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BETACOM C.indd - Glow-worm

1. ta LO gt z LJ POTENTIOMETER ats COVER Diagram 11 9 ON BRBEEL 123 4 5867 8 14555 a 8 DIP SWITCHES IN THE OFF POSITION Diagram 11 10 14565 DIP SWITCH ON POSITION DIP SWITCH OFF POSITION Diagram 11 12 42 11 Commissioning 11 8 Completion GB It is a requirement that the Benchmark Installation Commissioning and Service Record is completed and left with the user IE it is necessary to complete a Declaration of Conformity to indicate compliance to 1 5 813 An example of this is given in the current edition of l S 813 11 9 Instruct the User e Demonstrate then instruct the User about the lighting procedure and heating system controls operation e Advise that to ensure the continued efficient and safe operation of the boiler it is recommended that it is checked and serviced at regular intervals The frequency of servicing will depend upon the installation conditions and usage but in general once a year should be enough e 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 e The user shall not interfere with or adjust sealed components e It is the Law th
2. a SECURING 7 SCREWS Diagram 10 1 36 R 24V LOW VOLTAGE ROOM THERMOSTAT TERMINAL BLOCK Nooo e N FITTED BRIDGE Diagram 10 2 18 z FITTED BRIDGE WTHOUT ROOM THERMOSTAT e OC WTH ROOM THERMOSTAT Diagram 10 3 10 Electrical Connection 10 3 System Controls 230V Ifa mains voltage thermostat is to be used Unclip the two front retaining clips on the controls fascia see diagram 10 3 Unclip and carefully pull down the control circuit board cover see diagram 10 4 to access the mains voltage connection located on the printed circuit board see diagram 10 5 On connection of a mains voltage room thermostat to the boiler the bridge wire on factory fitted plug must be cut to fit a connector block NOTE Mains powered thermostats must be connected directly to the mains circuit board as indicated in diagram 10 6 NOTE Ensure that the polarity of the mains connection is correct as reversed polarity may cause the appliance to malfunction NOTE While the boiler s main pcb pump three way valve and gas valve are supplied at 230V AC all other components and associated circuits are supplied at low voltage NOTE When re assembling take care NOT TO TRAP the cables and wires NOTE Connection to the mains electrical supply must be maintained at all times in or
3. OUTSIDE WALL FACE INTERNAL SURFACE Max distance from outside Min distance from outside wall face to min clearance wall face to min clearance LH 337 5mm LH 127 5mm RH 337 5mm RH 127 5mm Diagram 9 1 OSErL OzpbL 9 1 Flue Length and Restrictors The maximum permissable horizontal flue length is 2 5 metres plus the flue terminal assembly this can be achieved by use of the accessories see diagram 9 3 However should an additional 90 or 2 x 45 elbows be used then the length MUST be reduced by 1 metre The diagram 9 1 shows the length achievable by using the kit A2043600 When extension pipes are used the flue system must be designed to have a continuous fall to the boiler of at least 2 5 44mm metre to allow condensate to run back into the boiler and out via the condensate drain The flue can be installed from inside the building when access to the outside wall face is not practicable The flue restrictor is supplied in the documentation pack the correct size is supplied for the boiler output Betacom 24c 83mm Betacom 30c 88mmg The flue restrictor must be fitted in the flue adaptor for concentric flue installations less than 1 metre and twin flue installations less than 2 metres equivalent length Full instructions are provided in the documentation pack 21 9 Telescopic Flue Length Preparation and Install
4. Diagram 14 17 PRESSURE SAFETY RELIEF VALVE 14589 UNSCREW TO REMOVE DISCHARGE PIPE R H HYDRAULIC BLOCK Diagram 14 18 14 Replacement of parts 14 18 R H and L H Hydroblock For access refer to section 14 1 Drain the boiler circuit refer to section 14 2 Refer to diagram 14 12 Remove the secondary heat exchanger see section 14 12 Remove the pump assembly see section 14 9 and 14 10 Remove the section of the hydroblock from the pump by releasing the clip Release the heat exchanger outlet pipe nut and rotate the pipe for easy removal of the left section of the hydroblock Disconnect the three way valve motor electrical connection and remove the motor by releasing the clip see section 14 21 Release the nut connecting the CH outlet connection to the hydroblock Disconnect the DHW sensor see section 14 3 Remove the screw securing the left part of the hydroblock to the combination boiler Fit the replacement hydroblock parts in reverse order to removal ensuring all seals are correctly located and replaced if necessary Open the isolating valves on the flow and return connections refill vent and pressurise boiler ensuring all joints are sound 14 19 Filter For access refer to section 14 1 Drain the boiler circuit refer to section 14 2 Refer to section 12 5 to remove Remove the filter in the inlet to the hydroblock Clean or fit a replacement filter Fit the c
5. 7 Flame sense ionisation 0020061573 electrode 8 Safety valve oo20061610 9 _ CHNTC sensor 0020061581 O h safety thermostat reset 0020061584 Limit thermostat oo20061592 Water flow sensor 0020061608 Low water pressure switch 0020061607 Wo Description J moaei Panno Car oweterma ooo 0020061598 0020061647 Timer clock 0020061649 a _ Tmerde Burner bar manifold 0020061570 64 15 Spare parts 69tL A NR a A A 0 Diagram 15 17 65 16 Manual Handling IMPORTANT With regards to the Manual Handling Opera tions 1992 Regulations the following lift operation exceeds the recommended weight for a one man lift General recommendations when handling Clear the route before attempting the lift Ensure safe lifting techniques are used keep back straight bend us ing legs Keep load as close to body as possible Do not twist repo sition feet instead If 2 persons performing lift ensure co ordinated movements during lift Avoid upper body top heavy bending do not lean forward sideways Recommend wear suitable cut resistant gloves with good grip to protect against sharp edges and ensure good grip Always use assistance if required Removal of carton from delivery van Recommend 2 person lift or 1 person with use of sack truck If 1 person is performing lift straddle the load tilt and place carton into
6. Make sure that the system has been thoroughly flushed out with cold water and that all cleanser if used has been removed With the gas service isolation valve closed with no demand from any external controls and the power supply to the boiler switched off test for gas soundness and purge air from the gas supply 11 2 Filling the System On completion of the boiler installation and ensuring that all water connections are correctly made the boiler may be filled with water via the filling loop not supplied with the boiler 1 Ensure that two manual feed valves and boiler isolation valves are open see diagram 11 1 2 Release the cover cap of the boilers automatic air vent situated on top of the pump see diagram 11 2 The manual feed valves must be closed and the filling loop disconnected once the pressure sensor sited on the boilers control panel indicates a system pressure between 1 0 and 1 5 bar see diagram 11 3 3 Check that all the water connections throughout the system are sound and bleed each of the heating systems radiators in turn As air is vented the system pressure may need topping back up to 1 0bar Air must be vented from the boiler s pump by unscrewing the pumps integral vent plug and allowing water to bleed for a few seconds Take care not to allow water to splash onto any electrical components 4 When the system is bled of any air it must be filled until the pressure display indicates a system pressure of
7. 2 Controls for domestic central heating system and hot water BRECSU Gas Supply The gas installation must be in accordance with the relevant standards In GB this is BS6891 In IE this is the current edition of l S 813 Domestic Gas Installations The internal diameter of the gas supply from the governed meter to the boiler s gas inlet connection must not be less than 22mm The supply from the governed meter must be of adequate size to provide a steady inlet working pressure of 20mbar 8in wg for natural gas at the boiler In addition to the demand of any other gas appliances being serviced from that supply On completion test the gas installation for tightness using the pressure drop method and suitable leak detection fluid purge in accordance with the above standard Domestic Hot Water All domestic hot water circuits connections fittings must be in accordance with the relevant standards and water supply regulations GB Guidance G17 to G24 and recommendation R17 to R24 of the Water Regulations Guide IE The current edition of l S 813 Domestic Gas Installations Heating System In GB it is necessary to comply with the Water Supply Water Fittings Regulations 1999 for Scotland the Water Byelaws 2000 Scotland To comply with the Water regulations your attention is drawn to The Water Regulations guide published by the Water Regulations Advisory Service WRAS gives full details of the requirements
8. Isolate the boiler from both the Gas and Electricity supplies The burner must be removed from the boiler by removing the front panel hermetic chamber cover and combustion chamber cover Remove the two securing screws one on each side of the burner see diagram 11 13 The old injector bar manifold must be removed The ignition electrode and flame ionisation electrode cables must be removed by opening the control panel and gaining access to the PCB Disconnect the plugs of the ignition and flame ionisation electrodes see diagram 11 15 Fit new injector bar manifold new sealing washer and tighten ensuring that the injector size is marked 0 75 mm for LPG both for Betacom 24c and Betacom 30c Fit burner and re assemble The joint must be checked for Gas Tightness 14555 g DE BA iS ang ER lt i b t DUS m AA j E BAHBBHB O KA SI FLAME AND IGNITION ELECTRODE LEADS Diagram 11 15 14557 LEFT HAND SIDE OF BURNER RIGHT HAND SIDE OF BURNER Diagram 11 13 14566 KK lt _ BURNER SENSING TUBE Remove the gasket of cables with the cables inside Diagram 11 14 DIP SWITCH ON POSITION DIP SWITCH OFF POSITION 8 DIP SWITCHES IN THE OFF POSITION DIP RBGAGEEH 1234
9. In IE the requirements given in the current edition of l S 813 Domestic Gas Installations and the current Building Regulations must be followed Boiler Design Boiler Design These boilers are 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 appliance has a built in frost protection device that protects the boiler from freezing Once the controls are set the boiler operates automatically Condensate Drain A plastic drain pipe must be fitted to allow discharge of condensate to a drain Condensate should if possible be discharged into the internal household draining system If this is not practical discharge can be made externally into the household drainage system or a purpose designed soak away see section 9 for more details Pluming from flue terminal Like all condensing boilers this appliance will produce a plume of condensation from the flue terminal in cool weather This is due to the high efficiency and hence low flue gas temperature of the boiler This is normal and not an indication of a fault Safety Devices Electrical Supply Failure The boiler will not work without an electrical supply Normal operation of the boiler should resume when the electrical supply is restored Reset any external controls to resume normal operation of the central heating If the boile
10. Recommend secure appliance onto truck with suitable straps Ensure safe lifting techniques are used keep back straight bend us ing legs Keep load as close to body as possible If 2 persons perform ing lift ensure co ordinated movements during lift Avoid upper body top heavy bending do not lean forward sideways Clear the route before attempting the lift If removing boiler from truck straddle the load and tilt forwards to facilitate secure grip Ensure safe lifting techniques are used keep back straight bend using legs Do not twist reposition feet instead Take care to avoid trip hazards slippery or wet surfaces and when climbing steps and stairs Always use assistance if required Carriage of carton from point of delivery to point of installation roofspace Recommend 2 person lift Ensure co ordinated movements during lift Avoid upper body top heavy bending do not lean forward side ways Clear the route before attempting the lift Take care to avoid trip hazards slippery or wet surfaces and when climbing steps and stairs When transferring appliance into roofspace recommend 1 person to be in roofspace to receive the appliance and other person to be below to pass up and support appliance Ensure safe lifting techniques are used keep back straight bend using legs Keep load as close to body as possible Always use assistance if required It is assumed safe access flooring and adequate lighting are pro
11. Vol CO ppm Appliance Natural gas Propane Natural gas Propane EE Se tolerance tolerance Betacom 24c Km 3 85 0 5 9 60 0 5 pH Betacom 30c 8 10 0 5 2 90 0 5 9 30 0 5 3 35 0 5 Should any CO value exceed the value in the table investigation of the cause such as cleaning the heat exchanger and checking the integrity of the flue must be carried out GAS RATE CHECK The boiler is fitted with a fully modulating automatic gas valve With all other gas appliances turned off measure the gas rate at the gas meter Check that the gas rate is as stated in the table below Gas rate Appliance Maximum net heat input in kW Natural gas in m h nominal Betacom 24c 25 7 2 72 Betacom 30c 28 5 3 02 COMPLETION If it is not possible to achieve the required results for either the combustion or gas rates it will be necessary to complete a full service of the appliance and then repeat the combustion check procedure If after servicing and adjustment of the appliance the combustion values are still unacceptable and after further remedial work has been carried out the appliance must be disconnected until the CO CO2 ratio is acceptable Advice can be sought from the Glow worm Technical Helpline 12 1 Servicing All routine servicing requirements can be achieved by the removal of the front panel and inner casing panel see diagram 12 2 Before commencing with a service or replacement of parts The b
12. connections refill vent and re pressurise the system check for leakage COVER 14494 SECURING SCREWS 4 OFF Diagram 14 6 57 14 Replacement of parts 14 10 Pump body For access refer to section 14 1 Remove the motor as described in section 14 9 Remove the low water pressure sensor refer to section 14 11 Remove the secondary heat exchanger as described in section 14 12 Refer to diagram 14 7 Remove the expansion vessel pipe by removing the clip on the pump body clip at the rear see diagram 14 8 Remove the pressure gauge connection and electrical connection form the R H hydroblock Disconnect the union nuts pressure safety relief valve and pump outlet Refer to diagram 14 9 Remove the fixing screws from the pump and R H hydroblock at the bottom of the boiler Remove the pump assembly Refer to diagram 14 10 Remove the pump body automatic air vent and brass union connector from the R H hydraulic assembly by releasing the clips Fit these to the replacement pump body Fit the replacement pump body and associated parts in reverse order ensuring that all sealing washers are sound and fitted correctly and the polarity of the electrical connections are correct Open the isolating valves on the low and return connections refill vent and re pressurise the system ensuring all joints are sound SECURING UNION g NUT ki UNION NUT PRESSU
