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18-30sxi Range Installation & Service Manual Boilers - Glow-worm

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1. S A PEN Diagram 3 6 0020008155A 14 4 Heating System 4 1 General The boiler is for use only with sealed central heating systems The safety valve is an integral part of the boiler and it cannot be adjusted The digital read out on the controls fascia indicates the system pressure when there is no demand The circulation pump is integral with the boiler 4 2 Expansion Vessel The boiler has an integral expansion vessel with a capacity of 8 litres 1 76 gallons with a change pressure of 0 5bar NOTE The expansion vessel volume depends on the total water system volume and the initial system design pressure To check if an additional expansion vessel is required an accurate calculation of vessel size is given in the currentissue of BS5449 and BS7074 Part 1 for IE refer to the current edition of I S 813 Domestic Gas Installations 4 3 Flow Rate The flow rate through the boiler must not be allowed to fall below that given in Table 3 The system can be fitted with a lockable balancing valve if necessary in the main flow or return pipes shown as valve A in diagram 4 1 4 4 Bypass The boiler is fitted with an adjustable automatic bypass Ensure that under no circumstances does the flow rate drop be
2. Max distance from outside Min distance from outside wall face to min clearance wall face to min clearance LH 458mm RH 486mm TOP SIDE FLUE STANDARD LH RH 75mm Diagram 3 2 N 75 min to 540 max 9 208 min to 413 max WALL THICKNESS N WALL THICKNESS 3 OUTSIDE BOILER OUTSIDE BOILER WALL FACE MOUNTING WALL WALL FACE MOUNTING WALL NOTE If necessary it is permitted to increase NOTE If necessary itis permitted to increase this dimension to 600mm max this dimension to 600mm max TOP REAR FLUE STANDARD Diagram 3 1 TOP REAR FLUE TELESCOPIC Diagram 3 3 NOTE If necessary itis permitted to NOTE If necessary it is permitted to increase this dimension to 600 max ES increase this dimension to 600mm max 9 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 330mm LH 125mm RH 358mm RH 153mm TOP SIDE FLUE TELESCOPIC Diagram 3 4 13 0020008155A 3 Flue Location and Ventilation UNDER CAR PORT etc MINIMUM SITING DIMENSIONS FOR FANNED FLUE TERMINALS POSITION MM HORIZONTAL FLUES OPENING WINDOWS B ABOVE AN OPENING AIR BRICK OPENING WINDOWS C HORIZONTALLY TO AN OPENING AIR BRICK OPEN
3. 11 1 Preliminaries A competent person in accordance with the current issue of BS6798 should carry out commissioning NOTE Remove the inner casing panel see diagram 11 1 Make sure that the system has been thoroughly flushed out with cold water without the pump in place Refit the pump fill the system with water making sure that all the air is properly vented from the system and pump see diagram 11 2 Before operating the boiler check that all external controls are calling for heat 0020008155A 11 Commissioning 11 2 System Commissioning Open the two central heating isolating valves slots in line with the length of the valve see diagram 7 1 To enable the system pressure to be viewed turn the heating temperature knob to the OFF position Turn the mains electricity supply on to the appliance and ensure that the mains switch on the appliance fascia is set to the on position The system pressure should be viewed on the digital display on the front of the appliance see diagram 1 of the Users Instructions Pressurise the system until the pressure on the display reads at least 1 0bar Make sure that the automatic air vent works correctly and that the black cap is loosely fitted to allow air to escape see diagram 11 2 Check the heating system and boiler connections for water soundness 11 3 Preparation for Lighting Isolate the boiler from the mains electrical supply Test for gas soundness and pur
4. 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 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 lf 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 personis 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 lf 2 persons performing 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 reposition feet instead Take care to avoid trip hazards slippery or wet surfaces and when climbing steps and stairs Always use assistance if required 0020008155A Manual Handling Car
