 7 e Remove the front panel refer to Section 17 3 e Lower the control panel refer to Section 17 4 e Remove the sealed chamber cover refer to Section 17 5 e Remove the combustion chamber cover refer to Section 17 7 e Remove burner refer to Section 17 9 e Remove the left hand side panel refer to Section 17 6 e Undo and remove screw securing sense assembly to the burner injector assembly see diagram 20 6 e Disconnectthe electrical connection from the inline connector Note the routing of the cable 20 14 Heat exchanger refer to diagram 20 7 Before starting refer to the front of Section 20 Important information e Remove the front panel refer to Section 17 3 e Remove the sealed chamber cover refer to Section 17 5 e 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
46. essel 20 38 Micro accumulator vessel heating element refer to diagram 20 27 Before starting refer to the front of Section 20 Important information e Drain hot water circuit only e Remove the micro accumulatior vessel refer to Section 20 37 e Lower the control panel refer to Section 17 4 e Gain access to rear of control panel see diagram 20 9 e Disconnect the electrical connection plug to the micro accumulator vessel heating element at the control board PCB connection H4 see diagram 20 9 e Release the micro accumulator vessel heating element cable from the securing clips note the routing of the cable for reassembly e Pull out micro accumulator vessel thermistor securing clip and remove thermistor from heating element 20 39 Expansion vessel refer to diagram 20 28 Renewal of the expansion vessel requires the boiler to be removed from the wall As an alternative a separate expansion ACCUMULATOR THERMISTOR P Diagram 20 25 Bend back securing tab to release micro accumulator vessel i MICRO _ ACCUMULATOR VESSEL k m A To i a i vik gt m m y si a Diagram 20 26 4000123944 2 vessel ofthesame specification may be connected as close as possible to the boiler leaving the originalin position referto the installation instructions Replacing the expansion vessel Before starting refer to the front of Section 20 Important information e For this operation the boiler must be
47. f Section 20 Important information e Remove the front panel refer to Section 17 3 e Lower the control panel refer to Section 17 4 e Remove the sealed chamber cover refer to Section 17 5 Removethe combustion chamber cover referto Section17 7 e Remove burner from boiler refer to Section 17 9 e Remove and replace injectors as required Note The injectors may be cleaned remove injectors inspect and clean Do not use a wire or sharp instrument Note Make sure that injector size marked on each injector is the same as that given in Section 1 Technical Data for the type of gas being used 4000123944 2 20 E of Parts 20 10 Burner injector assembly refer to diagram 20 5 and 20 6 Before starting refer to the front of Section 20 Important information e Remove the front panel refer to Section 17 3 e Lower the control panel refer to Section 17 4 e Remove the sealed chamber cover refer to Section 17 5 Remove the combustion chambercover referto Section17 7 e Remove burner from boiler refer to Section 17 9 e 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 e Undo and remove thesense and ignition electrode assemblies e Remove the burner injector assembly securing screws e Remove the burner injector assembly by lifting up easing the gas connection through t
48. he grommet in the sealing chamber Note Take care not to damage the insulation e When refitting burner injector assembly ensure the gas connection locates correctly through the grommet Note Make sure that injector size marked on each injector is the same as that given in Section 1 Technical Data for the type of gas being used 20 11 Overheat thermostat Before starting refer to the front of Section 20 Important information e Remove the front panel refer to Section 17 3 e Remove the sealed chamber cover refer to Section 17 5 e Locate overheat thermostat on heating flow pipe on right hand side of boiler see part of diagram 20 7 e Disconnect electrical connections from thermostat e 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 e When refitting electrical connections to replacement thermostat the polarity is not important 20 12 Ignition electrode Before starting refer to the front of Section 20 Important information e Remove the front panel refer to Section 17 3 e Lower the control panel refer to Section 17 4 e Remove the sealed chamber cover refer to Section 17 5 e Remove the combustion chamber cover refer to Section 17 7 e Remove the burner refer to Section 17 9 e Remove the right hand side panel refer to Section 17 6 e Undo and remove screw securing electrode ass