13. 1 5 bar 5 If the pressure exceeds 1 5 bar discharge the excess pressure from the system via a radiator valve or pipe connection Do not use the safety discharge valve as the valve seat may become contaminated with debris and fail to re seal 38 R LO O PUMP VENT PLUG Diagram 11 1 IMPORTANT NOTE In order to maintain the appliances warranty after initial filling the heating system must be thoroughly flushed using a propriety cleanser to remove foreign material and contaminants 2 AUTOMATIC AIR 3 VENT COVER CAP Diagram 11 2 14481 SYSTEM PRESSURE 1 5 bar Diagram 11 3 11 Commissioning ap PRESSURE GAUGE STANDBY IR 8 INDICATOR DISPLAY OO 8 5 2 DOMESTIC HOT WATER CENTRAL HEATING TEMPERATURE FUNCTION TEMPERATURE CONTROL CONTROL RADE Diagram 11 4 11 3 Control Panel Functions diagram 11 4 Central heating and domestic hot water temperature controls The boiler s integral control unit monitors and adjusts both the boiler s hydraulic circuit and D H W water outlet temperatures by means of sensors located on the CH heating and D H W flow outlets The sensors electrical resistance which is dependant on temperature determines the current passing through the control potentiometers located on the control panel The respective potentiometer control
14. 1 Boiler Dimensions and Hydraulic Schematic All dimensions are given in millimetres except as noted The general arrangement of the boiler is shown in diagram 2 1 and the hydraulic and gas schematics diagrams showing the central heating hydraulic circuit and domestic hot water hydraulic circuit in diagram 2 2 The data label is positioned on the control box back cover Seep An LKL LA L A O 1 EA i e R LI Si SEA A Re VW O Jwi Se LI a DS A LLL ae Na zon TO F MY b ZE om DOMESTIC HOT WATER HYDRAULIC CIRCUIT Diagram 2 2 10 3 Boiler Location Clearances and Ventilation 3 1 Location This boiler is not suitable for outdoor installation 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 This boiler is suitable for installation in bathroom zones 2 and 3 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 3 2 Clearances The boiler should be positioned so that at least the minimum operational and s
15. BRACKET PACK of 5 Part No 2000460486 90 BEND O Part No 2000460484 45 BEND PACK OF 2 Part No 2000460485 Diagram 9 19 6962 L 30 9 12 Flue Installation Refer to diagram 9 20 and secure the flue adapter in position on top of the boiler with four screws supplied NOTE The rubber O rings of each section should be lubricated prior to assembly Do not use mineral oils or grease silicon grease or water is recommended Secure the first extension pipe to the flue adapter with the securing collar supplied by positioning the collar centrally over the joint then tighten the two screws on the securing collar see diagram 9 21 Fit more extension pipes as required using the collar and screws supplied with each extension pipe To fit position the collar centrally over the joint tighten the two screws on the securing collar Using the holes provided in the securing collar drill and insert the two self tapping screws supplied see diagram 9 22 The rubber O rings of each section should be lubricated prior to assembly NOTE Do not use mineral oils or grease silicon grease or water is recommended When installing the flue it is recommended that it is supported every 2 metres and at every bend by a fixing bracket Project the rise of the flue pipe to roof level and cut a 150mm hole in the roof 9 13 Flue Terminal Installation a Pitched Roof Fit the required pitched roof weather collar over the 1
16. FLAT ROOF WEATHER COLLAR WEATHER COLLAR Part No 2000460479 Part No 2000460478 ba a 45 Fal ELBOW x2 90 ELBOW Part No A2011300 Part No A2011400 Diagram 9 25 9 16 Twin flue The twin flue system is available as an option when the top horizontal or vertical flue system is not appropriate The system can provide an independent horizontal air inlet and flue outlet horizontal air inlet and vertical flue outlet or vertical air inlet and flue outlet via a concentric terminal The system is made up from accessories see diagram 9 25 NOTE The air and flue outlets do not have to be equal lengths 2x45 bends can replace 1x90 bend if necessary The maximum permitted combined air inlet flue outlet flue length is 14 3 metres for Betacom 24C 11 9 metres for maximum flue length must be reduced by 1 metre see diagram 9 24 NOTE When using 90 bends any horizontal run should be inclined by a minimum of 44mm metre 2 5 towards the boiler to facilitate condense removal Alternatively use 45 bends to avoid horizontal runs in the flue pipe O46Z L 9 17 Terminal Position The clearances for a flue outlet are given in the Flue Location and Ventilation section In addition the horizontal air inlet must not be closer than 300 mm from a flue outlet on the same wall or 1200mm from an opposing flue outlet 9 18 Installation Details The parts available for a twin flue system installation are shown in diagram
17. any openings doors vents or windows under the roof Care is required to protect the roof if made of plastic sheeting If the carport comprises of a roof and two or more walls seek advice from the local gas supply company before installing the boiler H and J See diagram 4 2 These dimensions comply with the building regulations but they may need to be increased to avoid wall staining and nuisance from pluming depending on site conditions 4 3 Terminal Guard A terminal guard is required if persons could come into contact with the terminal or the terminal could be subject to damage If a terminal guard is required it must be positioned to provide minimum of 50mm clearance from any part of the terminal and be central over the terminal The guard should be similar to that shown in diagram 4 3 A suitable guard is manufactured by Tower Flue Components Morley Rd Tonbridge Kent TN9 1RA Size 280mm x 280mm x 270mm GZECL pe oe a JI pe A JANN ER ANT RY PAT PONN AT ES Diagram 4 3 13 5 Water System Heating 5 1 General The boiler is designed to operate on fully pumped pressurised sealed systems operating at a maximum of 3bar pressure and maximum design flow temperature of 85 C 5 2 Safety Valve The safety valve is an integral part of the boiler and it cannot be adjusted The pipe from the safety discharge valve must not discharge above an entrance window or any type of public access ar
18. dial allows manual setting of the maximum required temperature reference value being between 30 and 85 C for CH heating and 35 and 64 C for D H W When the boiler operates in heating or D H W mode the current received is compared to the manually set reference value The difference of the two values operates the modulation of the gas valve adjusting the useful heat output generated and stabilising the temperature to within 1 C Re set function Should the boiler lock out at any time please check the gas supply and ionisation probe position the boiler may be re started by switching to standby O position waiting 15 30 seconds Switching back to its previous position once the fault has been eliminated Function switch The three position switch allows the boilers operation to be set to Stand by centre position Heating D H W left hand position or D H W only right hand position 11 3 Commissioning The Betacom 24c and 30c boilers have been tested and pre set at the factory and is dispatched with its on board controls set to provide a maximum central heating and D H W output Consequently once all the connections have been made and the boiler has been filled with water to the designed system operating pressure the boiler may be fired prior to adjusting its on board parameters to match the heating systems requirements 11 4 Initial Lighting Prior to firing Check that the electrical supply to
19. gauge to the pressure outlet of the gas valve Turn the boiler s function switch to the Winter position Heating and Hot Water see diagram 11 4 Turn the central heating temperature control to maximum setting Remove the protective cover from the gas valve adjuster Turn the inner screw using a screwdriver clockwise to increase the pressure setting anticlockwise to decrease the pressure setting After correct adjustment see Boiler specification section page 8 re connect the electrical connector and protective cover and replace the combustion cover to the boiler Maximum setting Remove the sensing tube from the gas valve see diagram 14 14 Remove the protective cover from the gas valve adjuster Push the ball inside the modulating gas valve coil using a sharp pointed tool Turn the nut with a 10mm spanner keeping the ball in without any rotation clockwise to increase the pressure setting anticlockwise to decrease the pressure setting After correct adjustment see Boiler specification section page 8 Finally replace the sensing tube to the gas valve 60 GAS VALVE AND MANIFOLD INLET CONNECTIONS SENSING TUBE 08 14585 MODULATING COIL ELECTRICAL AND EARTH CONNECTIONS ELECTRICAL PLUG Diagram 14 14 GAS VALVE ADJUSTER 15524 Diagram 14 15 14 Replacement of parts 15525 Diagram 14 16 SECURING 14
20. hot water tap and CH start up This delay can be set to 45 seconds by setting dip switch 3 into the OFF position see diagram 11 10 and 11 11 255 seconds delay setting The boiler is capable of up to 255 seconds ignition delay anti cycling time before re ignition following burner shut down on the primary hydraulic water reaching its set temperature This delay can be increased up to a maximum of 255 seconds by turning potentiometer P5 clockwise see diagram 11 12 Pump working mode setting The boiler has a factory set to operate the pump for pre purge and post purge times 45 secs This delay can be excluded by fitting dipswitch 2 into ON position see diagram 11 10 and 11 11 However this may then cause the boiler over heat thermostat to trip out Setting the Heating output The Betacom 24c and 30c boilers are factory set to give maximum CH heating output The maximum heat output for heating is pre set on P2 potentiometer see diagram 11 12 The adjustment for max CH has no effect on max DHW capacity of the boiler lgnition capacity can be increased decreased by turning P4 potentiometer clockwise counter clockwise Boiler type is pre set on Dip Switch 8 OFF position denotes 24 kW and ON position denotes 28 kW Dipswitch 1 and 7 must always be in the OFF position Dipswitch 4 must always be in the OFF position Potentiometer 7 No adjustment required
21. issue of BS6798 and be carried out by a competent person approved at the time by the Health and Safety Executive and as described in the following regulations The manufacturer s instructions supplied The Gas Safety Installation and Use Regulations The appropriate Buildings Regulations either The Building Regulations The Building Regulations Scotland The Building Regulations Northern Ireland The Water Fittings Regulations or Water byelaws in Scotland The Health and Safety at Work Act Control of Substances Hazardous to Health COSHH The Current I E E Wiring Regulations Where no specific instructions are given reference should be made to the relevant British Standard Code of Practice In IE the installation must be carried out by a competent person approved at the time by the Health and Safety Executive and installed in accordance with the current edition of l S 813 Domestic Gas Installations the current Building Regulations and reference should be made to the current ETCI rules for Electrical Installation GB the following Codes of Practice apply BS4814 BS6798 BS5440 Part 1 and 2 BS5546 Part 1 BS5449 BS6891 BS6700 BS7074 Part 1 and 2 BS7593 BS7671 IE 1 S 813 BS5546 BS 5449 BS 7074 BS 7593 NOTE For further information see the current issue of the Building Regulations approved document L1 in the UK and the following current issues of 1 Central heating system specification CheSS and
22. po sition on truck Recommend secure appliance onto truck with suitable straps Ensure safe lifting techniques are used keep back straight bend using legs Keep load as close to body as possible If 2 persons performing lift ensure co ordinated movements during lift Always use assistance if required Carriage of carton from point of delivery to point of installation ground floor Recommend 2 person lift or 1 person with use of sack truck If 1 person is performing lift straddle the load tilt and place carton into position on truck Recommend secure appliance onto truck with suitable straps Ensure safe lifting techniques are used keep back straight bend using legs Keep load as close to body as possible If 2 persons per forming lift ensure co ordinated movements during lift Clear the route before attempting the lift If removing boiler from truck straddle the load and tilt forwards to facilitate secure grip Ensure safe lifting techniques are used keep back straight bend using legs Do not twist repo sition feet instead Take care to avoid trip hazards slippery or wet surfaces and when climbing steps and stairs Always use assistance if required Carriage of carton from point of delivery to point of installation first or higher floor cellar Recommend 2 person lift or 1 person with use of sack truck If 1 person is performing lift straddle the load tilt and place carton into position on truck
23. should be identified as to its use e Afused three pin plug and shuttered socket outlet may be used instead of a fused spur box provided that it is not used in a room containing a fixed bath or shower e The boiler is suitable for installation in bathroom zones 2 and 3 10 1 Electrical Wiring The boiler is supplied factory wired complete with 1 5 m of mains lead All electrical connections to the mains supply must be made in full accordance with the current l E E regulations The boiler must be connected to an effective earth system A3 amp fused three pin plug and shuttered socket outlet may be used instead of a fused spur box provided that it is not used in a room containing a fixed bath or shower 35 10 Electrical Connection 10 2 System Controls 24V WARNING UNDER NO CIRCUMSTANCES MUST ANY MAINS VOLTAGE BE APPLIED TO ANY OF THE TERMINALS ON THE 24V CONNECTION The 24V low voltage room thermostat terminal block is located on the left side of the rear cover of the controls box To access the 24V low voltage room thermostat terminal block remove the front panel secured with two screws lift off the two retaining lugs see diagram 10 1 Carefully pull forward and down the controls fascia see diagram 10 2 On connection of a voltage free room thermostat to the boiler the factory fitted bridge across the room thermostat terminal block must be removed see diagram 10 3 RETAINING LUGS KA ANA A 14457