5. 14 21 Bypass Tube For access refer to section 14 1 Refer to section 12 8 and drain the boiler heating circuit Refer to diagram 14 15 Remove the retaining clips to remove the bypass tube Replace the bypass tube refill vent and pressurise the boiler Check for leaks 14 22 Automatic Bypass Valve For access refer to section 14 1 Refer to section 12 8 and drain the boiler heating circuit Refer to diagram 14 15 Remove the retaining clip to remove the bypass valve Replace the reduced pressure zone valve refill vent and pressurise the boiler Check for leaks 14 23 Central Heating Filter Refer to section 12 7 AUTOMATIC AIR VENT 11507 Diagram 14 14 FLOW PIPE CONNECTOR AUTOMATIC s BYPASS VALVE ELECTRICAL LEAD AND PLUG 11605 V LOW WATER PRESSURE SENSOR E BYPASS TUBE Diagram 14 15 0020008155A 14 Replacement of Parts 14 24 Heating Circuit Drain Point Refer to section 12 8 to drain the boiler heating circuit Refer to diagram 14 16 Remove the retaining clip to remove the drain point Replace the draining point refill vent and pressurise the boiler Check for leaks 14 25 Inner Casing Panel Seal For access refer to section 14 1 Refer to diagram 14 17 Remove the inner casing panel To replace remove the old seal thoroughly clean the casing surfaces Fit the new seal it is supplied to the correct length R
6. 12 8 Draining of Boiler Heating Circuit Drain down the Heating Circuit only by closing the heating flow and return isolating valves on the wall mounting jig see diagram ea Attach a length of hose to the drain point and open the drain valve see diagram 12 11 After servicing or replacing parts close the drain valve and remove the hose Open the heating flow and return isolating valves and refill vent and pressurise the heating circuit See section 11 2 Check for leaks 12 9 Inner Casing Panel Seal Check Check the condition of the seal replace as required To replace remove the old seal thoroughly clean the casing sufaces Fitthe new seal itis supplied to the correct length see diagram 12 12 RETAINING CLIP SS X HOUSING 9184 FIXING JIG CENTRAL HEATING RETURN FILTER e GAS SERVICE DRAIN POINT DRAIN VALVE MOUNTING JIG Diagram 12 11 FRONT CASING gt S PANEL INNER CASING PANEL Diagram 12 12 0020008155A 13 Fault Finding NOTE Before trying to operate the boiler make sure that All gas supply cocks are open and that the gas supply has been purged of air There is a permanent mains supply to the boiler There is a heating demand from the external controls WARNING Always isolate the boiler from the electrical supply before carrying out any electrical replace
7. Any fault arising from incorrect wiring cannot be put right under the terms of the Glow worm guarantee All system components must be of an approved type Electrical components have been tested to meet the equivalent requirements of the BEAB Connection of the whole electrical system and any heating system controls to the electrical supply must be through a common isolator Isolation should preferably be by a double pole switched fused spur box having a minimum contact separation of 3mm on each pole The fused spur box should be readily accessible and preferably adjacent to the boiler It should be identified as to its use A fused three pin plug and shuttered socket outlet may be used instead of a fused spur box provided that a They are not used in a room containing a fixed bath or shower b Both the plug and socket comply with the current issue of BS1363 The mains electrical supply must be maintained at all times in order to provide domestic hot water Do not interrupt the mains supply with a time switch or programmer WARNING UNDER NO CIRCUMSTANCES MUST ANY MAINS VOLTAGE BE APPLIED TO ANY OF THE TERMINALS ON THE VOLTAGE FREE HEATING CONTROLS CONNECTION PLUG 10 1 Mains Cable IMPORTANT If a replacement supply cable is required it must be purchased Part No S1008600 10 2 External controls Mains Voltage Gain access to the 230V interface by unclipping the controls fascia and hinging forward see diagram 10