49. ification that we require Do not use reconditioned or copy parts that have notbeen clearly authorised by Hepworth Heating To ensure the continued efficient and safe operation of the boiler it is recommended that it is checked and serviced at regular intervals The frequency of servicing will depend upon the particular installation conditions and usage but in general once a year should be enough It is the law that any servicing is carried out by a competent person 17 1 Products of combustion check Top Flue To obtain a products of combustion reading unscrew the left hand sampling point cap on the flue elbow located on top of boiler see diagram 17 1 Rear Flue To obtain a products of combustion reading unscrew the sampling point cap on the flue spigot located between the boiler and the wall see diagram 17 1 Connect the analyser tube onto sampling point Referto the combustion product values in Section 1 Technical Data Switch on the electrical supply and gas supply then operate the boiler On completion of the test switch off the electrical supply and the gas supply remove analyser tube and replace sampling point cap 17 2 Service Check and Preparation e Isolate boiler from the gas and electrical supplies Drain the Domestic hot water cuircuit and the boiler refer to diagram 17 2 e On completion check all gas carrying parts for soundness with leak detection fluid e Remove boiler casing as follows 1
50. l be connected in accordance with the current issue of BS 7671 and any applicable local regulations 4000123944 2 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 at3A maximum This method of connection must be bya fused double pole isolating switch with a minimum contactseparation 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 BS 1363 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 notless than 0 75mm 24 0 20mm Gas leak or fault WARNING Ifa 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 o
51. ll radiator valves open The temperature rise will cause release of the air contained in the water of the central heating system e Air driven towards the boiler will be automatically released through the automatic air vent e The air trapped at the highest point of the system must be released by bleeding the radiators Check the burner gas rate required ten minutes from lighting Refer to Data Label on electrical controls box Should there be any doubtaboutthegas rate it should be checked at the meter Onreaching maximum temperature the boilershould be turned offand the system drained as rapidly as possible whilst still hot e Refill system to a pressure of 1 5 bar and vent as before e Restart boiler and operate until a maximum temperature is reached If necessary refer to page 30 to adjust the bypass Shut down boiler and vent heating system If necessary top up heating system and make sure that a pressure of at least 1 bar is indicated when system is COLD Flush the domestic hot water system by opening the hot water taps for several minutes Completion Remove the magnetic user instructions label from the document envelope and position it on the surface of the boiler casing Adjust the boiler temperature control and any system controls to their required settings ForlE itis necessary to complete a Declaration of Conformity to indicate compliance to S 813 An example of this is given in the current edition of 1 S 813
52. lve 11940a Wall template 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 v 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 APPLIANCE 230V External controls connection plug HANGING BRACKET Bag containing 3 x 22mm Installation connection pipes 2 x 15mm Installation connection pipes Bag containing 4x 22mm boiler connection pipes 1x15mm boiler connection pipe FIXING JIG Inclusive Isolating Valves Bag containing 4x 15mm fibre washers Shown as x in diagram 4x 22mm fibre washers large bore Shown as y in diagram 5 x 22mm fibre washers small bore shown as z in diagram oJ CO AN i NE oe Sealing Washers 30ciplus Description V 1 1 15 mm Gas valve Connection only w 46 22mm smalbore 5 x w Y 3m 22mm tagebore The quantity shown in bracket denote