24. the boiler is On The green boiler Stand by indicator will light and the gas service isolation valve is in the open position see diagram 11 1 Set the boiler s central heating and domestic hot water temperature controls to maximum by turning them fully clockwise Set the external room thermostat if fitted to maximum and open the thermostatic radiator valves to maximum Switch the boilers function switch to the central heating and domestic hot water position The boiler s control unit will now automatically carry out pre ignition safety checks before igniting the burner 39 11 Commissioning 11 5 Setting Operational Pressure Minimum setting Remove the sensing tube from the gas valve Remove one lead from the modulating gas valve coil see diagram 11 6 Refer to diagram 11 7 Connect a suitable pressure gauge the pressure outlet of the gas valve Turn the boiler s function switch to the Winter position Heating and Hot Water see diagram 11 4 Turn the central heating temperature control to maximum setting Remove the protective cover from the gas valve adjuster Turn the inner screw using a screwdriver clockwise to increase the pressure setting anticlockwise to decrease the pressure setting After correct adjustment see Boiler specification section page 8 re connect the electrical connector and protective cover and replace the sensing tube to the boiler Maximum setting Remove the sens
25. the filter and reinstate the cold water inlet connection to the boiler fit new gasket as required Fully open the isolating valve on boiler s cold water inlet and check for leaks YU Hb IBBOGA ni 14556 iQose ou IGNITION AND FLAME ELECTRODE LEADS Diagram 12 6 SPARK GAP 4mm 14566 SENSING TUBE GROMMET SSS Diagram 12 7 14557 TI SECURING SC TI REW LEFT HAND SIDE OF BURNER RIGHT HAND SIDE OF BURNER Diagram 12 8 COLD WATER INLET FILTER 14574 COLD WATER INLET ISOLATION VALVE Diagram 12 9 49 13 Fault finding EFFECT SENSOR r AIR PRESSURE GAS CONTROL RIV can ie SWITCH j NI b O r r PUMP LIMIT IGNITION F THERMOSTAT amp WATER ELECTRODES r PRESSURE DOMESTIC r w Q WITCH HOT WATER FLAME SENSOR W IONISATION W w ELECTRODE BD 6 W THREE WAY g CENTRAL HEATING NTC SENSOR ANE r 230V ROOM jA OVERHEAT SAFETY CHASSIS THERMOSTAT THERMOSTAT EARTH ee CONNECTION w i igh voltage FLOW hig ge a SE
26. thermostat plug is required to fit to PCB board SEALING WASHERS 5 OFF f CONDENSATE WALL TEMPLATE OUTLET PIPE WALL HANGING BRACKET COLD WATER 8 FILTER 8 a BAB C H ISOLATION VALVE RETURN L W COLD WATER ISOLATION VALVE INLET GAS ISOLATION VALVE SAFETY DISCHARGE C H ISOLATION PIPE VALVE FLOW Diagram 6 1 6 1 Appliance Pack Please check the contents of the carton Appliance Isolation Valves Wall Hanging Bracket Wall Template Service Installation and User Manual Guarantee Card and Benchmark Log Book see diagram 6 1 Literature and appliance not illustrated Handling IMPORTANT With regards to the Manual Handling Operations 1992 Regulations the following lift operation exceeds the recommended weight for a one man lift refer to section 17 Manual Handling To remove the appliance refer to diagram 6 2 1 Carefully slit or remove the sealing tape being careful not to scratch the appliance door 2 Fully open the carton lid and remove any instructions and components 3 Read the instructions carefully before installation of the appliance 4 Roll the carton onto its open face 5 Lift the carton free of the inner packaging 6 Remove the mounting bracket and valve package 7 Stand the boiler on its base within the expanded polystyrene block and remove the top packaging piece 8 If you wish to remove the expanded polystyrene base lie the appl
27. to 14637 230V TEST POSITION Diagram 13 1 section 11 5 Check that the heating system pressure indicates at least 1 0 mbar if not fill and vent the system as described in section 11 2 Check that all external controls are on 13 2 Re set function Should the boiler lock out at any time please check the 14571 gas supply and ionisation probe position the boiler may be re started by switching to standby O position waiting 15 30 seconds and switching back to its previous position once the fault has been eliminated see diagram 11 4 GAS SERVICE ISOLATION VALVE OPEN Diagram 13 2 Boiler Stand by Indicator lII Flashing Fault on CH sensor IA Flashing Fault on Outdoor sensor ik Flashing Fault on Air Pressure Switch g Flashing bar Ja Fault on DHW sensor Flashing Overheat Themostat Flashing l 8 w Low System Pressure 14520 Flashing lames or Gas Failure Diagram 13 3 51 13 Fault finding 13 2 Fault finding chart 1 Check electrical supply central heating sensor and frost protection Check the following carefully before starting Gas supply is on adequate and purged Electricity supply is on Polarity is correct CH system pressure is between 1 and 2 bar Pump spins freely Replace main PCB DHW taps
28. to the butt joint see diagram 9 6 If the measurement Y exceeds 525mm then the appropriate length of extension pipe is required If the dimension is less than 315mm DO NOT cut the flue it can project to a maximum of 600mm refer to diagram 9 5 If this is not desirable then a Standard flue MUST be used and cut to length x LLbbL WALL THICKNESS BUTT JOINT WALL FACE WALL FACE Diagram 9 4 3 MAXIMUM S COLLAR OUTSIDE WALL FACE Diagram 9 5 lt Ztvl BUTT JOINT m n OUTSIDE WALL FACE Diagram 9 6 23 9 Telescopic Flue Length Preparation and Installation t 6Z6ZL pO SECURING CHODDZDAAZAL L TELESCOPIC HOSEN mm TERMINAL ASSEMBLY Diagram 9 7 8 I S LOCATING SEALING COLLAR Diagram 9 8 SEALING COLLAR SECURING COLLAR IZA AA CH AD ADA LL a man Diagram 9 9 24 9 5 Flue Fitting With the air duct seams aligned and the flue set to the required length Y mark the securing hole position in the air duct Drilla 3mm diameter hole at this position take care not to pierce the inner flue duct Secure with screw provided and tape the joint see diagram 9 7 Fit the sealing collar onto the locating ring on the flue terminal see diagram 9 8 With the flue elbow removed push the flue assembly into the wall externally or internally until the end of the asse
29. 5 7 Bypass The system s water must always be allowed to circulate whenever the circulation pump is running A return by pass must be provided NOTE It is no longer permissible to use non thermostatic radiator valves to allow by pass through a radiator Diagram 5 2 shows the pump head remaining for the heating system depending on the bypass setting and the speed setting of the pump see section 12 Commissioning Ensure that under no circumstances does the flow rate drop below the figure specified refer to Boiler Specification Table 5 8 Filling the Sealed System With water via the filling loop see diagram 5 3 the filling loop is not supplied with the boiler 5 9 Draining Points Draining taps must be provided at all low points of the system which will allow the entire system to be drained Draining taps shall be to the current issue of BS2879 5 Water System Domestic Hot Water 5 10 Water Pressure To obtain the best hot water performance from your boiler it is suggested that the cold water supply to the boiler is the first draw off from the incoming mains supply NOTE The boiler will not operate unless there is a minimum pressure of 0 25 bar 3 6 Ibf in with a flow rate of 2 5 l min The minimum working pressure to obtain the maximum domestic flow is 24c 0 7 bar 10 15 Ibf in 30c 0 7 bar 10 15 Ibf in The maximum working pressure of the domestic hot water circuit is 8 bar If the cold water supply pressure
30. 50mm hole in the roof Make good the tiling or slating around the collar incorporating the flashing of the weather collar Position the angle cap over the weather collar in the correct orientation to attain the correct angle for your roof b Flat Roof Fit the aluminium weather collar over the 150mm hole in the roof ensuring a weather tight seal From above carefully place the flue terminal through the weather collar 9 14 Flue Terminal to Boiler Connection Should the clearances above the boiler to roof not allow for extensions it is permitted to cut the flue terminal ensuring the relationship of flue and air duct lengths are retained 9 Vertical Flue Length Preparation and Installation 9 15 Completion of Installation With the flue terminal positioned in the roof the length of the final pipe can be determined If a telescopic length cannot be used then a standard flue length can be cut to make the correct length Cut the flue to the desired length measuring from the O ring end and discard the plain end of the tube The cuts must be square and made free of burrs to allow correct assembly NOTE The flue pipe is 10mm longer than the air pipe see diagram 9 23 Carefully push the terminal assembly upwards to allow room for fitting the final flue piece Fit a fixing bracket to the terminal assembly Pull the terminal assembly down and join to the flue system Ensure that the terminal is making a weather tight seal on the wea
31. 5678 oi oe m m ap pa 4 S ej m Ce cee 8 tu 88 MAIN PCB 560650 E 0000 8 FN EJ PC 00000000 Diagram 11 16 44 11 Commissioning Nat Gas G20 to LPG G31 Conversion Factory settings for DIP switches EM DS2 Betacom 24c NG FF OFF OFF OFF Betacom 30c LPG OFF FF Dip switch 7 must be in the ON position for LPG and OFF for NG Dip switch 8 must be in the OFF position for Betacom 24c and ON for Betacom 30c To set the Minimum Setting Remove one lead from the gas valve modulating coil see diagram 11 17 Turn boiler s function switch to the winter position both CH and DHW Turn the Central Heating temperature control knob to the maximum position Connect a suitable pressure gauge to the pressure outlet on the gas valve see diagram 11 18 Remove the protective cover from the gas valve Turn inner adjuster with a flat blade screwdriver Turn Clockwise to increase burner pressure Turn Counter Clockwise to decrease burner pressure After adjustment connect electrical lead and protective cover To set the Maximum Setting Connect a suitable pressure gauge to the burner pressure test point on the gas valve Remove the protective cover from the gas valve adjuster Connect a suitable pressure gauge to the pressure outlet of the gas valve Turn boiler s function switch to the winter position Turn the Central Heating temperatur
32. 586 GAS ISOLATION VALVE SUPPLY PIPE CONNECTION Diagram 14 17 Checking the gas rate The boiler is fitted with a fully modulating automatic gas valve With all other gas appliances turned off measure the gas rate at the gas meter Check that the gas rate is as stated in the table below Gas rate Appliance Maximum net heat input in kW Natural gas in m h nominal Betacom 24c 25 7 2 72 Betacom 30c 28 5 3 02 Checking the combustion products While adjusting the burner pressure at maximum and minimum combustion products can be checked according to the table below Combustion Products CO Vol CO ppm Propane Appliance Natural gas Propane Natural gas tolerance tolerance tolerance tolerance Mn Max Mn 0 5 0 5 Betacom 24 _ 860 05 385 05 960 05 440205 Betscom 306 810405 290405 930 05 335 05 14 Replacement of parts 14 15 Expansion vessel For access refer to section 14 1 Drain the boiler circuit refer to section 14 2 Refer to diagram 14 16 Disconnect the flexible pipe coupling on expansion vessel Release and remove the nut securing the expansion vessel to the boiler Remove the side panels Remove the air pressure switch refer to section 14 6 Remove the flue if required Lift the vessel out of boiler from the gap over the chassis and fit the replacement vessel to the boiler in reverse order to removal ensuring that seali
33. 9 25 33 9 Twin Flue Length Preparation and Installation 9 19 Boiler Connection Place the twin flue adaptor onto the outlet of the boiler with the air inlet to the left hand side see diagram 9 26 Secure the adaptor to the top panel with the screws provided Care should be taken when inserting the screw through the hole in adaptor top To facilitate engagement it is recommended that the rubber O rings are lubricated with silicone grease or water prior to assembly 9 20 Air and Flue Pipe Installation The air and flue pipes can now be built up from the boiler The flue must be designed with a continuous fall towards the boiler If using the horizontal flue pipe or 90 bends the pipe must be inclined at 44mm metre 2 5 minimum see diagram 9 24 Alternatively if space allows use 45 bends in place of 90 bends The rubber O rings of each section should be lubricated prior to assembly with silicone grease When building the flue up it is recommended that it is supported every 2 metres and at every bend by a fixing bracket 9 21 Horizontal Terminal Installation With due consideration to terminal clearances mentioned in section 4 2 drill the one or two holes as required with a 90mm core drill Push the horizontal terminal through the wall allowing approx 100mm to protrude outside Push a grey rubber wall seal onto either side of the wall ensuring that both wall seals are pushed up to the wall s
34. Boiler operated on DHW mode Does burner flame modulate No Check wiring connection to DHW CH sensor Normal operation Check DHW flow sensor and main PCB board and replace them if necessary Check the operation of the modulation coil on the gas valve and replace if necessary Diagram 13 8 14500 54 13 Fault finding 13 6 Fault finding chart 6 Check ignition system START When heat demand is N requested does fan and 2 pump perform pre purge Yes Does sparking start No at burner Yes Does burner light Does boiler try to ignite 3 times with 1 minute intervals Is ionisation fault LED flashing Reset boiler by turning to Standby O for 15 secs before returning to previous position Adjust burner pressure with ignition capacity trimmer Check and if necessary clean burner Check gas supply is live and purged Is overheat thermostat LED or DHW CH sensor Yes Check related sensors and if necessary replace them Check main PCB and replace if necessary LED or low water pressure LED flashing Check wiring connection and placing of ignition electrodes Yes Normal Yes Does boiler light now No Is flame present before lockout condition No No Check right positioning of ignition and Check and if necessary os ionisation electrodes replace gas valve Che
35. CC 13mm TERMINAL CATCH FLUE DUCT L 1imm Diagram 9 16 SEALING COLLAR a PR N SECURING N AW COLLAR UE TRIM RING Lp8cL czpbl Q PPP mn Diagram 9 17 28 9 10 Flue Fitting Remove the flue elbow Separate the flue duct from the terminal by twisting to release the terminal catch then pull out of the retaining seal refer to diagram 9 16 The flue duct cutting length L 11mm is shown in diagram 9 16 The air duct should be cut at the opposite end to the terminal The plastic flue duct MUST be cut at the opposite end to the terminal catch The plastic flue duct extensions MUST be cut at the opposite end to seal The cut ducts must be de burred and all filings and debris removed Insert the flue duct into the air duct terminal assembly remembering to engage the catch within the terminal NOTE If the seals require lubricant to ease installation do not use mineral oils or grease only silicon grease or water is recommended Fit the sealing collar behind the locating lugs on the flue terminal see diagram 9 17 Push the flue assembly into the wall externally or internally initially until the end of the assembly protrudes a short way from the inside face of the wall This will enable the internal trim ring if required to be positioned and allow the flue assembly to be drawn back into the flue elbow Secure the flue elbow in position on top of the boiler with four to