8. Diagram 10 3 0020008155A 26 9808 CONTROL PANEL REAR COVER c STRAIN RELIEF gt CABLE EXIT SECURING SCREW 3 a MAINS CABLE EXTERNAL CONTROL CABLE Diagram 10 4 11 Commissioning Please ensure the Benchmark logbook is completed and left with the user and the magnetic lighting instruction label is placed on the surface of the boiler casing LPG CONVERSION 30sxi only NOTE Steps 11 1 to 11 3 will need to be completed before the appliance can be converted The 30sxi can be converted to run on LPG Propane G31 This conversion should only be carried out by a competent person During the conversion to Propane use of a suitable flue gas analyser is necessary As an option a chargeable boiler only commissioning service can be provided by Glow worm Service by calling telephone No 01773 828100 Tools required to make the conversion are a 2mm Allen key and an electricians screwdriver Ensure that the appliance supply pressure 37mb 1 2 Access the gas valve Refer to diagram 11 3 and turn the gas valve throttle fully clockwise Turn the throttle back anti clockwise by 5 2 turns Ensure that the gas analyser is set to the correct fuel setting Propane Attach combustion analyser to the combustion test point See diagram 12 1 Unclip the controls fascia to reveal the service potentiometer on the rear of the user interface See diagr
9. Electronic igniter defective Check air inlet duct Check connections to igniter unit Ignition fault lockout Went out when lit As F1 possible cause Overheat fault Overheat stat operated Maximum temperature exceeded Check thermistor connections Air in system with thermistor at maximum setting Faulty overheat stat connection Check that pump is wired into appliance and not from programmer This would cause no pump overrun Central heating flow thermistor fault Thermistor cable defective broken thermistor faulty Check that thermistor attached correctly to pipe Water pressure sensor fault Faulty sensor connection check wiring Central heating return thermistor fault Thermistor cable defective broken thermistor faulty Check that thermistor attached correctly to pipe Main board connection fault Check wiring between mainboard and user interface User interface connection fault Check wiring between mainboard and user interface Main PCB connection fault Check connections and wires Central heating flow temperature is greater than 95 C System fault Possible pump failure Check Thermistor on flow Flame detection fault flame presence for more than 5 seconds after burner stop Gas valve defective Power supply is less than 170V Check electrical supply polarity User interface fault Faulty User Interface Central heating thermistor unplugged Check Ther
10. 1 Remove the red link from the mains voltage heating controls connection plug and connect as shown diagrams 10 2 amp 10 3 then route the external control cable as shown on diagram 10 2 Close the fascia panel and open the rear cover of control panel See diagram 10 4 Secure the external control cable in the strain relief see diagram 10 4 Thread the external control cable through rear of the control panel where the other cables exit see diagram 10 4 Close rear cover of control panel External control should be fitted in accordance with the rules in force Refer to wiring diagram in Section 13 25 RETAINING LATCHES 11505 CONTROLS FASCIA Diagram 10 1 EXTERNAL CONTROLS CABLE MAINS VOLTAGE 11408 Diagram 10 2 0020008155A 10 Electrical Connections 10 4 Electrical Connections Testing Carry out preliminary electrical system checks as below 1 Test insulation resistance to earth of mains cables 2 Test the earth continuity and short circuit of cables 3 Test the polarity of the mains N e 2 THERMOSTAT m CONNECTIONS OPGE 230V CONTROLS CONNECTOR J15 MAINS INTERFACE CONNECTION BOX CONTACT ROOM THERMOSTAT FROST b THERMOSTAT 3 AMP FUSE EXTERNAL CLOCK POLE ISOLATOR b 230V AC ROOM THERMOSTAT 230V AC FROST THERMOSTAT L N E E 230V 50Hz PERMANENT MAINS SUPPLY
11. 14 18 14 Replacement of Parts 14 27 Hydroblock Assembly Left Hand Refer to section 12 8 to drain the boiler heating circuit Refer to diagram 14 15 Undo the connector on the bottom of the flow pipe from the hydroblock Undo the nut connecting flow pipe to heat exchanger Lift the flow pipe up out of the way Remove the bypass tube refer to section 14 20 Undo the safety discharge valve union and remove the pipework Remove the securing clip and withdraw the safety discharge valve refer to section 14 15 Remove securing clip 1 below hydroblock see diagram 14 19 Undo three securing screws on the underside of the left hand hydroblock Remove screw in back plate Lift out the left hand hydroblock Remove any remaining components for refitting into the replacement left hand hydroblock Refill vent and pressurise the boiler Check for any leaks 14 28 Hydroblock Assembly Right Hand For access refer to section 14 1 Refer to section 12 8 to drain the boiler heating circuit Refer to diagram 14 15 Undo the connector on the bottom of the return pipe from the hydroblock Undo the nut connecting return pipe to heat exchanger Lift the return pipe up out of the way Undo the coupling at the base of the expansion vessel see diagram 14 8 Remove the clip holding the expansion vessel coupling into the top of the right hand hydroblock Move the coupling out of the way Remove pump head refer to s