53. mum heating temperature 87 C Expansion vessel effective capacity 8 litres Expansion vessel charge pressure 0 5 bar Maximum system capacity at 75 C 156 litres Safety valve maximum service pressure 3 bar Hotwater Heat input max NETQ 32 6 kW 111 231 BTU H Heat input min NETQ 12 5 kW 42 650 BTU H Heat output max NETP 29 6 kW 100 995 BTU H Heat output min NET P 10 3 kW 34 155 BTU H Maximum hot water temperature 65 C Minimum hot water temperature 38 C Specific flow rate for 35 C temp rise 12 1 litres min ia Threshold flow rate 1 7 litres min 450 ere Maximum supply pressure 10 bar Minimum supply pressure 0 5 bar The 30ci plus is delivered in two separate Combustion packages Products outlet diameter 60 mm Fresh air inlet diameter 100 mm e The boiler including fixing jig complete with Combustion productsvalues CO 40ppm isolating valves and fittings OU J g o d gs NOx 81ppm e flue system Electrical Diagram 1 1 Electrical supply 230 V 50Hz Electncal rating 122 W fused at 3A Level of protection IPX4D Fuse rating 1 25mA Natural Gas G20 Bumer injector 1 2 mm Inlet pressure 20 mbar Maxi Bumer pressure 13 3 mbar Mini Bumer pressure 2 15 mbar Gasrate maximum 3 45 m h Butane Gas G30 Bumer injector 0 73 mm Inlet pressure 29 mbar Maxi Bumer pressure 25 5 mbar Mini Bumer pressure 4 7 mbar Gas rate maximum 2 53 kg h Propane Gas G31 Bumer injector 0 73 mm Inlet pressure
54. n the instructions 4000123944 2 Part No 802037 801862 801910 801915 801857 801911 801891 801978 801904 801913 801888 801887 801923 802038 801892 801979 801936 801912 801903 801853 801854 802026 802027 56 G C No E94 796 E92 063 E84 014 E91 904 E92 064 E83 997 E91 945 E92 058 E84 000 E91 949 E91 917 E91 922 E84 018 E94 797 E91 924 E92 059 E91 960 E88 839 E88 838 E92 054 E92 057 E94 802 E94 801
55. ng red LED 16 and phone and F and flashing red LED 17 and phone and F and flashing red LED 18 and phone and F and flashing red LED 19 and phone and F and flashing red LED 0 5bar flashing and F and flashing red LED Lack of water fault lt 0 5b 2 7bar flashing and F and flashing red LED Upper water pressure gt 2 7b FAULT NO HEATING pee ia heating Rectify fault on external controls controls calling for heat YES Rectify check the 230V 9 J Is the polarity correct coniro s Doar YES aulty main PCB does boiler fire in central heating y 10301 YES Faulty 230V controls board 39 4000123944 2 11669 18 Fault Finding FAULT NO HOT WATER BUT THE HEATING IS WORKING Is the water pressure greater apr rae teas than 0 5 bar e appliance will not operate YES Find out why the pressure is so low Is the water flow rate greater Check the cold water inlet filter l for dirt Is the cold water tap fully open A rE O UE Check the heat exchanger for scaling Change or clean it Is flow detector operating YES Check the connectors on the flow sensor and the control board PCB lf 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 the sensing electrode Is the gas
56. nger tighten only PIPE 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 rearofthe appliance having first moved and secured the blanking plate to the top outlet e Ensure the plastic plugs are removed from water and gas pipes NOTE There will be some spillage of water e 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 E Diagram 9 1 the recommended weight for one man lift e Liftthe boiler up and engage boiler onto the hanging bracket refer to diagram 7 1 e Fit the boiler jig connection pipes and washers between the boiler and isolating valves see diagram 7 1 FILLING DEVICE FILLING LOOP EXTENSION Diagram 9 2 Diagram 9 3 4000123944 2 18 9 Boiler Installation l 9 3 Heating safety valve 3 bar RED and domestic safety valve 10 bar BLUE discharge refer to diagrams 9 4 HEATING SAFETY DOMESTIC SAFETY VALVE 3 bar RED VALVE 10 bar BLUE Two short discharge pipes and washers are supplied in the fittings pack fit these to the heating safety valve 3 bar and the domestic water safety valve 10 bar The discharge must be extended using pipe not less
57. ngs 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 see diagram 13 3 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 outofthe 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 RETAINING LATCHES rvs l i CONTROLS INTERFACE PCB EXTERNAL CONTROLS CABLE MAINS VOLTAGE Diagram 13 3 21 STRAIN RELIEF EXTERNAL CONTROLS CABLE Diagram 13 4 TO MAIN PCB CONNECTOR J5 CONTROLS I
58. of flue bends requires the max extended flue lengths to be reduced by MES _ 1m for 90 and 0 5m for 45 65mm 11 1 Horizontal Telescopic Top Flue Le Kit of parts refer to diagram 11 1 Top oi boiler 11 2 Horizontal telescopic flue system eqengnot front panel Rear and side flue lengths and dimensions see diagram 11 2 Drill Screw and Tape not supplied 20mm referto diagram 6 1 Min Clearance REAR FLUE The flue kit A2004500 is 660 mm long and comprises Telescopic flue assembly Fixing collar seal Fixing collar 65mm Extemal rubber sealing collar F Screws 6 off Screws 4 off Note Top of boiler supplied in plastic bag casing not front panel Telescopic Top flue kit Diagram 11 1 Diagram 11 2 4000123944 2 22 11 Horizontal Telescopic Top Flue Installation 11 3 Installation of telescopic flue assembly e Remove the elbow D and the telescopic flue assembly A from the flue kit Referto Step 1 diagram 11 3 Fitthe 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 e Refer to Step 2 diagram 11 3 Remove the telescopic flue assembly A from the prepared hole in the wall make sure the air duct is extended to its required length The flue duct at the elbow end must protrude 25mm Drill secure with two screws and tape to secure the air d