36. Class 3 Class 3 Flue Type C12 C32 C42 C52 C12 C32 C42 C52 See Commissioning section for NG G20 to LPG G31 conversion Installation to G31 Propane is by conversion kit only Boiler Components Lou UI Venn A Heating Flow 22mm B D H W Outlet 15mm C Gas Inlet 22mm D Cold Water Inlet 15mm E Heating Return 22mm Key 1 D H W Sensor 14 Air Pressure Switch 2 Diverter Valve Motor 15 Condensing Unit Turbo heat exchanger 3 Diverter Valve 16 Overheat Safety thermostat 4 Condensate Trap 17 Ignition Electrode 5 Limit Thermostat 18 Heating Circuit Pressure Safety Valve 6 Expansion Vessel At rear of the boiler 19 Secondary Heat Exchanger 7 Burner 20 Automatic Air Vent 8 Flame Sensor Electrode 21 Water Pressure Switch Sensor 9 CH Sensor Heating Sensor 22 Pump 10 Combustion Chamber 23 Gas Valve 11 Primary Heat Exchanger 24 D H W Flow Sensor 12 Fan Hood 25 Filter Valve Below the pump 13 Fan cest 2 Boiler Dimensions and Hydraulic Schematic 43343 150 720 CONDENSATE CONNECTION I BOILER O A 86 86 l lt e a l 151 151 405 24c 430 30c iiti CENTRAL HEATING fA DOMESTIC WATER RETURN i i Diagram 2 1 2
37. E WAY VALVE PUMP CONNECTION PIPE CONNECTION PIPE Diagram 14 13 59 14 Replacement of parts 14 14 Gas valve For access refer to section 14 0 Ensure that gas supply to boiler is turned off Refer to diagrams 14 14 and 14 15 Disconnect the electrical connections to the modulating coil Remove the screw to disconnect the gas valve electrical plug Release the connections from gas valve and manifold inlet Remove the sensing tube Retaining the washers for use on reassembly Release the main gas connection between the gas valve supply pipe and gas inlet isolation valve retaining the washer for use on reassembly see diagram 14 15 Remove the gas valve s two securing screws and washers from the underside of the boiler see diagram 14 17 Rotate the gas pipe and withdraw gas valve assembly Refit in reverse order to removal the polarity of the wires to the modulating coil is not important Check gas soundness and correct boiler operation Following replacement the maximum and minimum settings for natural gas must be checked to ensure they are 12 5 mbar I 2 5 mbar for the Betacom 24 and 14 mbar 2 3 mbar for Betacom 30 respectively Check the gas valve settings and re calibrated by the following method if required Minimum setting Remove the sensing tube from the gas valve Remove one lead from the modulating gas valve coil see diagram 14 15 Refer to diagram 14 16 Connect a suitable pressure
38. Glow worm Betacom Installation and Servicing 24c G C No 47 019 08 30c G C No 47 019 09 High Efficiency Condensing Combination Boilers www glow worm co uk 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 First Year Guarantee We recommend you complete and return as soon as possible your guarantee registration card If your guarantee registration card is missing you can obtain a copy or record your registration by telephoning the Glow worm Customer Service number 01773 828100 Customer Service 01773 828100 Technical Helpline 01773 828300 General and Sales enquiries Tel 01773 824639 Fax 01773 820569 To register your Glow worm appliance call 0800 0732142 Benchmark places responsibilities on both manufacturers and installers The purpose is to ensure that customers are provided with the correct equipment for their needs that it is installed commissioned and serviced in accordance with the manufacturer s instructions by a competent person approved at the time by the Health and Safety Executive and that it meets the requirements of the appropriate Building Regulations The Benchmark Checklist can be used to demonstrate compliance with Building Regulations and should be provided to the customer for futu
39. LOW GUTTER DRAIN SOIL PIPE 25 E BELOW EAVES 25 F BELOW A BALCONY OR CAR PORT 25 G FROM VERTICAL DRAIN PIPES AND SOIL PIPES 25 H FROM INTERNAL EXTERNAL CORNERS 25 H TO A BOUNDARY ALONGSIDE THE TERMINAL 300 l ABOVE ADJACENT GROUND OR BALCONY LEVEL 300 J FROM SURFACE OR A BOUNDARY FACING THE TERMINAL 600 K FACING TERMINALS 1200 L FROM OPENING DOOR WINDOW IN CAR PORT INTO DWELLING 1200 M VERTICAL FROM A TERMINAL 1500 N HORIZONTALLY FROM A TERMINAL 300 VERTICAL FLUES P FROM ANOTHER TERMINAL 600 Q ABOVE ROOF LEVEL 300 R FROM ADJACENT OPENING WINDOW 1000 S FROM ADJACENT WALL TO FLUE 300 Diagram 4 2 4 1 Flue Options There are various flue options to choose from as illustrated in diagram 4 1 The flue lengths and installation are described in section 9 4 2 Flue Terminal Position In GB the minimum acceptable siting dimensions for the terminal from obstructions other terminals and ventilation openings are shown in diagram 4 2 In IE the minimum distances for flue terminal positioning must be those detailed in 1 S 813 Domestic Gas Installations The terminal must be exposed to the external air allowing free passage of air across it at all times Being a condensing boiler some pluming may occur from the flue outlet This should be taken into consideration when selecting the position for the terminal Carports or similar extensions of a roof only or a roof and one wall require special consideration with respect to
40. NSOR br di aa riw g O Fe li br 88 N LI Dnonnonn w A rir en 8 re F2 Eb F 8 j bjbr jgly gly FO bmi PRINTED 8 a bi er gy CIRCUIT L b g y ED BOARD rw 5 gt e et w 8 E5 0000 8 an an an ne 30 ami OOJEB 3887 am O O w w w 24V ROOM THERMOSTAT CONNECTION low voltage KEY rlr BROWN LEN w w BLUE GREENYELLOW 230V 50Hz PERMANENT MAINS SUPPLY LZEY Lou GREEN USER FUSED AT 3A a BLACK Li INTERFACE 24V TIME MOE FUSE RATINGS CLOCK RED F1 2A WHITE low voltage F2 2A 14593 13 Fault finding 13 1 Preliminary fault finding The following checks should be performed before proceeding m LI ImI b onto specific diagnostics r Check the external electrical supply to the boiler is on and a N supply of 230V is present at the L and N terminals Check the electrical installation and boiler carry out tests for earth continuity polarity short circuit and resistance to earth using a suitable multimeter An aid to test Remove the front casing panel see diagram 10 1 and hinge down the control box Unclip to gain access to the mains circuit board see diagram 10 4 Carry out the tests on the mains circuit board see diagram 13 1 Check chassis earth at a bare metal point on the boiler Check that there is a gas supply to the boiler and the gas service isolation valve is turned on see diagram 13 2 Check pressure at the gas service isolation valve refer
41. RE PUMP ELECTRICAL GAUGE BODY CONNECTION GE On Diagram 14 7 SECURING U U USGREWS 2 SCREW Diagram 14 9 AUTOMATIC 2 AIR VENT S BRASS UNION CONNECTOR R H HYDRAULIC ASSEMBLY Diagram 14 10 sa EXPANSION PIPE Il Ia N SECURING SCREW A z CLIP MI Gl K 2 PUMP BODY W N US 2 EJ a N e Diagram 14 8 58 14 Replacement of parts 14 11 low water pressure sensor For access refer to section 14 1 Drain the boiler circuit refer to section 14 2 Locate the low water pressure sensor at the front right hand side of the boiler and remove the electrical sensors connections see diagram 14 11 Remove the low water pressure sensor by turning it in an anticlockwise direction Fit the replacement sensor in reverse order of removal ensuring all washers are fitted Replace damaged washers as necessary Open the isolating valves on the flow and return connections refill vent and re pressurise the system ensuring all joints are sound 14494 LOW WATER PRESSURE SENSOR ELECTRICAL CONNECTIONS Diagram 14 11 14 12 Secondary heat exchanger For access refer to section 14 1 Drain the boiler circuit refer to section 14 2 Remove the two screws which connect the heat exchanger to the L H R H hydroblocks see diagram 14 12 Remove the heat exchanger from the gap on the left hand side Fit the new heat exchanger che
42. TE A2043700 LS 0 5m CJ EXTENSION 45 Bend 2000460481 2000460485 20ff 1m EXTENSION 2000460482 4 VERTICAL ZN 87 50 Bend 2m FLUE 2000460484 EXTENSION ADAPTOR 2000460483 A2024600 Diagram 9 12 26 9 Standard Flue Length Preparation and Installation 9 7 Standard Horizontal Flue A2043400 Refer to diagram 9 11 for kit contents 9 8 REAR Flue Temporarily secure the flue elbow measure the distance from the outside wall to the butt joint see diagram 9 13 If the measurement Y exceeds 665mm then the appropriate length of extension pipe is required The minimum dimension is 180mm to suit a 75mm min wall thickness The flue can project to a maximum of 600mm refer to diagram 9 14 9 9 SIDE Flue Temporarily secure the flue elbow measure the distance from the outside wall to the butt joint see diagram 9 15 If the measurement Y exceeds 665mm then the appropriate length of extension pipe is required The minimum dimension is 262 5 to suit a minimum wall thickness of 75mm The flue can project to a maximum of 600mm refer to diagram 9 14 sy gt WALL THICKNESS BUTT JOINT WALL FACE WALL FACE Diagram 9 13 8 MAXIMUM a COLLAR OUTSIDE WALL FACE Diagram 9 14 ry BUTT JOINT gt OUTSIDE WALL FACE 20MIN Mi Diagram 9 15 27 9 Standard Flue Length Preparation and Installation AIR DUCT i
43. TO CARRY OUT THE CHECK OF COMBUSTION PERFORMANCE NOTE BS 6798 2009 Specification for installation and maintenance of gas fired boilers of rated input not exceeding 70kW net advises that e The person carrying out a combustion measurement must be assessed as competent in the use of a flue gas analyser and the interpretation of the results e The flue gas analyser used should be one meeting the requirements of BS7927 or BS EN50379 3 and be calibrated in accordance with the analyser manufacturers requirements e Competence can be demonstrated by satisfactory completion of the CPA1 ACS assessment which covers the use of electronic portable combustion gas analysers in accordance with BS 7967 parts 1 to 4 Q ISOLATION VALVES SHOWN CLOSED SAFETY DISCHARGE PIPE a Oo C H ISOLATION VALVE FLOW C H ISOLATION CONDENSATE D H W GAS ISOLATION COLD WATER VALVE RETURN OUTLET PIPE OUTLET VALVE INLET ISOLATION VALVE INLET Diagram 12 1 46 12 Servicing COMBUSTION CHECK AND SETTING GAS VALVE e Remove the front casing panel see diagram 10 1 and hinge down the control box Taking care not to touch any internal components proceed as follows e Connect the CO combustion analyser to the relevant test point While adjusting the burner pressure at maximum and minimum combustion products can be checked if required according to the table below Combustion Products l CO
44. ar 116 Ibf in2 Minimum domestic water supply pressure 0 25 bar 3 6 Ibf in2 0 25 bar 3 6 Ibf in2 Maximum domestic hot water temperature Maximum central heating temperature 64 C 85 C 64 C 85 C Maximum domestic hot water output at 35 AT 9 4 L min 10 5 L min Expansion vessel capacity 7 litres 1 53 gallons 8 litres 1 76 gallons Expansion vessel pre charge pressure Minimum flow rate around the central heating circuit at 35 rise Electrical supply 1 0bar 14 6 Ibf in2 776 L hr 230V 50Hz fused 5A 1 0bar 14 6 Ibf in2 1032 L hr 230V 50Hz fused 5A Maximum power comsumption 220 Watt 220 Watt EN60529 IP clasification IPX4D IPX4D Internal fuse rating on main PCB Gas supply governed meter only NG 2A G20 NG G31 Propane 2A G20 NG G31 Propane Gas category Il2H3P Il gt H3P Inlet gas working pressure NG 20 mbar 20 mbar Heat input maximum 25 7 kW 28 5 kW Heat output maximum 24 7 kW 27 6 kW Heat input minimum 11 kW 11 kW Heat output minimum Usefull efficiency at 100 load 10 2 kW 96 10 2 kW 96 8 Usefull efficiency at 30 load Burner injector NG LPG G31 1 20 mm 0 75mm 102 4 103 3 1 15 mm 0 75mm 14 mbar Burner pressure minimum NG 2 5 mbar SEDBUK rating Band B 86 0 Band 86 4 Burner pressure maximum NG 12 5 mbar NOx
45. are closed No CH selector to SUMMER position Check supply lead F1 and F2 fuses and replace if necessary AA Is water pressure Does fan run No and air pressure switch LED flashing at full speed LED flashing Yes Yes GO TO CHART IV Is water pressure between 1 and 2 bar Check pump connection cables and Yes 230V AC supply at pump Check low water pressure switch Fill up system and cable connections to 1 2 bar Change main PCB If temperature of system is less than 6 deg frost protection is activated Check and if necessary replace low water pressure switch Check CH sensor cable q__Yes Is CH sensor connections LED flashing Is CH sensor LED flashing Does burner light Change main PCB GO TO CHART 6 Diagram 13 4 14496 52 13 Fault finding 13 2 Fault finding chart 2 Check domestic hot water operation START Open DHW taps Is DHW flow rate at least Yes Is DHW or CH 2 5 It min sensor LED flashing Yes No Check cold water inlet pressure Check if water filter Is overheat thermostat Yes Check and y is clean LED flashing necessary reset or replace overheat No Go to chart 4 Diagram 13 5 Check and if necessary replace DHW or CH sensor No Check and if necessary replace water flow sensor 14497 13 3 Fault finding chart 3 Check central heating operation START Ensure DHW taps are closed Is overheat Yos Chec
46. at any servicing is carried out by a competent person approved at the time by the Health and Safety Executive e Advise the user that like all condensing boilers this appliance will produce a plume of condensation from the flue terminal in cool weather This is due to the high efficiency and hence low flue gas temperature of the boiler e Advise the user of the precautions necessary to prevent damage to the system boiler and the building in the event of the heating system being out of use during frost or freezing conditions e Advise the user that the permanent mains electrical supply SHOULD NOT be switched off as the built in frost protection and pump saver program will not operate e Advise the User 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 should be drained to avoid the risk of freezing NOTE Sealed System Contact your installation servicing company as draining refilling and pressurising MUST be carried out by a competent person approved at the time by the Health and Safety Executive e Leave these instructions and the Benchmark Installation Commissioning and Service Record with the user 43 11 Commissioning Nat Gas G20 to LPG G31 Conversion 11 10 LPG CONVERSION all models IMPORTANT Gas conversion must be carried out by a competent person approved at the time by the Healih and Safety Executive
47. ation Top Outlet Horizontal Concentric Flue Packs FLUE 3 A2043600 Horizontal telescopic flue pack ELBOW A2037300 Horizontal telescopic flue pack black terminal S D SCREW x 4 SEALING SCREW x 2 TAPE telescopic only Dia SCREW x 2 GASKET SEALING fitted COLLAR ki SCREW x 1 TELESCOPIC TERMINAL ASSEMBLY SEALING COLLAR Diagram 9 2 CEGGL DEFLECTOR FLUE TERMINAL KIT 0020060582 BLACK 0020060583 WHITE 99 BLACK TERMINAL KIT A2043700 Q 0 5m SS EXTENSION 45 Bend 2000460481 2000460485 2off 1m EXTENSION 3 2000460482 VERTICAL 87 5 Bend 2m FLUE 2000460484 EXTENSION ADAPTOR 2000460483 A2024600 Diagram 9 3 22 9 Telescopic Flue Length Preparation and Installation 9 2 Horizontal Telescopic Flue A2043600 Refer to diagram 9 2 for kit contents 9 3 REAR Flue Ifawall thickness is between 210mm min to 420mm max then the flue can be used without extensions Temporarily secure the flue elbow measure the distance from the outside wall to the butt joint see diagram 9 4 If the measurement Y exceeds 525mm then the appropriate length of extension pipe is required If the dimension is less than 315mm DO NOT cut the flue it can project to a maximum of 600mm refer to diagram 9 5 If this is not desirable then a Standard flue MUST be used and cut to length 9 4 SIDE Flue Temporarily secure the flue elbow measure the distance from the outside wall