12. 4 For IE itis 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 1 5 813 Testing Flue Gases If any doubt exists that the flue products are not exhausting correctly investigate by use of a gas analyser FGA 11 Commissioning Instructions to the User 11 8 User Controls and Options The mains reset switch is used to restart the boiler after a fault condition has occurred i e ignition failure The central heating water temperature control knob allows the user to set the desired temperature NOTE Ifthere is no demand the digital display shows the water pressure Temperature Display The digital display normally shows the operating temperature of the unit when there is a central heating demand 11 9 Pump Exercise Program After a power cut or every 24 hours in frost setting summer mode the pump will run for one minute to prevent it from sticking This will also occur during normal operating if there is no demand for more than 24 hours 11 10 Frost Protection The boiler has a built in frost protection programme as long as the electricity and gas are left switched on This device operates the burner and system pump when the temperature inside the boiler falls to 39C When the temperature inside the appliance reaches 10 C the burner will shut down and after a short period the pump will stop This device prim
13. Air Vent E84001 6 2000801897 Central Heating Filter E84002 f 801722 Heating flow thermistor Heating return thermistor E84003 8 801649 Gas valve E84004 9 2000802779 Mains Reset Switch H20701 10 801655 Igniter Unit E84015 11 2000801909 By pass E84016 12 2000801 923 230V Controls Interface E84018 13 2000802731 Main PCB 14 2000801380 Pump head only E77408 15 801645 Fan 16 2000802661 User Interface 18sxi E84024 16 2000802642 User Interface 30sxi 17 801632 Burner 18sxi E84021 17 801702 Burner 30sxi E84249 14 Diagram 15 1 Because of our constant endeavour for improvement details may vary slightly from those shown in these instructions 0020008155A 48
14. Fault Finding Replacement of Parts Spare Parts SECTION a PAGE No ans oNN 0020008155A Important Information 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 Sheet 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 Gas Category This boiler is for use only on G20 natural gas but the 30sxi may be converted for use on G31 gas Propane L P G Gas safety Installation and use Regulations In your interests and that of gas safety itis the law that ALL gas appliances are installed and serviced by a competent person in accordance with the above regulations Testing and Certification This boiler is tested and certificated for safety and performance It is therefore important that no alteration is made to the boiler without permission in writing from 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 CE Mark This boiler meets the re
15. REQUIRE A NEW GASKET WHEN REFITTED Drop down the control panel into the service position see diagram 10 4 Disconnect the gas supply at the gas service cock Remove the two gas pipe retaining clips one located below gas valve and the other one located on the underside of the boiler chassis see diagram 12 4 Pull sealing grommet down gas pipe see diagram 12 4 Push the gas pipe upwards further into gas valve connection and then rotate anti clockwise looking down until the gas pipe end is over the large hole in boiler chassis see diagram 12 4 Withdraw the gas pipe from gas valve connection and remove NOTE When replacing ensure that the sealing grommet situated below the gas valve is correctly re seated Disconnect the gas control valve plug at the gas control valve Disconnect the electrical leads from the fan Remove the five combustion chamber front retaining nuts see diagram 12 5 Gently remove the fan gas control valve and burner assembly from the combustion chamber see diagram 12 3 Clean the burner with a soft brush taking great care not to damage the front insulation DO NOT use wire or sharp instruments to clean the holes of the burner Inspect the burner for any signs of damage Inspect the sealing rings and replace if necessary Removal ofthe burner is not necessary during a normal service 12 4 Combustion Chamber and Heat Exchanger Refer to diagram 12 3 Remove loose debris from combustion chamb