59. oid 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 11 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 barand 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 e Provision shall be made fora drain valve at the lowest point of the system e Where thermostatic radiator valves are fitted notall radiators must be fitted with this type of valve and in particular where a room thermostat is installed e Inthe case of an existing installation itis ESSENTIAL thatthe system is thoroughly flushed prior to installing the new boiler Using aproprietary productsuchas FernoxorSentinel Contact the product manufacturers for specific details 4000123944 2 3 Heating System Design Bypass fully shut a ae Open 1 4 turn M MM 4 i ae Aa n a Um ies m 7 z Open 1 2 turn SS 7 600 800 1000 Flow rate through heating system I h Open 1 turn k oO a O Cc
60. ommissioning Boiler Settings Changing Gas Type Routine Cleaning and Inspection Fault Finding Wiring Diagram Replacement of Parts Spare Parts SECTION WO COND UBWN FE PAGE No O N O UI UU A 4000123944 2 Important Information Gas safety Installation and use Regulations In your interests and that of gas safety itis the law that ALL gas appliances are installed and serviced by acompetent 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 requirement
61. p Flue Installation 12a 1 The Horizontal Top flue kit 86285H Suitable for installations that require a max flue length L of 740mm If a shorter flue length is required the flue can be cut to a min length L of 260mm rear or 300mm side See diagram 12a 2 for min flue lengths SIDE FLUE 11886a 12a 2 Flue systems rear and side refer to 70mm diagram 12a 1 2 65mm Note Top of boiler casing not front panel 12a 3 Flue cutting refer to diagram 12a 3 Important Do not leave any burrs or sharp edges on the cut ends ofthe pipes 20mm refer to diagram 6 1 E Min Clearance REAR FLUE The flue kit 86285H is 810 mm long and compnses Air duct pipe Flue duct pipe Fixing collar seal Fixing collar External rubber sealing collar Internal flange Gasket 65mm Note Horizontal Top flue kit Diagram 12a 1 Top of boiler casing not front panel Diagram 12a 2 4000123944 2 24 12 Horizontal Top Flue Installation 12a 4 Installation of horizontal top flue assembly Outside Flue Important If the flue has been cut ensure that there are no wall face centre line burrs that could damage the O ring e For flue systems less than 0 5 m long fit the flue restrictor a into the fan outlet see diagram 10a 4 e Remove the backing from the self adhesive gasket H and carefully fit gasket to base of elbow C e
62. per motor e Remove the two screws securing stepper motor to the gas control valve e Fit replacement gas control valve stepper motor A F e Note Take care not to damage the O ring Diagram 20 17 4000123944 2 50 20 Replacement of Parts l 20 30 Heating safety valve 3 bar RED refer to diagram 20 19 Before starting refer to the front of Section 20 Important information e Remove the front panel refer to Section 17 3 j i GAS CONTROL e Lower the control panel refer to Section 17 4 f E VALVE Drain down the boiler only refer to section 20 1 e Undo discharge pipe union nut e Pull out slotted metal clip from valve body and remove valve lt a a Ss STEPPER 20 31 Three way valve head refer to diagram a sce MOTOR 20 20 Before starting refer to the front of Section 20 Important information e Remove the front panel refer to Section 17 3 e Lower the control panel refer to Section 17 4 Diagram 20 18 e For ease of access remove the right hand side panel refer to Section 17 6 e Remove electrical plug from valve head e Pull out slotted metal clip from valve body and remove valve head from body e Fit replacement valve head in reverse order to removal i Note _ mos PRESSURE i da DE S RELIEF 1 When refitting clip ensure that letters YES are as shown pi j a s VALVE 2 It is not necessary to drain boiler to carry out this work 20 32 Three way valve act