48. bends any horizontal extension pipe should be inclined by a minimum of 44mm metre 2 5 towards the boiler to facilitate condense removal see a in diagram 9 18 Alternatively use 45 bends to avoid horizontal runs see b in diagram 9 18 The terminal siting should be as shown in diagram 4 2 Measure the distance of flue length required for the installation The flue must be designed with a continuous fall towards the boiler po A sh U 21 2 k x Se The maximum permitted straight flue length is 6 8 metres for Betacom 24C 5 8 metres for Betacom 30C for each 90 or 45 x2 bends fitted the maximum length must be reduced by 1 metre Maximum flue calculated equivalent length w X y z E1 and E2 should be less than 6 8 m for Betacom 24c 5 8 m for Betacom 30c m N lel m B 9 5 li z No z a b Diagram 9 18 29 9 Vertical Flue Length Preparation and Installation EXTENSION PIPE inclusive a 70mm securing collar and screws 2 METRE Part No 2000460483 1 METRE Part No 2000460482 0 5 METRE Part No 2000460481 SZCZ FLUE ADAPTER Part No A2024600 0 TELESCOPIC PIPE inclusive securing 70mm collar and screws Part No A2036900 SLIDING SLEEVE Part No 2000460487 o FLAT ROOF WEATHER COLLAR Part No 2000460478 PITCHED ROOF 9 WEATHER COLLAR Part No 2000460479 FIXING
49. carried out in accordance with BS7593 2006 using a cleanser such as Sentinel X300 or X400 Fernox Restorer or Salamander corrosion guard cleaner IMPORTANT Ensure all cleanser is removed from the whole system before adding an inhibitor Although the boiler is designed to inhibit the formation of scale in hard water areas above 200mgll a proprietary scale reducer should be fitted in the cold water supply to the boiler Failure to comply with this requirement may invalidate your guarantee Refer to the current issue of BS 5449 and BS 7593 on the use of inhibitors in central heating systems 14 A o 2 eat Additional A Flow expansion Domestic control vessel Hot Water if required I I Heating outlet o E NE na a j D A Flow A Flow control control valve valve Heating return g Diagram 5 1 5 6 General On installation it is important to ensure that the heat exchanger is not a natural collecting point for air and where possible the system pipe work should have a gradient to ensure any excess air is carried naturally to other purpose made air release points In high water volume systems or under floor heating systems where prolonged operation of the boiler is expected at temperatures below 60 C a by pass must be installed on the boiler outlet in order to prevent condensation forming inside the boiler body Failure to comply with this requirement will invalidate the manufacturer s guarantee
50. ck and if necessary clean injectors Diagram 13 9 15558 55 14 Replacement of parts 14 1 General Replacement of parts must be carried out by a competent person Before replacing any parts the boiler should be isolated from the mains electric supply and the gas should be turned off at the gas service isolation valve on the boiler The boiler is cold Ensure that components with electrical connections are disconnected before removal Unless stated otherwise parts are replaced in the reverse order to removal After replacing any parts always test for gas tightness and if necessary carry out functional test of the controls For replacement of parts the front casing of the boiler will need to be removed To remove undo the two screws on the underside of the front casing and lift off the retaining lugs see diagram 10 1 The side panels can be removed to aid replacement of parts see diagram 12 3 To hinge a side panel undo and remove the two screws securing each side panel to the boiler 14 1 Draining of Boiler To prevent the need to drain the entire heating system when replacing the boiler s integral pump expansion vessel safety relief valve and pressure sensor the boiler s hydraulic circuit may be isolated from the central heating circuit by closing the boilers isolation valves Opening the discharge safety valve will then drain the boiler s hydraulic circuit NOTE clean the valve seat to ensure it seals befor
51. cking that the plate numbers are the same and reassemble in reverse order ensuring all washers are fitted or replaced as required Open the isolating valves on the flow and return connections refill vent and re pressurise the system ensuring all joints are sound ZZ Saison SECURING SCREWS ooma 0 Diagram 14 12 14 13 Primary Heat Exchanger For access refer to section 14 1 Drain the boiler circuit refer to section 14 2 Refer to diagram 14 13 Remove the pipe clips on the pipes of primary heat exchanger Remove the CH temperature sensor on the return pipe Remove the pump and three way valve connection pipes Release the pipe connections retaining the washers for re assembly Remove the combustion chamber cover see section 12 1 Carefully remove the heat exchanger by pulling forward taking care not to damage the insulation Fit the new heat exchanger and reassemble the boiler in reverse order ensuring all the washers are fitted or replaced as required Open the isolating valves on flow and return connections refill vent and re pressurise system ensuring the all joints are sound 14584 PIPE CLIP PIPE CLIP sim aoe A ay Cy C8 JUSH le CH Sa PRIMARY i HEAT EXCHANGER OVERHEAT SAFETY THERMOSTAT THRE
52. cting installation This appliance is deemed to be a one person lift when removed from the carton Fit bracket securely onto wall before lifting appliance into position Obtain firm grip on front and sides of appliance lift upwards onto worktop if practicable Ensure stable balance achieved and lift upwards to drop into place onto bracket If 2 persons positioning onto bracket obtain firm grip at front and sides base of boiler Ensure co ordinated movements during 2 person lifts to ensure equal spread of weight of load If 1 person positioning onto bracket recommend obtain firm grip supporting base of boiler Ensure safe lifting techniques are used keep back straight bend using legs when lifting load from floor level Do not twist reposition feet instead Keep boiler as close as possible to body throughout lift to minimise strain on back Always use assistance if required Recommend wear suitable cut resistant gloves with good grip to protect against sharp edges and ensure good grip when handling appliance Positioning of Appliance for Final Installation in roof space restricting installation This appliance is deemed to be a one person lift when removed from the carton Obtain firm grip on front and sides of appliance lift up wards ensure stable balance achieved and lift upwards to drop into place onto bracket If 2 persons positioning onto bracket obtain firm grip at front and sides base of boiler Ensure co ordinated movem
53. d Vent Pipe A External Soil and Vent Pipe or Rainwater Pipe SINK CONSTITUTES EXTERNAL LENGTH AB BRE OF PIPE 3M MAX 22mm MIN 622mm MIN NO RESTRICTION UE ON LENGTH OPEN END OF PIPE NOTE FOR EXTENDED Internal Termination into Combined Sink Waste DIRECT INTO GULLEY PIPE RUNS 32mm DIA BELOW GROUND BUT PIPE SHOULD BE USED ABOVE WATER LEVEL External Termination to a Gulley or Hopper EXTERNAL LENGTH OF PIPE 3M MAX 22mm MIN TERMINATION FROM APPLIANCE GROUND either or 22mm MIN NO RESTRICTION ON LENGTH OPEN END OF PIPE DIRECT INTO GULLEY BELOW GROUND LEVEL BUT ABOVE WATER LEVEL 500mm MIN 25mm MIN 100mm PLASTIC TUBE BOTTOM OF TUBE SEALED 300mm MIN HOLE DEPTH 400mm MIN 2 ROWS OF 3 x 12mm HOLES AT 25mm CENTRES 50mm FROM ae BOTTOM OF TUBE HOLES TO Internal Termination Downstream of FACE AWAY FROM HOUSE Sink Waste External Termination into Soakaway NOTE PIPEWORK SHOULD ALWAYS FALL AWAY FROM BOILER BY AT LEAST 2 5 44mm FOR EVERY 1M Diagram 8 3 20 9 Telescopic Flue Length Preparation and Installation Horizontal Telescopic Flue 380 min to 590 max FLUE LENGTH 210 min to 420 max FLUE WALL THICKNESS OUTSIDE WALL FACE BOILER MOUNTING WALL NOTE If necessary it is permitted to increase this dimension to 600mm max Max flue length 590mm Min flue length 380mm
54. der to provide domestic hot water frost protection and pump over run facility Ensure that the boilers electrical supply is not interrupted by any external controls 10 4 Electrical Connections Testing Carry out preliminary electrical system checks prior to making the final connection 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 RETAINING CLIPS 14539 CONTROLS FASCIA Diagram 10 3 RETAINING CLIPS 2 ko CONTROLS CIRCUIT BOARD COVER Diagram 10 4 BRIDGE PLUG R LS R n ou D al Jwa _ non Tiong ccof nana o ol ae oo olip pon T EN i frep li CJ JEN MG Hse 2 A WZI PRINTED CIRCUIT BOARD l Diagram 10 5 N 230V ROOM 3 THERMOSTAT 49 a d 50 X20 230V ROOM THERMOSTAT CONNECTION ON PRINTED CIRCUIT BOARD Diagram 10 6 37 11 Commissioning ISOLATION VALVES SHOWN OPEN IMPORTANT At the time of commissioning complete all relevant sections of the Benchmark Checklist located in the centre pages of this document 11 1 Preliminaries All Systems Do Not operate the boiler without water The commissioning should be carried out by a competent person approved at the time by the Health and Safety Executive and in accordance with the current issue of BS6798
55. des replace any damaged seals as necessary Fit replacement burner in reverse order Check gas soundness and boiler operation eu aou ap aa BURNER INJECTOR BAR 14577 oi Diagram 14 4 14 8 Printed circuit board For access refer to section 14 1 Turn off and isolate the electrical supply Unclip the two front retaining clips on the controls fascia see diagram 10 3 Unclip and carefully pull down the control circuit board cover see diagram 10 4 Remove the electrical connections to the PCB by pulling carefully noting the locations of all the terminals Release the four screws securing the PCB to the control panel and lift out the PCB Fit the replacement PCB in reverse order to removal ensuring that the PCB electrical connections are fully pushed home Check and re set as necessary the potentiometers and dip switches to the same value as the old PCB SECURING SCREWS 4 OFF 14578 PRINTED CIRCUIT BOARD Diagram 14 5 14 9 Pump head For access refer to section 14 1 Drain the boiler s circuit as detailed in section 14 2 Remove the screws see diagram 14 6 Pull off the motor remove the cover and disconnect the electrical connections from cable box Fit the replacement motor in reverse order ensuring correct polarity of the electrical connections Re open the isolating valves on the flow and return
56. e C H sensor Fit replacement C H sensor Re fit the electrical connections PRIMARY HEAT EXCHANGER OUTLET PIPE 14576 CENTRAL HEATING SENSOR ELECTRICAL CONNECTIONS Diagram 14 2 14 5 fan unit For access refer to section 14 1 Refer to section 12 2 to replace the fan Fit the replacement fan unit in reverse order and reconnect the electrical connections and sensing tube 14 Replacement of parts 14 6 Air pressure switch For access refer to section 14 1 The air pressure switch is located above the expansion vessel see diagram 14 3 Remove the sensing tubes and electrical connections from the air pressure switch noting which tube is connected to which port Remove the air pressure switch by unclipping it from the bracket Fit the replacement air pressure switch in reverse order of removal SECURING SCREWS 2 OFF BRACKET 14543 ELECTRICAL CONNECTIONS SENSING TUBES 2 OFF Diagram 14 3 AIR PRESSURE SWITCH 14 7 Burner Refer to section 12 3 to replace the burner Retain all washers gaskets for use on re assembly Remove the burner injectors as shown in diagram 14 4 Fit the burner injectors to the new burner injector bar and tighten ensuring that the injector size marked on each injector is the same as stated in the Boiler Specification section page 8 for the type of gas being used Replace the burner bar and re fit the burner bla
57. e Parts Servicing and Maintenance To ensure the continued efficient and safe operation of the boiler it is recommended that it is checked and serviced as necessary at regular intervals The frequency of servicing will depend upon the particular installation conditions and usage but in all cases the boiler must be serviced at least once a year 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 s own service organisation using the telephone number on the inside front cover of this literature Benchmark scheme Glow worm support the Benchmark initiative It is very important that the Installation Commissioning and Service Record is completed by the installation engineer and handed over to the user Spare Parts Remember when replacing a part on this appliance use only spare parts that you can be assured conform to the safety and performance specification that we require Do not use reconditioned or copy parts that have not been clearly authorised by Glow worm If a part is required contact Glow worm s own service organisation Please quote the name of the appliance this information w
58. e control knob to the maximum position Push the ball inside gas valve modulating coil using a sharp pointed tool Turn outer nut with a 10mm spanner keeping the tool pushed in Turn Clockwise to increase burner pressure Turn Counter Clockwise to decrease burner pressure After adjustment connect electrical lead and protective cover Betacom 24c Betacom 30c NG LPG NG LPG G20 G31 G20 G31 mbar mbar mbar mbar Burner operating 2 5 2 3 pressure minimum Burner operating 12 5 36 5 14 36 0 pressure maximum MODULATING COIL 15524 GAS VALVE ADJUSTER 15525 Diagram 11 18 45 12 Servicing IMPORTANT NOTES 1 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 and usage but in all cases the boiler must be serviced at least once a year 2 Itis the Law that any servicing is carried out by a competent person approved at the time by the Health and Safety Executive 3 Before commencing with a service or replacement of parts the boiler should be isolated from the electrical supply and the gas supply should be turned off at the gas service isolation valve 4 When replacing a part on this appliance use only spare parts that you can be assured conform to the safety and performance specification that we require Do
59. e re filling the boiler After replacing parts open the heating flow and return isolating valves and refill vent and pressurise the heating circuit refer to section 11 2 Check for leaks 14 2 Draining of Boiler Hot Water Circuit Drain the Domestic Hot Water circuit by closing the cold water isolation valve on the boiler Open one or more hot water taps to drain the hot water circuit After replacing parts open the cold water isolation valve and slowly open a hot water tap to remove air Close the hot water tap and check for any leaks 14 3 Domestic hot water sensor For access refer to section 14 1 The domestic hot water sensor is located on the left side of the hydroblock s hot water side see diagram 14 1 Carefully disconnect the electrical connections from the domestic hot water sensor Remove the domestic hot water sensor using a 13mm spanner Fit the replacement domestic hot water sensor ensuring the washer is correctly fitted Re fit the electrical connections to the replacement sensor 56 14575 05 LZ A zaj Q DOMESTIC HOT ELECTRICAL WATER SENSOR CONNECTIONS Diagram 14 1 14 4 Central heating sensor For access refer to section 14 1 The C H sensor is located on left side of the combustion chamber on the outlet of the primary heat exchanger see diagram 14 2 Unclip the C H sensor from the pipe Disconnect the electrical connections from th