16. and remove Disconnect wiring from pump head Reconnect wiring to new pump head and fit cover Fit the new pump head with O ring Refill vent and pressurise the boiler Check for leaks 41 11490 FLOW AND RETURN PIPE SECURING SCREWS AND CLAMPS Diagram 14 9 11602 SECURING SCREWS Diagram 14 10 0020008155A 14 Replacement of Parts 14 15 Safety Discharge Valve For access refer to section 14 1 Refer to section 12 8 and drain the boiler heating circuit Refer to diagram 14 12 Undo the safety discharge valve union and remove from the pipework Remove the securing clip and withdraw the safety discharge valve Refill vent and pressurise the boiler Check for leaks 14 16 Heating Flow Thermistor For access refer to section 14 1 Refer to diagram 14 13 Remove the electrical connections from the thermistor Remove the retaining clip from the flow pipe Remove the thermistor from the retaining clip Note that the polarity of the wiring to thermistors is unimportant 14 17 Heating Return Thermistor For access refer to section 14 1 Refer to diagram 14 15 Remove the electrical connections from the thermistor Remove the retaining clip from the return pipe Remove the thermistor from the retaining clip Note that the polarity of the wiring to thermistor is unimportant 14 18 Overheat Thermostat For access refer to
17. measure the distance from the outside wallto the butt joint see diagram 9 5 If the measurement Y exceeds 652mm then the appropriate length of extension pipe is required The minimum dimension for Lhd is 270 and Rhd 242 to suit a minimum wall thickness of 75mm fitted measure the distance from the outside wall to the butt Y 3 joint see diagram 9 6 Ifthe measurement exceeds 525mm FLUE then the appropriate length of extension pipe is required if the OUTER AIR gt dimension is less than 320mm DO NOT cut the flue it can RUBBER pis a project to a maximum of 600mm if this is not desirable then a CREER DRILL AND Standard flue MUST be used and cut to length SCREW Y 9 N WALL THICKNESS 112 oo oem OUTSIDE WALL FACE DRILL AND INNER PLASTIC COLLAR COLLAR TOP SIDE FLUE STANDARD Diagram 9 5 OUTSIDE BOILER WALL FACE MOUNTING WALL Y Ire E TOP REAR FLUE STANDARD Diagram 9 3 OUTER FLUE RUBBER DUCT AIR COLLAR DUCT COLLAR M o DRILL AND i g 9 SCREW WALL THICKNESS 112 7 DRILL AND SCREW OUTSIDE WALL FACE INNER PLASTIC COLLAR COLLAR OUTSIDE BOILER WALL FACE MOUNTING WALL DRILL AND SCREW TOP REAR FLUE TELESCOPIC Diagram 9 4 TOP SIDE FLUE TELESCOPIC Diagram 9 6 23 0020008155A 9 Flue Preparation Telescopic and Standard Flue 9 2 cont d Flue and Air Ducts Telescopic The Telescopic Flue system MUST NOT be cut Adjust the flue
18. see diagram 7 1 All routine servicing requirements can be achieved by the removal of the front panel and inner panel only To remove simply undo the two screws on the underside of the front panel and lift off see diagram 11 1 Undo the two screws on the front of inner panel and lift off see diagram 11 1 Unless stated otherwise any part removed during servicing should be replaced in the reverse order to removal Servicing should always include the removal of any debris from the condensate pipe and siphon After completing any servicing of gas carrying components ALWAYS test for gas soundness and carry out a functional test of the controls Testing Flue Gases If any doubt exists that the flue products are not exhausting correctly investigate by use of a gas analyser FGA 12 2 Spark Electrode Disconnect the electrode lead and two securing screws Withdraw the spark electrode carefully from the combustion chamber see diagram 12 2 and 12 5 Inspect the tips for damage Clean away any debris and check the spark gap is 3 5mm to 4 5 mm Check the electrode gasket for signs of leakage and replace if necessary 0020008155A 30 LO N COMBUSTION ANALYSER TEST POINT FLUE DUCT EXTENSION Diagram 12 1 SPARK GAP 2 3 5 to 4 5 SPARK ELECTRODE m SCREW 2 OFF EARTH Diagram 12 2 12 Servicing 12 3 Burner NOTE IF THE BURNER HAS TO BE REMOVED IT WILL