63. r 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 orcorrosion taking place Call yourInstallation Servicing company Protection Against Freezing The appliance has a built in frost protection programme as long as the electricity and gas are left switched on This device operates the burner and system pump when the temperature inside the boiler falls below 6 C Any other exposed areas of the system should be protected by a separate frost thermostat 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 free
64. ressure This setting is used only to reduce burner pressure at maximum setting if the network pressure is constantly higher than normal pressure Settings 12 2 mbar Natural gas G20 23 2 mbar Butane G30 29 8 mbar Propane G31 Lock the boiler at maximum burner pressure as follows Press the mode button for about 10 seconds Use or to display code 96 Press the mode button to confirm The display idicates line 1 in the data menu The figure on the left is the data the one on the right Is the setting for the data Scroll through the data using or until you reach 8 Press the mode button the figure on the right begins to flash Change it to 2 using or Press the mode button to confirm This mode will time out after 15 minutes Adjust the maximum burner pressure setting Press the mode button for about 10 seconds Use or to display code 35 Press the mode button to confirm The display idicates line 23 in the data menu The figure on the left is the data the one on the right Is the setting for the data Scroll through the data using or until you reach 25 Press the mode button the figure on the right begins to flash Change it to the required setting 0 to 199 using or Press the mode button to confirm 17 Routine Cleaning and Inspection REMEMBER when replacing a parton this appliance use only Spare parts that you can be assured conform to the safety and performance spec
65. rnal If fitted Check the 3 way valve is not passing into the control oar 11799 ls the heating temperature on the boiler set high enough 11899p domestic hot water heat exchanger 41 4000123944 2 18 Fault Finding 9966p FAULT THE WATER AT THE TAPS IS LUKE WARM Is the temperature higher if you reduce the flow through the taps Check that the flow restrictor on the cold e Check the 3 way valve is not passing into the radiators The radiators should stay cold in Summer setting water inlet is fitted Check the rate of flow e Check burner pressure is correct FAULT THE FAN DOES NOT START Is there 230V ac at fan during demand Check continuity of fan harness YES YES Faulty fan replace Faulty C replace FAULT THE FAN RUNS BUT THERE ARE NO SPARKS e CHECK CONTINUITY OF IGNITION ELECTRODES AND LEADS e CHECK POWER SUPPLY FROM PCB TO IGNITION UNIT CONNECTIONS TO THE AIR PRESSURE SWITCH Electrical contacts Air flow switch take off 4000123944 2 42 9968p 19 Wiring Diagram MICRO ACCUMULATOR AIR PRESSURE s SWITCH CaN HEATING ELEMENT br 3 ss SENSE MICRO ACCUMULATOR AN J ELECTRODE VESSEL THERMISTOR i l IGNITION ELECTRODES bk bk FN it IGNITER L GAS Dinig UNIT fy UU OVERHEAT Z T gt CONTROL y gt THERMOSTAT ZE P LI w Y WATER OW ZF D PRESSURE N S gt SENSOR CA
66. s for new hot water boilers fired with liquid or gaseous fuels Type test for purposes of Regulation 5 certified by Notified body 0049 Product production certified by Notified body 0049 The CE mark on this appliance shows compliance with 1 Directive 90 396 EEC on the approximation of the laws of the Member States relating to appliances burning gaseous fuels 2 Directive 73 23 EEC on the harmonization of the Laws of the Member States relating to the electrical equipment designed for use within certain voltage limits 3 Directive 89 336 EEC on the approximation of the Laws of the Member States relating to electromagnetic compatibility Control of Substances Hazardous to Health The adhesives and sealants used in this appliance are cured and give no known hazard in this state Insulation pads ceramic fibre These can cause irritation to skin eyes and the respiratory tract If you have a history of skin complaint you may be suscepti ble 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 Allsystem components shall be of an approved type and shal