60. ea 5 3 Expansion Vessel The boiler s integral expansion vessel with a capacity of 7 litres 1 5 gallons is pre charged to a pressure of 0 5bar and will accommodate a system volume of 125 litres at an average water temperature of 75 C and maximum system pressure of 3 bar NOTE The expansion vessel volume depends on the total water system volume and the initial system design pressure In GB Guidance on vessel sizing is also given in the current issue of BS5449 and BS7074 Part 1 In IE current edition of l S 813 Domestic Gas Installations If the system volume is more than 125 litres an additional expansion vessel must be fitted to suit the size of the system Atypical installation of an additional pressure vessel is shown in diagram 5 1 5 4 Flow Rate If it is necessary to alter the flow rate the system can be fitted with a lockable balancing valve in the main flow or return pipes shown as valve A in diagram 5 1 The flow rate through the boiler must not be allowed to fall below that given in Boiler Specification Table The heating circuit should be designed and balanced to give a 20 C temperature rise across the boiler flow and return 5 5 Water Treatment Existing system It is ESSENTIAL that prior to installing the new boiler the system is thoroughly flushed New system For optimum performance after installation the boiler and its associated central heating system should also be flushed Flushing should be
61. ents during 2 person lifts to ensure equal spread of weight of load If 1 person positioning onto bracket recommend obtain firm grip support ing base of boiler Ensure safe lifting techniques are used keep back straight bend using legs when lifting load from floor level Do not twist reposition feet instead Keep boiler as close as possible to body throughout lift to minimise strain on back Always use assistance if re quired Recommend wear suitable cut resistant gloves with good grip to protect against sharp edges and ensure good grip when handling appliance It is recommended a risk assessment of the roof space area be carried out before moving the appliance into the area to take into account access stability of flooring lighting and other factors and appropriate measures taken 17 Declaration of conformity Glow worm EC declaration of conformity Name and Address of the Glow worm manufacturer Nottingham Road Belper Derbyshire DE56 1JQ Identification of product Gas condensing boiler Appliance type BETACOM 24C BETACOM 30C BETACOM 24C S BETACOM 30C S The appliance types satisfy the essential requirements of the relevant directives and Standards 90 396 EEC including amendments Designed and built to CE type examination certifi Directive on the approximation of the law of the cate member states relating to appliances burning gaseous fuels PIN no CE 0051BP2727 CE 0051BP2728DR 92 42 EEC including amendme
62. ervicing clearances are provided see diagram 3 1 Additional clearances may be beneficial around the boiler for installation and servicing For flue installations where external access is not practicable consideration should be given for the space required to insert the flue internally which may necessitate clearance larger than those specified in diagram 3 1 3 3 Timber Frame Buildings If the boiler is to be installed in a timber frame building it should be fitted in accordance with the Institute of Gas Engineers document IGE UP 7 1998 If in doubt seek advice from local gas undertaking or Glow worm 3 4 Combustible Material The boiler and flue are suitable for installation onto and through combustible materials provided that 1 The boiler must be sited at least 1m away from flammable materials and heat sensitive walls must be protected by appropriate insulation 2 Minimum 5 mm clearance is maintained around the circumference of the flue air intake 3 The combustible surface and fixings are suitable for supporting the load 4 The minimum clearances from the boiler case are maintained 3 5 Room Ventilation The boiler is room sealed so a permanent air vent is not required 3 6 Cupboard or Compartment Ventilation If the boiler is installed in a compartment there must be purpose made ventilation for cooling purposes Make sure the cupboard or compartment air vents are positioned to be clear of obstructions at all t
63. exceeds this then a pressure reducing valve must be fitted in the supply to the boiler Where cold water mains are fitted with a water meter check valve s or loose jumper stopcock a domestic hot water mini expansion vessel may need to be fitted To obtain the best hot water performance from your boiler it is suggested that supplies to faucets are run in 15mm copper as short as possible and where practical be insulated to reduce heat loss 5 11 Hard Water Areas re The temperatures within the heat exchanger are limited by H m QH Chart 3 the boiler control system to minimise scale formation within T the hot water pipework However in areas where the water is 6 hard i e more than 200mg litre it is recommended that the 5 hot water setting is reduced and that a scale reducer is fitted 4 refer to the manufacturer s instructions or consult the local water company for additional advice ai 2 1 0 0 0 0 5 1 0 1 5 2 0 2 5 3 0 3 5 Q m3 h Diagram 5 2 R SUPPLY R PIPE BOILER BOILER CONTROL VALVE DOUBLE TYPE CA BACKFLOW CHECK PREVENTION DEVICE FLOW RETURN VALVE FLOW RETURN HOSE UNION CONTROL CONTROL VALVE VALVE l SUPPLY gt PIPE HEATING DAJ TEMPORARY HEATING CONTROL HOSE CONNECTION IRCUIT CIRCUIT VALVE UNION CIRCU a GAP DRAIN TUNDISH POINT Method 2 Method 1 Diagram 5 3 15 6 Installation Preparation CHECK IF 230V
64. iance on its back to do so 6 2 Site Requirements The boiler mounting wall should be suitable for the weight of the appliance and be true and flat NOTE Due to the varied site conditions we do not supply fixings and advise that the installer should supply those which are suitable Qi vesrl Diagram 6 2 16 6 Installation 6 3 Wall Template Take the wall template from the document pack and place in the desired position on the wall giving due consideration to the required boiler clearances see section 3 and the flue you are fitting Mark the position of the flue centre if fitting a side flue extend the flue centre line into the corner then 170mm along the adjacent wall see diagram 6 3 For extended side flues the flue hole centre should be determined by extending the dashed inclined line on the template to the side wall then 149mm along the adjacent wall see diagram 6 2 This dashed line is drawn at 44mm metre 2 5 rise from the boiler To allow for the flue passing through the wall at this angle a 125mm hole should be drilled irrespective of internal or external installation Remove the wall template whilst drilling the flue hole 6 4 Flue Hole Cutting External access flue installation can use a 105mm diameter core drill Internal access only flue installation will need a 125mm diameter core drill NOTE The flue is designed with an internal fall of 44mm metre 2 5 therefore the ho
65. ibres may cause a temporary irritation High dust levels may irritate eyes and upper respiratory system It is important therefore that sensible precautions are applied when exchanging components If you have a history of skin complaint you may be susceptible to irritation Normal handling should not cause discomfort but follow good hygiene and wash your hands before eating drinking or going to the lavatory If you suffer irritation to the eyes or severe irritation to the skin seek medical advice Manual Handling With regards to the Manual Handling Operations 1992 Regulations the appliance exceeds the recommended weight for a one man lift refer to section 16 for more information The handling of the boiler may involve lifting pushing and pulling the use of a sack truck may be required The following handling techniques and precautions should be considered Grip the boiler at its base Be physically capable Use safety clothing where appropriate e g gloves safety footwear Ensure safe lifting techniques are used Keep back straight Avoid twisting at the waist Avoid upper body top heavy bending Always grip using the palm of the hand Use designated hand holds Keep load as close to body as possible Always use assistance if required Electrical Supply The boiler MUST be earthed All system components shall be of an approved type and all wiring to current l E E wiring regulati
66. ill be on the name badge on the front of the appliance If in doubt seek advice from the local gas company or Glow worm s own service organisation using the telephone number on the inside front cover of this booklet Boiler Specification Boiler Design These boilers are 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 The appliance has a built in frost protection device that protects the boiler from freezing Once the controls are set the boiler operates automatically fitted within the boiler BOILER SPECIFICATION Lift weight 37 kg 82 Ib ebepL 38 kg 84 Ib Total weight installed 40 kg 88 Ib 41 kg 90 Ib Gas connection O D 22mm copper 22mm copper Heating flow and return connection O D 22mm copper 22mm copper Domestic hot water connection O D Condensate connection O I D 15mm copper 21 5mm plastic 15mm copper 21 5mm plastic Safety valve discharge connection O D 15mm copper 15mm copper Heating circuit safety valve preset 3 5 bar 53 5 Ibf in2 3 5 bar 53 5 Ibf in2 Heating system minimum pressure 0 8 bar 11 6 Ibf in2 0 8 bar 11 6lbf in2 Heating system nominal pressure 1 5 bar 21 7 Ibflin2 1 5 bar 21 7 Ibflin2 Maximum domestic water supply pressure 8 bar 116 Ibf in2 8 b
67. imes Acompartment used to enclose the boiler must be designed and constructed specifically for this purpose An existing cupboard or compartment modified for the purpose may be used Refer to the current issue of BS6798 for guidance HI LO Betacom 24c 128 5cm 128 5cm Betacom 30c 142 5cm 142 5cm 20 gt KEY 600 300 on N tver NON COMBUSTIBLE MATERIAL Diagram 3 1 4 Flue Options and Terminal Clearances Top horizontal telescopic flue 260 100 Top horizontal standard flue 260 100 Part No A2043600 Section 9 page 21 Part No A2043400 Section 9 page 25 Plume Management Kit basic set white concentric flue 960 100 Part No A2044100 for use with Part No A2043400 and Part No A2043600 Section 9 page 35 Vertical Flue Vertical Flue Adapter concentric flue 960 100 Twin Flue Part No A2024600 Twin Flue Adapter concentric flue 980 Vertical flue terminal kit concentric flue 960 100 Part No A2011000 Section 9 page 32 Part No 2000460480 Section 9 page 29 Diagram 4 1 12 4 Flue Options and Terminal Clearances UNDER CAR PORT etc HORIZONTAL FLUES A DIRECTLY BELOW AN OPENING AIR BRICK OPENING WINDOWS 300 B ABOVE AN OPENING AIR BRICK OPENING WINDOWS 300 C HORIZONTALLY TO AN OPENING AIR BRICK OPENING WINDOWS 300 D BE
68. ing tube from the gas valve see diagram 11 5 Remove the protective cover from the gas valve adjuster Push the ball inside the modulating gas valve coil using a sharp pointed tool Turn the nut with a 10mm spanner keeping the ball in without any rotation clockwise to increase the pressure setting anticlockwise to decrease the pressure setting After correct adjustment see Boiler specification section page 8 Finally replace the sensing tube to the gas valve 40 GAS VALVE AND MANIFOLD INLET CONNECTIONS SENSING TUBE 14585 MODULATING COIL ELECTRICAL AND EARTH ELECTRICAL CONNECTIONS PLUG Diagrams R o GAS VALVE ADJUSTER se Diagram 11 6 11 Commissioning 8 Diagram 11 7 SECURING 8 GAS SCREWS v Z ISOLATION VALVE SUPPLY PIPE CONNECTION Diagram 11 8 11 6 Checking the gas rate The boiler is fitted with a fully modulating automatic gas valve With all other gas appliances turned off measure the gas rate at the gas meter Check that the gas rate is as stated in the table below Gas rate Appliance Maximum net heat input in kW Natural gas in m U h nominal Betacom 24c 25 7 2 72 Betacom 30c 28 5 3 02 Checking the combustion products While adjusting the burner pressure at maximum and minimum combustion products can be checked according to the table below Combustion Produc
69. k and if thermostat LED flashing a or Put CH temperature No No D a Is 230 VAC Ensure external controls eee PUTAR ts present on terminals of are calling for heat Yes Is CH sensor LED No Go to chart 5 flashing f Check and if No necessary replace Check and i Check and if necessary replace necessary replace Diagram 13 6 14498 53 13 Fault finding 13 4 Fault finding chart 4 Check domestic hot water operation START Does fan run Yes No Is 230 VAC present Yes between fan terminals No Check fan wiring connection Check and if necessary replace main PCB Check and if necessary replace fan Is switching pressure at test points greater than 1 05 mbar Is air pressure Yes Go to chart 6 switch activated No Yes Check and if necessary replace air pressure switch Check and and clean fan Check flue and air intake are correct and clean Check air pressure switch tube is clean No Diagram 13 7 14499 13 5 Fault finding chart 5 Check domestic hot water and central heating modulation START Boiler operated on central heating mode Does burner flame modulate No Check wiring Normal operation connection to CH sensor Check CH sensor and main PCB and replace them if necessary Check the operation of the modulation coil on the gas valve and replace if necessary START
70. le can be drilled horizontally If flue extension pipes are to be used then a core drill size of 125mm is required This will allow the extension pieces to slope at 44mm metre 2 5 towards the boiler 6 5 Wall Hanging Bracket Assembly The Wall Hanging Bracket is supplied in the main boiler packaging Reposition the wall template over the flue hole and mark the position of the fixing holes for the hanging bracket NOTE Due to the varied site conditions we do not supply fixings and advise that the installer should supply those which are suitable Drill fixing holes using a 8 5mm drill bit and insert suitable wall plugs Secure the wall hanging bracket to the wall Preparation 2 5 44mm metre a inclined extended a WALL flue length TEMPLATE 170 N PS m Js 90 Standard flue length Wen Horizontal Fixing points Diagram 6 3 17 7 Boiler fixing Gas Water Safety Discharge Connections Zver ISOLATION VALVES SHOWN CLOSED Diagram 7 1 7 1 System connection Connect the isolation valves including sealing washers and cold water inlet filter to the boiler ensuring the washers are fitted correctly see diagram 7 1 Make sure the isolation valves are closed 7 2 Safety Discharge Pipe Connect the safety discharge pipe see diagram 7 2 This must be extended using not less than 15mm o d pipe to discharge in a visible position
71. llation 9 25 Vertical Flue Length Preparation and Installation g 29 Twin Flue Length Preparation and Installation g 32 Plume Management Kit 35 Electrical Connection 10 35 Commissioning 11 38 Servicing 12 46 Fault Finding IS 50 Replacement of Parts 14 56 MAIN ee Spare Parts 15 64 Manual Handling 16 66 Declaration of Conformity UA 67 WARNINGS Gas Leak or Fault Turn off the gas emergency control valve immediately Eliminate all sources of ignition i e smoking blowlamps hot air guns etc Do not operate electrical lights or switches either on or off Open all doors and windows ventilate the area Metal Parts This boiler contains metal parts components and care should be taken when handling and cleaning with particular regard to edges Sealed Components Under no circumstances must the user interfere with or adjust sealed parts Important Information Gas Category This boiler is for use only on G20 natural gas Control of Substances Hazardous to Health Under Section 6 of The Health and Safety at Work Act 1974 we are required to provide information on substances hazardous to health The adhesives and sealants used in this appliance are cured and give no known hazard in this state CAUTION While there are no substances harmful to health contained within this boiler some component parts of the boiler insulation pads gaskets and rope seals are manufactured from man made fibres When damaged or broken these f