19. the standard flue length alone is being used then the flue hole of diameter 105mm can be cut in the position marked on the wall template For standard side flues the horizontal flue centre line on the wall template should be extended to the side wall and the vertical centre of the flue hole marked at 176mm from the back wall For installations with external access a 105mm diameter core drill can be used For installations with internal access only a 125mm diameter core should be used When using extension pipes with the horizontal rear flue a core drill size of 125mm should be used to allow the extension pieces to slope at 44mm metre 2 5 towards the boiler For extended side flues the flue hole centre should be determined by extending the dashed inclined line on the template to the side wall This dashed line is drawn at 44mm metre 2 5 rise from the boiler Where this line reaches the side wall a horizontal line should be marked The vertical centre line of the flue should then be marked at 176mm from the back wall see diagram 6 2 To allow for the flue passing through the wall at this angle a 125mm hole should be drilled irrespective of internal or external installation If necessary remove the wall template whilst drilling the flue hole 6 4 Fixing Jig and Hanging Bracket Fixing Reposition the wall template over the flue hole and mark the position of the fixing holes for the jig and the hanging bracket see diagr
20. the user controls are satisfied NOTE That after first power up the firing sequence changes After one minute stabilisation time the boiler will ramp slowly to full rate rather than going immediately to full rate This is an adaptive feature to cope with small system requirements 0020008155A 28 OFFSET 9 ADJUSTMENT GAS T VALVE THROTTLE ELECTRICAL PLUG PRESSURE TEST POINT Diagram 11 3 11 5 Testing Gas Case Off Case On Burner CO G20 9 1 0 2 0 5 9 3 0 3 0 5 Burner CO Propane G31 10 5 0 3 0 7 10 7 0 3 0 8 Should any doubt exist about the gas rate check it using the gas meter test dial and stop watch at least 10 minutes after the burner has lit making sure that all other gas burning appliances and pilot lights are off The approximate gas rate 18sxi 2 0m h 71 ft h 30sxi 3 0m h 107 ft h NOTE LPG G31 should be adjusted as described on the previous page It should be checked that the supply pressure is 37mb for LPG appliances The gas valve is factory set and should need no adjustment It should be checked that the supply pressure is 20mb when the boiler is firing at full rate This can be achieved by checking the inlet pressure at the pressure test point on the gas valve shown in diagram 11 3 Disconnect pressure gauge NOTE That the burner pressure cannot be measured at the gas valve as itis altered by the suction of the fan and modulated according to de
21. 0020008155A 02 05 Instructions for Use Installation and Servicing Tobeleftwiththe user 12041 18sx1 G C No 41 047 72 308 1 G C No 41 047 62 High Efficiency Condensing System Boiler low worm High Efficiency First Glow worm Nottingham Road Belper Derbyshire DE56 1JT 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 Guarantee This product is guaranteed for 24 months from the date of installation or 30 months from the date of manufacture whichever is the shorter for parts In addition this product is guaranteed for 12 months from the date of installation or 18 months from the date of manufacture whichever is the shorter for labour The second year of the parts guarantee from the beginning of the 13th month onwards after installation or manufacture is conditional upon the boiler having been serviced by a CORGI registered gas installer in accordance with the manufacturer s recommendations We strongly recommend regular servicing of your gas appliance but where the condition is not met any chargeable spare parts or components issued within the applicable guarantee period still benefit from a 12 month warranty from the date of issue by the manufacturer We recommend you complete and return as soon as possible you
22. 1200 100 rpm which will flash 12 on the digital display Check the CO value which should be 9 1 0 2 0 5 If adjustment proves necessary then proceed as follows Adjustment of the CO at minimum rate is very coarse so carefully adjust the CO with the offset adjustment to 9 1 0 2 0 5 see diagram 12 6 Rotate the service potentiometer fully clockwise and recheck the maximum rate combustion which should be 9 1 0 2 0 5 0 2 0020008155 32 After checking combustion rotate the service potentiometer fully anti clockwise so that the display indicates the water temperature Replace the cap on the test point and refit the control cover rear panel OFFSET ADJUSTMENT 12402 THROTTLE Diagram 12 6 CONTROLS USER INTERFACE FASCIA 11417 _ SERVICE RM eee Diagram 12 7 MAX POTENTIOMETERS 12 Servicing 12 7 Central Heating Return Filter Turn off the electrical supply to the boiler Refer to section12 8 and drain the heating circuit of the boiler Remove the filter retaining clip and clean filter or renew if necessary see diagram 12 10 Refit the filter ensuring the correct orientation The flat and hole in the filter positioned as shown in diagram 12 10 Secure with retaining clip Open the heating flow and return isolating valves and refill vent and pressurise the heating circuit See section 11 2 Check for leaks