67. s foreach day 1 to 7 of the week A flashing square is displayed below the current day of the 11538 0123 4 5 6 7 8 9 1011 12 13 14 15 16 17 18 19 20 21 22 23 24 EEEE Th LALLE LE 1234567 E lt week selected Press or to select the day 1 to 7 to be Set Press iy to set ON OFF times PROG and OD are displayed a flashing square will now be displayed below the 0 along the top of the display along with the corresponding time 00 00 p to the right of the display this indicates that 00 00 to 00 30 is setto OFF to set this to ON press OND Orto set 23 4 5 6 7 8 9 1011 12 13 14 15 16 17 18 19 20 21 22 23 24 IE EENE SERRE 11539 rN 1234567 00 00 orr PROG OFF ef to OFF press OFF continue setting the ON OFF times for the remainder of that day 24hr period in 30min intervals Press W PROG and is displayed press to select the next day or to select the previous day to be set continue setting the remaining days as required The display will default to normal after 60 seconds if no buttons are pressed 4000123944 2 1 Technical Data 30ci plus Net lift weight boiler only 41 kg Heating Heat input max NETQ 32 6 kW Gross lift weight boiler and packaging 47 kg 111 231 BTU H Heat input min NETQ 12 5 kW 42 650 BTU H Heat output max NETP 29 6 kW 100 995 BTU H Heat output min NETP 10 3 kW 35 144 BTU H Efficiency Sedbuk D 79 0 Maxi
68. s the number supplied Diagram 7 1 It is essential that this green sealing washer is only fitted to the gas valve connection in the position shown in the Fixing J ig diagram 4000123944 2 16 8 Boiler Preparation and System Connections 8 1 Cutting the flue hole Remove the walltemplate follow the instructions given onthe wall template e 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 e Top Outlet Side Rear hole cutting e 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 externalaccess usea 105mm diameter core drill Forinstallations 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 Ifthe appliance is notto be fitte
69. ssel thermistor e Pull out to remove the thermistor 20 37 Micro accumulator vessel refer to diagram 20 26 Before starting refer to the front of Section 20 Important information For this operation the boiler must be removed from the wall e IMPORTANT With regards to the manual handling operations 1992 regulations the following operation exceeds the recommended weight for one man lift e Remove the front panel refer to Section 17 3 Drain down the boiler and hot water refer to relevant parts of diagram 20 1 Note Itis not necessary to drain down entire heating system to Carry out this work e Disconnect the flue system e Disconnect the boiler pipes at the fixing jig e Disconnect the pressure relief valve discharge pipes e Disconnectthe mains cable and any external controls cables e Lift up to remove the boiler from the wall e From the rear of the boiler e Disconnect the inline electrical connection plug to the micro accumulator vessel thermistor e Remove the slotted metal clips to disconnect pipes from the bottom ofthe micro accumulatorvessel Note Take care there will be a loss of water e Remove the right hand side panel refer to Section 17 6 e Bend back securing tab to release vessel from boiler frame e Remove the vessel from the boiler taking care not to strain the heating element electrical cable e Pull out slotted metal clip and pull to remove heating element from micro accumulator v
70. switch e Disconnect the electrical connections from the mains switch 20 20 Central heating pump head refer to diagram 20 11 Before starting refer to the front of Section 20 Important information e Remove the front panel refer to Section 17 3 e 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 4000123944 2 48 MAINS SWITCH Diagram 20 10 PUMP ELECTRICAL CONNECTION HEX HEAD SCREW 4 OFF Diagram 20 11 e For ease of access if required remove the right hand side panel refer to Section 17 6 e Undo four head fixing screws and remove pump head Gainaccess to the pump electrical connection box and remove cover e Disconnect pump cable from pump avoid straining cables e Connect electrical connection to replacement pump head Fitreplacement pump head 20 21 Filling system tap refer to diagram 20 12 Before starting refer to the front of Section 20 Important information e Remove the front panel refer to Section 17 3 e Lower the control panel refer to Section 17 4 e Drain down the hot water circuit only referto relevant part of diagram 20 1 e Pull of the filling loop tap extension e Pull out slotted metal clip securing tap into housing remove tap e Pull out slotted metal clip an
71. taining 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 e Unclip and lift out PCB Fit replacement PCB in reverse order to removal Be careful not trap any of the cables Make sure that PCB connections are fully pushed onto replacement PCB INSULATION Diagram 20 9 4000123944 2 20 Replacement of Parts l 230V CONTROLS BOARD CONTROL PANEL 20 17 User interface board refer to diagram 20 10 Before starting refer to the front of Section 20 Important information e Unclip control panel user interface and hinge forward Do not strain the cables e Disconnectthe electrical connections from the user interface board e Remove the user inter face board retaining screw e Remove the user inter face board 20 18 230V Controls board refer to diagram 20 10 Before starting refer to the front of Section 20 Important information e Unclip control panel user interface and hinge forward Do not Strain the cables e Disconnect the electrical connection from the 230V controls board e Remove the 230V controls board retaining screw e Remove the 230V controls board 20 19 Mains switch refer to diagram 20 10 Before starting refer to the front of Section 20 Important information e Unclip control panel user interface and hinge forward Do not Strain the cables e Remove the mains