72. mbly protrudes a short way from the inside face of the wall This will enable the internal trim ring if required to be positioned and allow the flue assembly to be drawn back up to the flue elbow Secure the flue elbow in position on top of the boiler with the four screws supplied Draw the flue assembly from wall and engage the flue duct into the elbow and butt fit between the air duct and flue elbow Check the correct alignment of the flue Fit the securing collar in position mark through two of the pre drilled holes in the securing collar Remove securing collar and drill two 3mm diameter holes one in the elbow and one in the air duct take care not to pierce the inner flue duct Fit the securing collar and secure with screws provided see diagram 9 9 Slide the internal trim ring back against the wall securing in place with a small amount of sealant if required The cut ducts must be de burred and all filings and debris removed Insert the flue duct into the air duct terminal assembly remembering to engage the catch within the terminal NOTE If the seals require lubricant to ease installation do not use mineral oils or grease water is recommended 9 Standard Flue Length Preparation and Installation 9 6 Flue Length The maximum permissable horizontal flue length is 5 6 metres for Betacom 24c and 4 6 metres for Betacom 30c this can be achieved by use of the accessories see diagram 9 12 However should additional 90
73. ncy Regulations and therefore is deemed to meet the requirements of Directive 92 42 EEC on the efficiency requirements for new hot water boilers fired with liquid or gaseous fuels Type test for purposes of Regulation 5 certified by Notified body IMQ 51BP2727 CE Directives 90 396 EEC 51BP2728DR CE Directives 92 42 EEC Product production certified by Notified body IMQ 51BP2727 CE Directives 90 396 EEC 51BP2728DR CE Directives 92 42 EEC 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 harmonisation of the Laws of the Member States relating to 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 IMPORTANT Where no British Standards exists materials and equipment should be fit for their purpose and of suitable quality and workmanship The installation of this boiler must be carried out by a competent person approved at the time by the Health and Safety Executive and in accordance with the rules in force in the countries of destination Manufacturer s instructions must not be taken as overriding statutory requirements Statutory Requirements In GB the installation of the boiler must comply with the requirements of the current
74. ng washer is fitted to pipe connection before tightening replace the washer if necessary Using a pressure gauge ensure that expansion vessel charge pressure is O 5bar 7 5psi Open the isolating valves on the flow and return connections refill vent and pressurise the boiler ensuring all joints are sound OVER HEAT SAFETY THERMOSTAT 14588 ELECTRICAL CONNECTIONS FLEXIBLE PIPE CONNECTION TS SECURING NUT 14587 Diagram 14 16 14 16 Overheat safety thermostats For access refer to section 14 1 Remove the front panel combustion chamber cover and right side panel Refer to diagram 14 17 Locate the overheat safety thermostat at the front left hand side of the boiler and on the right hand side of the primary heat exchanger Disconnect the electrical connections from the thermostat Unclip the thermostat from the pipe Fit the replacement thermostat in reverse order of removal 62 LAE 14 17 Pressure safety relief valve For access refer to section 14 1 Drain the boiler circuit refer to section 14 2 Refer to diagram 14 18 Disconnect the discharge pipe on the outlet of the safety relief valve Unscrew to remove the safety relief valve from the R H hydroblock and retain the o ring for use on reassembly replace as necessary Fit the replacement safety relief valve in reverse order to removal and refill vent and pressurise boiler ensuring all joints are sound
75. not use reconditioned or copy parts that have not been clearly authorised by Glow worm 5 If any electrical connections have been disconnected and after their connection checks to the earth continuity polarity short circuit and resistance to earth must be repeated using a suitable multimeter 6 On completion the Benchmark Service Record should be completed General Inspection e Ensure that the gas analyser is set to the correct fuel n i W setting Prior to during servicing and after any maintenance or e Select the constant central heating with DHW function by changed parts the following must be checked turning the function switch refer to commissioning section e The integrity of the flue system and flue seals The boiler should fire automatically e The integrity of the appliance combustion circuit and NOTE Safe combustion can only be verified by measuring relevant seals CO CO2 ratio This ratio must not exceed 0 0008 e Electrical gas and water connections e System pressure B e the combustion performance refer to the following urner procedure Refer to Commissioning section 11 5 Setting operational e The operational gas inlet pressure and gas rates refer to pressure the commissioning section paragraph 11 5 Check that the burner pressure at maximum and minimum Correct any fault before continuing rate is as the value in the boiler specification table on page 8 If incorrect adjust as necessary COMPETENCY
76. nts Directive of efficiency relating to boiler burning gaseous fuels Designed and built according to European Stan dards 2006 95 EEC including amendments Directive on the harmonization of the laws of EN 483 Member States relating to electrical equip EN 656 ment designed for use within certain voltage limits EN 677 EN 60335 1 2004 108 EEC including amendments EN 60529 Directive on the approximation of the law of the EN 50165 member states relating to electromagnetic com EN 55014 patibility Any change to the appliance and or any use not according to the instructions will lead to the invalidation of this Declaration of Conformity Belper 13 05 2008 J d PY WR AB ai place date UK Marketihg Director Certification Group Manager John Collings Albrecht Nunn 67 O3 07 09 Because of our constant endeavour for improvement details may vary slightly from those shown in these instructions Glow worm Nottingham Road Belper Derbyshire DE56 1JT i
77. oiler should be isolated from the electrical and gas supplies e Remove the front casing panel by removing two screws at the bottom of the boiler and by lifting the front casing panel up to release from the retaining hooks see diagram 10 1 e Remove the boiler inner casing panel by removing two screws and by lifting the boiler inner casing panel up to release from the retaining lugs see diagram 12 2 e Remove the side panels by removing the screws on the upper and lower sides Remove the panels by swinging them out and lifting them up see diagram 12 3 e Remove the combustion chamber cover by removing six screws see diagram 12 4 47 nnn 12 Servicing RETAINING 3 8 SECURING i SCREWS 6 OFF i NET np INNER CASING 8 PANEL Es a LA IB a e j VIEWING i G 11 WINDOW VIEWING COMBUSTION WINDOW SECURING A gt SCREWS Diagram 12 2 Diagram 12 4 5 PLECTRICAL PRESSURE SWITCH 8 SIDE PANELS SECURING SCREWS 4 OFF Diagram 12 3 PRESSURE SWITCH CONNECTION TUBE SECURING SCREW FAN HOOD Diagram 12 5 48 12 Servicing 12 2 Fan removal Disconnect the electrical connections and air pressure switch connection tubes from the fan remove the fan securing screw and withdraw fan f
78. omponents in reverse order of removal ensuring all seals are correctly located and replaced if damaged Open the isolating valves on the flow and return connections refill vent and pressurise the boiler ensuring all joints are sound 14 20 Flow sensor For access refer to section 14 1 Refer to diagram 14 19 Remove the flow sensor using a pair of pliers Fit a replacement sensor in reverse order to removal 14562 FLOW SENSOR ELECTRICAL CONNECTION UNCLIP TO REMOVE Diagram 14 19 14 21 Three way valve motor For access refer to section 14 1 Refer to diagram 14 20 Ensure that the electric supply to the boiler is switched OFF Remove the electrical connection to the three way valve motor Remove the clips connecting the valve to L H hydroblock Fit the replacement valve in reverse order ensuring the valve is fitted properly ELECTRICAL CONNECTION 14590 THREE WAY VALVE MOTOR Diagram 14 20 63 15 Spare parts 15 1 Spare Parts When ordering spare parts contact Glow worm s own service organisation using the telephone number on the inside front cover of this booklet Please quote the name of the appliance and serial number to be found on the data label If ordering from British Gas also quote the G C number of the part Wou Desen oder Panno bajm O fent a Airpressure wien oczoo tose 5 onton tecrode wem oczoostsr e tonton eecrode et
79. ons External wiring must be correctly earthed polarised and in accordance with the relevant standards In GB this is BS 7671 In IE this is the current edition of ETCI rules The boiler MUST be connected to a permanent 230V ac 50Hz supply Connection of the whole electrical system of the boiler including any heating controls to the electrical supply MUST be through one common isolator and must be fused 3 Amp maximum Isolation should be by a double pole switched fused spur box with a minimum gap of 3mm for both poles The fused spur box should be readily accessible and preferably adjacent to the appliance It should be identified as to its use Alternatively connection can be made through an unswitched shuttered socket and 3A fused 3 pin plug both to the current issue of BS 1363 provided they are not used in a room containing a bath or shower Wiring to the boiler must be PVC 85 C insulated cable not less than 0 75mm2 24 0 20mm Testing and Certification This boiler is tested and certificated for safety and perform ance It is therefore important that no alteration is made to the boiler without permission in writing by Glow worm Any alteration not approved by Glow worm could invalidate the certification boiler warranty and may also infringe the current issue of the statutory requirements Statutory Requirements CE Mark This boiler meets the requirements of Statutory Instrument No 3083 The Boiler Efficie
80. or 2 x 45 elbows be used then the length MUST be reduced by 1 metre The diagram 9 10 shows the length achievable by using the kit A2043400 Standard Horizontal Flue 75 min to 560 max WALL THICKNESS G ZppL OUTSIDE WALL FACE BOILER MOUNTING WALL NOTE If necessary it is permitted to increase this dimension to 600mm max 87min Max flue length 730mm EGGL 20mm min clearance OUTSIDE INTERNAL WALL FACE SURFACE Max distance from outside Min distance from outside wall face to min clearance wall face to min clearance LH 477 5mm RH 477 5mm LH RH 75mm Diagram 9 10 When extension pipes are used the flue system must be designed to have a continuous fall to the boiler of at least 2 5 44mm metre to allow condensate to run back into the boiler and out via the condensate drain The flue can be installed from inside the building when access to the outside wall face is not practicable 25 9 Standard Flue Length Preparation and Installation A2043400 Top Outlet Standard Horizontal Concentric Flue Pack FLUE ELBOW SECURING SCREW x 4 COLLAR CCCEL SCREW x 2 GASKET TRIM RING fitted STANDARD TERMINAL ASSEMBLY SEALING COLLAR Diagram 9 11 a X l Q DEFLECTOR FLUE TERMINAL KIT 0020060582 BLACK BLACK TERMINAL KIT 0020060583 WHI
81. or installation of b attach the single pipe to concentric adaptor part number A2011500 to the base of vertical terminal assembly With the vertical terminal assembly positioned in the roof the length of the final pipe can be determined Cut the flue to the desired length measuring from the O ring seal end and discard the plain end of the tube The cut end should be square and free from burrs Carefully push the terminal assembly upwards to allow room for fitting the final flue piece s Fit a 100mm fixing bracket to the terminal assembly Part No2000460486 Pull the terminal assembly down and join to the flue system Ensure that the terminal is making a weather tight seal on the weather collar Secure the fixing bracket fitted to the terminal to the roofing struts or a purpose made batton 9 Plume Management Kit IMPORTANT The flue outlet must not be positioned within 300mm 12997 from an opening air brick or opening windows Ss FLUE N gt A OPENING WINDOW _ OR DOOR NA IS 150mm ONA NOCNE Diagram 9 27 9 25 Plume Management Kit The Plume Management Kit Part No A2044100 white or A2044000 black can be used to overcome many site issues The Plume Management Kit will fit to the Top Horizontal Telescopic Rear Horizontal Telescopic and Standard Horizontal Flue This enables the fl
82. outside the building facing downwards preferably over a drain To ease future servicing it is advisable to use a compression type fitting to extend the safety discharge valve tube The pipe must have a continuous fall and be routed to a position so that any discharge of water possibly boiling or steam cannot create any danger to persons damage to property or external electrical components and wiring 7 3 Boiler Hanging Lifting the boiler into position lean the top of the boiler slightly to the wall and position just above the hanging bracket Lower the boiler slowly onto the hanging bracket making sure the boiler is located in the boiler mounting slots see diagram 7 3 IMPORTANT With regards to the Manual Handling Operations 1992 Regulations the following lift operation exceeds the recommended weight for a one man lift refer to section 17 Manual Handling 18 8rebL my A MN K VIEWED FROM THE REAR OF THE BOILER Diagram 7 2 9vebL Diagram 7 3 8 System Pipes and Condensate Connections 8 1 Condensate Trap Connection Aflexible condensate outlet pipe is supplied and should be used to couple the condensate trap to a 22mm to 25mm O D non corrosive plastic pipe overflow pipe see diagram 8 1 NOTE the pipe should have a fall of a least 2 5 44mm metre away from the boiler Condensate should if possible be discharged in
83. r does not resume normal operation reset the appliance If the boiler does not resume normal operation after this call your Installation Servicing company or Glow worm service Overheating Safety The boiler software is designed to recognise the potential for an overheat Boiler Lockout The temperature of the water flowing from the primary heat exchanger is monitored by an overheat thermostat located on the outlet pipe If the water temperature gets too hot the switch opens cutting off the electrical supply to the gas valve and causing the boiler to Lockout Once activated the boiler has to be manually re set by switching the control knob off for 15 seconds and on again Low Water Pressure A hydraulically operated primary pressure sensor monitors water pressure or water shortage in the primary hydraulic circuit and will switch the boiler off if the pressure is below 0 3bar The boiler will not operate until the circuit has been re pressurised Flue Blockage For HK type an air pressure switch situated in the boiler s fan compartment monitors the boiler s flue operation Ifa partial obstruction within the flue occurs the fan will continue operating but the boiler s burner will shut down until the blockage is cleared Frost protection The boiler s control unit has in built frost protection device that fires the boiler s burner when the temperature of primary hydraulic water falls below 6 C The device works irrespective of an
84. re reference Installers are required to carry out installation commissioning and servicing work in accordance with the Benchmark Code of Practice which is available from the Heating and Hotwater Industry Council who manage and promote the Scheme Visit www central heating co uk for more information penchmar THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS These instructions consist of Installation Servicing Fault Finding Replacement of Parts and Spares The instructions are an integral part of the appliance and must to comply with the current issue of the Gas Safety Installation and Use Regulations be handed to the user on completion of the installation CONTENTS DESCRIPTION SECTION PAGE Warnings 4 Important Information 4 Statutory Requirements 3 Boiler Design 6 INTRODUCTION Safety Devices 6 Servicing Maintenance and Spare Parts T Boiler Specification 8 Boiler Components 9 Boiler Dimensions and Hydraulic Schematic 2 10 Boiler Location Clearances and Ventilation 8 11 Flue Options and Terminal Clearances 4 12 Water System Heating 5 14 Water System Domestic Hot Water 5 1 Installation Preparation 6 16 Boiler Fixing Gas Water Safety Discharge Connection ra 18 System Pipes and Condensate Connection 8 19 INSTALESTION Condensate Connections 8 20 Telescopic Flue Length Preparation and Installation 9 21 Standard Flue Length Preparation and Insta
85. rom fan hood with its 56 bend see diagram 12 5 12 3 Burner removal Remove the burner assembly from the combustion chamber as follows Pull off the ignition and flame electrode leads from mains circuit board and remove the wires with grommet from the combustion chamber base see diagrams 12 6 and 12 7 Remove the burner retaining screws at the sides and remove the burner see diagram 12 8 12 4 Visually check For debris damage and clean replace as necessary the following items Heat exchanger Burner Fan compartment Electrodes and Insulation gaskets IMPORTANT Clean the heat exchanger using a soft brush or vacuum cleaner Do not use any tool likely to damage painted finish of heat exchanger Clean the burner by washing in soapy water Allow to dry thoroughly before re fitting Do not use wire or a sharp instrument to clean the burner injectors Ensure the ignition electrode gap is set to 4 mm see diagram 12 7 12 5 Cold water inlet filter The boiler is fitted with a cold water inlet filter which must be inspected on each service see diagram 12 9 To access the filter Close the isolating valve on the boiler s cold water domestic inlet by turning the valve head fully clockwise Open one or more hot water taps to drain the domestic hot water circuit Disconnect the cold water inlet connection to the boiler Clean and inspect the filter replace if necessary as described in replacement of parts section 14 19 Re fit
86. rque headed screws supplied Draw the flue assembly from wall and engage the flue duct into the elbow and butt fit between the air duct and flue elbow Ensuring the correct alignment of the terminal Fit the securing collar into position mark through two of the pre drilled holes in the securing collar Remove securing collar and drill two 3mm diameter holes one in the elbow and one in the air duct take care not to pierce the inner flue duct Fit the securing collar and secure with screws provided see diagram 9 17 Slide the internal trim ring back against the wall securing in place with a small amount of sealant if required NOTE If the air and flue ducts have been correctly cut to the instructions the sealing collar should fit flush with the outside wall check this 9 Vertical Flue Length Preparation and Installation 9 11 Vertical flue The vertical flue system is available as an option where the boiler position does not permit the use of the top horizontal flue system The system is made up from accessories The accessories include terminal assembly bends 45 and 90 flue extensions fixing bracket and appropriate weather collar see diagram 9 19 The maximum permitted straight flue length is 6 8 metres for Betacom 24C 5 8 metres for Betacom 30C for each 90 or 2x45 bends fitted the maximum length must be reduced by 1 metre see diagram 9 18 NOTE 2x45 bends can replace 1x90 bend if necessary When using 90
87. ther collar Secure the fixing bracket fitted to the terminal to the roofing struts or a purpose made batton EXTENSION PIPE SECURING COLLAR SECURING SCREW 2 14528 N to FLUE SECURING ki ADAPTER ge SCREW 4 SEALING GASKET Diagram 9 20 Diagram 9 21 EXTENSION D PIPE A SECURING COLLAR SECURING M il SCREW 2 EXTENSION PIPE i Diagram 9 22 9 co A EXTENSION DO NOT CUT NG kai END DUCT DUCT Diagram 9 23 31 9 Twin Flue Length Preparation and Installation 14530 Secure long flue lengths horizontal amp vertical to walls or ceiling at every joint or on straight flue runs at every joint and every metre flue run a 100 mm NW APPROX 100 mm APPROX 21 2 44mm metre Diagram 9 24 32 9 Twin Flue Length Preparation and Installation TWIN FLUE ADAPTOR with gasket supplied stuck to adaptor LITERATURE TWIN FLUE ADAPTOR KIT A2011000 VERTICAL CONCENTRIC TERMINAL Part No 2000460480 Black TWIN PIPE 80mm TO CONCENTRIC ADAPTOR X Part No A2011600 SINGLE PIPE 80mm METRE TO CONCENTRIC EXTENSION ADAPTOR Part No A2011100 Part No A2011500 HORIZONTAL TERMINAL e Part No A2011200 100mm FIXING BRACKET x 5 Part No 2000460486 mann FIXING BRACKET Part No A2012800 PITCHED ROOF
88. to the household internal drainage system If this is not practicable discharge can be allowed into the external household drains or a purpose designed soak away refer to diagram 8 3 It is recommended that any external condensate drain pipe is insulated and also preferably of 32mm diameter to prevent freezing in adverse weather conditions It is not necessary to provide air breaks or extra traps in the discharge pipe as there is already a 75mm high trap inside the boiler Fitting an extra trap may cause the boiler siphon to work incorrectly Refer to BS5546 or BS6798 for advice on disposal of boiler condensate 8 2 System Pipes Connection Plumb gas and water system pipe work up to the isolation valves using olives supplied see diagram 8 2 Do not subject isolation valves to heat The whole of the gas installation including the meter should be inspected tested for tightness and purged in accordance with the current issue of BS6891 and in IE the current edition of l S 813 Domestic Gas Installations CONDENSATE OUTLET PIPE LCSVL CONDENSATE TRAP Diagram 8 1 14552 ISOLATION VALVES SHOWN CLOSED Diagram 8 2 19 8 Condensate Connections INTERNAL SOIL EXTERNAL SOIL 8 ANE VENT STACK AND VENT STACK 8 EXTERNAL MAX 3M 22mm MIN 22mm MIN NO RESTRICTION NO RESTRICTION ON LENGTH ON LENGTH Internal Soil an
89. ts i CO Vol CO ppm Appliance Natural gas Propane Natural gas Propane tolerance tolerance tolerance tolerance m Mm w m Betacom 246 _ 860 05 385 0 5 960 05 4 40 0 5 Betacom30c _ 810 05 2 90405 9 30 05 3 35 0 5 11 Commissioning 11 7 Boiler Adjustments The boiler incorporates 4 potentiometers and a bank of dip switches to allow adjustment to its pre set parameters These are situated on the rear ofthe control panel The potentiometers can easily be accessed by removing the cover on the rear of control panel However to reach the dip switches the control panel must be opened see diagram 10 4 Setting the maximum CH heating flow temperature The boiler is dispatched with a maximum flow temperature factory set to 85 C Where a lower maximum temperature is required such as in the case of under floor heating the factory setting can be altered between a maximum of 50 C and a minimum of 30 C by fitting dip switch 6 into ON position see diagram 11 11 Setting the boiler s integral pump The boiler s integral pump is factory set to operate in both C H and D H W mode Where an external pump is incorporated into the system design the integral pump may be disconnected in C H mode by fitting dip switch 5 into the ON position see diagram 11 11 Setting the 45 seconds delay The boiler is factory set to exclude the delay of 45 seconds before re ignition between the closing of a
90. ue products to exhaust further away from the boiler thereby reducing the impact of pluming NOTE The flue air inlet can be sited closer to doors opening windows and air bricks than stated in section 4 2 see diagram 9 27 The maximum length of the Plume Management Kit must NOT exceed 2m with a horizontal concentric flue length of 1m max For each 90 bend or 2 x 45 bends the maximum length of the Plume Management Kit must be reduced by 1m For more information contact Glow worm refer to page 2 The Plume Management Kit is supplied with installation instructions Refer to BS5546 or BS6798 for advice on disposal of boiler condensate 10 Electrical Connection WARNING This appliance must be earthed e This appliance must be wired in accordance with these instructions Any fault arising from incorrect wiring cannot be put right under the terms of the Glow worm guarantee e All system components must be of an approved type Electrical components have been tested to meet the equivalent requirements of the BEAB e Do not interrupt the mains supply with a time switch or programmer e Connection of the whole electrical system and any heating system controls to the electrical supply must be through a common isolator e Isolation should preferably be by a double pole switched fused spur box having a minimum contact separation of 3mm on each pole The fused spur box should be readily accessible and preferably adjacent to the boiler It
91. urface see examples b and c diagram 9 24 9 22 Vertical Terminal Installation With due consideration to terminal clearances mentioned in Section 4 2 project the rise of the flue pipe to roof level and cut 150mm hole in the roof a Pitched Roof Fit the required pitched roof weather collar over the 150mm hole in the roof Make good the tiling or slating around the collar incorporating the flashing of the weather collar Position the angle cap over the weather collar in the correct orientation to attain the correct angle for your roof One way round gives a pitch of 25 38 and the other gives 37 50 b Flat Roof Fit the aluminium weather collar over the 150mm hole in the roof ensuring a weather tight seal 9 23 Horizontal Pipes Completion of Installation Having built the pipe s from the boiler to the terminal s the length of the final pipe piece can be determined Cut pipes at the opposite end to the O ring seal making square and free from burrs Push the horizontal terminal through the wall to engage the final pipe piece and pull back ensuring the grey wall seals are fully pulled up to the outside and inside wall faces 34 SECURING 2 SCREW 4 RI SEALING PLUG Diagram 9 26 9 24 Vertical Pipes Completion of Installation Refer to diagram 9 24 For installation of a attach the twin pipe to concentric flue adaptor part number A2011600 to the base of vertical terminal assembly F
92. vided in the roof space Itis recommended a risk assessment of the roof space area be carried out before moving the appliance into the area to take into account access stability of flooring lighting and other factors and appropriate measures taken Unpacking of appliance from carton Recommend 2 persons unpack appliance from carton Always keep working area clear Recommend cut base end of carton and open carton flaps then tilt boiler forwards from its side onto its base and remove carton by sliding up over the boiler Ensure safe lifting tech niques are used keep back straight bend using legs Keep load as close to body as possible Always use assistance if required Dispose 66 Z of packaging in a responsible manner Recommend wear suitable cut resistant gloves with good grip to protect against sharp edges and ensure good grip when handling appliance outside packaging Positioning of Appliance for Final Installation no obstructions This appliance is deemed to be a one person lift when removed from the carton Fit bracket securely onto wall before lifting appliance into position Obtain firm grip on front and sides of appliance lift upwards ensure stable balance achieved and lift upwards to position in place on bracket Ensure safe lifting techniques are used keep back straight bend using legs when lifting load from floor level Do not twist reposition feet instead Keep boiler as close as possible to bod
93. y room thermostat setting and will protect the complete heating system On reaching a water temperature of 15 C the boiler reverts to normal operation NOTE If the boiler will not be used for long periods of time during cold weather in order to avoid freezing the electric supply must be left ON and all the central heating isolation valves must be left open The internal frost protection device will then operate the boiler if the temperature falls too low However if the electrical supply is to be turned off the boiler the heating system and domestic hot water circuit must be drained Safety Discharge Valve A safety discharge valve and discharge pipe are fitted to the boiler This valve must not be touched Should there be any discharge from the pipe isolate the boiler electrical supply and call your installer or Glow worm s own service organisation using the telephone number on the inside front cover of this booklet Condensate Drain Blockage As a safety feature the boiler will stop working if the condensate drain becomes blocked During freezing conditions this may be due to the forming of ice in the condense drain external to the house Release an ice blockage by the use of warm cloths on the pipe the boiler should then restart NOTE If the boiler fails to resume normal operation and all external controls are calling for heat then call your Installation Servicing company or Glow worm service Servicing Maintenance and Spar
94. y throughout lift to minimise strain on back Ensure co ordinated movements to ensure equal spread of weight of load Always use assistance if required Recommend wear suitable cut resistant gloves with good grip to protect against sharp edges and ensure good grip when handling appliance Positioning of Appliance for Final Installation above worktop foreseeable obstructions etc This appliance is deemed to be a one person lift when removed from the carton Fit bracket securely onto wall before lifting appliance into position Obtain firm grip on front and sides of appliance lift upwards onto worktop if practicable Ensure stable balance achieved and lift upwards to position in place on bracket If 2 persons positioning onto bracket obtain firm grip at front and sides base of boiler Ensure co ordinated movements during 2 person lifts to ensure equal spread of weight of load Ensure safe lifting techniques are used keep back straight bend using legs when lifting load from floor level Do not twist reposition feet instead Keep boiler as close as possible to body throughout lift to minimise strain on back Avoid upper body top heavy bending do not lean forward sideways Always use assistance if re quired Recommend wear suitable cut resistant gloves with good grip to protect against sharp edges and ensure good grip when handling appliance Positioning of Appliance for Final Installation within compartment etc restri

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