72. the boiler only refer to relevant part of diagram 20 1 e 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 AIR VENT information e Remove the front panel refer to Section 17 3 e Lower the control panel refer to Section 17 4 e Disconnect gas Supply pipe union nuts at the gas control valve e Disconnect injector supply pipe union nut at the gas control valve Slacken the union nut at the burner injector bar e Remove gas control valve retaining clip from the underside of gas control valve e Remove the wire restraining clip from underside of gas control valve e Ease gas control valve forwards and disconnect electrical connections to gas control valve Note The washers must be kept for use on reassembly e Withdraw gas control valve assembly e Fit gas restrictor to replacement gas control valve e 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 e Remove the front panel refer to Section 17 3 e Lower the control panel refer to Section 17 4 e Remove the gas control valve refer to Section 20 28 e Disconnect the electrical connection from step
73. tis recommended that itis checked and serviced as necessary at regular intervals butin general once a year should be enough refer to guarantee registration on the inside front cover of this literature If this appliance is installed in a rented property there is a duty of care imposed on the owner of the property by the current issue of the Gas Safety Installation and Use Regulations Section 35 Servicing maintenance should be carried out by a competent person in accordance with the rules in force in the countries of destination To obtain service please call your installer or Glow worm Service using the telephone number on the inside front cover of this literature Please be advised that the Benchmark logbook should be completed by the engineer on completion of commissioning and servicing All CORGI Registered Installers carry a CORGI ID card and have a registration number Both should be recorded in your benchmark Logbook You can check your installer is CORGI registered by calling CORGI direct on 01256 372300 4000123944 2 Spare Parts REMEMBER When replacing a parton this appliance use only Spare parts that you can be assured conform to the safety and performance specification that we require Do not use reconditioned or copy parts that have not been clearly authorised by Hepworth Heating Ltd If a part is required contact Glow worm Service using the telephone number on the inside front cover of this booklet
74. trol panel refer to Section 17 4 e Clean or replace the water inlet filter refer to section 17 12 20 6 Central Heating Filter Itmay benecessary to clean orreplace the central heating filter Before starting refer to the front of Section 20 Important information Clean or replace the central heating filter refer to section 17 13 20 7 Cold water inlet restrictor Before starting refer to the front of Section 20 Important information e Remove the front panel refer to Section 17 3 e 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 e Remove the retaining wire 45 RETAINING CLIPS ELECTRICAL CONNECTORS T SR SENSING L TUBE Diagram 20 3 COLD WATER INLET UNION NUTS RESTRICTOR CO ER IN ISOLATING VALVE Undo union nuts from boiler cold water in isolating valve Diagram 20 4 e Clean and inspectrestrictor replace ifnecessary see diagram 20 4 20 8 Burner refer to Section 17 9 Before starting refer to the front of Section 20 Important information e Remove the front panel refer to Section 17 3 e Lower the control panel refer to Section 17 4 e Remove the sealed chamber cover refer to Section 17 5 Remove the combustion chamber cover referto Section17 7 e Remove the burner refer to Section 17 9 20 9 Burner injectors refer to diagram 20 5 Before starting refer to the front o
75. uator refer to diagram 20 21 Before starting refer to the front of Section 20 Important information e Remove the front panel refer to Section 17 3 e Lower the control panel refer to Section 17 4 Diagram 20 19 Drain down the boiler only refer to relevant part of diagram 20 1 e Remove the gas control valve refer to Section 20 28 e Remove 3 way valve head refer to Section 20 31 e Remove the three way valve actuator see diagram 20 21 20 33 Ignition unit refer to diagram 20 22 Before starting refer to the front of Section 20 Important information e For ease of access remove the left hand side panel refer to Section 17 6 e Disconnect electrical connections e Remove ignition unit securing screw THREE WAY VALVE HEAD Diagram 20 20 51 4000123944 2 20 Replacement of Parts e Pullupwards to release and remove the ignition unit from the retaining slot 20 34 Domestic hot water plate to plate heat exchanger Before starting refer to the front of Section 20 Important information e Remove the front panel refer to Section 17 3 e Lower the control panel refer to Section 17 4 e Drain down the boiler and hot water circuit refer to relevant parts of diagram 20 1 e Remove the water flow sensor refer to Section 20 24 Unclip the central heating thermistor e Unscrew the heating flow pipe union nut swing pipe forwards e Remove the system water pressure sensor refer to Section 20
76. uct take care notto drillthe inner flue pipe Fitthe fixing collar seal B to the telescopic flue assembly A Referto Step 3 diagram 11 3 Fitthe 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 gasketto base of flue elbow Fitthe 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 e Refer to Step 4 diagram 11 3 Fit rubber sealing collar E into groove atthe outer end ofthe airduct pipe A Carefully pull flue duct pipe into the elbow D Ifthe 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 e Refer to Step 5 diagram 11 3 Fit the fixing collar C using the two screws G STEP 1 Outside wall face 11879 FLUE LENGTH IMPORTANT Flue BUTT FIT centre line BOILER STEP 2 B FIXING Drill screw 2 off COLLAR and tape the Air Duct SEAL 2 off FG STEP 3 cin EXTERNAL RUBBER O RING GASKET H F SEALING COLLAR OLES STEP 4 B p COLLAR Diagram 11 3 23 4000123944 2 12 Horizontal To
77. ue 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 15 UNDER CAR PORT etc MINIMUM SITING DIMENSIONS FOR THE POSITIONING OF FLUE TERMINALS HORIZONTAL FLUES A DIRECTLY BELOW ABOVE OR HORIZONTALLY TO AN OPENING AIR BRICK OPENING WINDOWS AIR VENT OR ANY OTHER VENTILATION OPENING 300 BELOW GUTTER DRAIN SOIL PIPE 75 BELOW EAVES 200 BELOW A BALCONY OR CAR PORT 200 FROM VERTICAL DRAIN PIPES AND SOIL PIPES 150 FROM INTERNAL EXTERNAL CORNERS OR TO A BOUNDARY ALONGSIDE THE TERMINAL 300 ABOVE ADJ ACENT GROUND OR BALCONY LEVEL 300 FROM SURFACE OR A BOUNDARY FACING THE TERMINAL 600 FACING TERMINALS 1200 FROM OPENING DOOR WINDOW IN CAR PORT INTO DWELLING 1200 VERTICAL FROM A TERMINAL 1500 HORIZONTALLY FROM A TERMINAL 300 VERTICAL FLUES M FROM ADJACENT WALL TO FLUE 300 FROM ANOTHER TERMINAL 600 FROM ADJ ACENT OPENING WINDOW 1000 ABOVE ROOF LEVEL 300 Diagram 6 2 ee ae a a a A Diagram 6 3 4000123944 2 7 Fixing J ig The fixing jig is supplied within the boiler pack and is made up as follows A Heating flow isolating valve B Domestic hot water outlet C Gas service cock D Cold water inlet isolating valve E Heating return isolating va
78. zing Make sure that if fitted the immersion heater in the cylinder is switched off If in doubt consult your servicing company e If the boiler loses water the pressure will be indicated a and the boiler ON indicator b will flash red indicating a fault Fillthe system by the filling device c atthe bottom ofthe boiler until the pressure gauge reads 1 0 bar A mains inlet pressure of 2 0 bar is required to reach a fill pressure of 1 0 bar Reset boiler refer to diagram 2 switch On Off to 0 wait for five seconds Switch On Off to 1 to reset the appliance e Warning Take care not to overfill the boiler Ata 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 referto diagram 1 Ifthe fault continues call the relevant Servicing organisation or Glow worm Service using the telephone number on the inside front cover of this literature BOILER DRAIN VALVE Diagram 1 Appliance Introduction The 30ciplus boileris a wall mounted modulating combination boiler with electronic ignition providing central heating and instantaneous hot water The boilers are equipped with a litre domestic hot water Storage vessel that ensures maximum hot water temperature Stability during domestic demand The boiler is ofthe IL category for use with Natural Gas G20 as distributed in the United

30ci Plus Installation & Service Manual Boilers - Glow-worm

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30ci Plus Installation &amp; Service Manual Boilers - Glow-worm

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30ci Plus Installation & Service Manual Boilers - Glow-worm