23. 20008155A 4 Heating System 4 6 Water Treatment Inthe case of an existing installation it is ESSENTIAL that prior to installing the new boiler the system is thoroughly flushed For optimum performance after installation of a new system the boiler and its associated central heating system should also be flushed Flushing should be carried out in accordance with BS7593 1992 using acleanser such as Sentinel X300 or X400 or Fernox Superfloc For long term corrosion protection after flushing an inhibitor suitable for stainless steel exchangers should be used refer to the current issue of BS 5449 and BS 7593 on the use of inhibitors in central heating systems Examples are Sentinel X100 and Fernox IMPORTANT Itis ESSENTIAL thatthe cleanser is fully removed from the system after flushing and before adding inhibitor Take care to ensure that all low points in the system are fully drained For all systems follow the manufacture s instructions but where new radiators are fitted do not leave the cleanser in the system for longer than 24 hours 4 7 Draining Tap A draining tap must be provided at the lowest points of the system which will allow the entire system to be drained A drain tap for the appliance is provided as an integral part of the hydroblock see diagram 12 11 SUPPLY PIPE BOILER CONTROL VALVE DOUBLE CHECK FLOW RETURN VALVE HOSE UNION 1 1 HEATING TEMPORARY IRCUIT CONT
24. GULATIONS BUILDING REGULATIONS In IE reference should be made to the current edition of I S 813 Domestic Gas Installations and the current ETCI rules The boiler must be mounted on a flat wall which is sufficiently robust to take its total weight see Table 1 2 2 Clearances The boiler should be positioned so that at least the minimum operational and servicing clearances are provided see diagram 2 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 2 1 2 4 Timber Frame Buildings Ifthe boileristo be installed in atimber building it should be fitted in accordance with the Institute of Gas Engineers document IGE UP 7 1998 If in doubt seek advice from the local gas undertaking or Glow worm 2 5 Room Ventilation The boiler is room sealed so when it is installed in a room or space a permanent air vent is not required 2 6 Cupboard or Compartment Ventilation Due to the high efficiency and hence low casing temperature of this boiler cupboard or compartment ventilation is not necessary Leave existing air vents 0020008155A LJ 200 T A removable compartment door be placed at least 5mm in front of the appliance MIN
25. IMUM CLEARANCE FROM PERMANENT SURFACES Diagram 2 1 12 3 Flue Location and Ventilation 3 1 Flue Options This boiler is suitable for concentric Horizontal and Vertical flues elevated horizontal and vertical twin all are fitted onto the top of the boiler The Glow worm Flue Options Guide available on request or through the web site describes in detail the necessary accessories These instructions describe the use of the standard and telescopic horizontal flues The instructions for all other flues will be contained in those packs 3 2 Flue Length The maximum permissable horizontal flue length is 10 metres plus the flue terminal this can be achieved by use of the accessories however should additional 90 or 2 x 45 elbows be used then the length MUST be reduced by 1metre 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 drain The flue can be installed from inside the building when access to the outside wall face is not practicable The diagrams 3 1 to 3 4 describe the lengths achievable without the use of extensions or elbows 87min Max flue length 717mm 20mm min clearance OUTSIDE INTERNAL WALL FACE SURFACE
26. ING WINDOWS D BELOW GUTTER DRAIN SOIL PIPE E BELOW EAVES F BELOW A BALCONY OR CAR PORT G FROM VERTICAL DRAIN PIPES AND SOIL PIPES H TO A BOUNDARY ALONGSIDE THE TERMINAL ABOVE ADJACENT GROUND OR BALCONY LEVEL J FROM SURFACE OR A BOUNDARY FACING THE TERMINAL K FACING TERMINALS L FROM OPENING DOOR WINDOW IN CAR PORT INTO DWELLING M VERTICAL FROM A TERMINAL N HORIZONTALLY FROM A TERMINAL VERTICAL FLUES P FROM ANOTHER TERMINAL Q ABOVE ROOF LEVEL R FROM ADJACENT OPENING WINDOW S FROM ADJACENT WALL TO FLUE A DIRECTLY BELOW AN OPENING AIR BRICK 300 300 300 25 25 25 25 H FROM INTERNAL EXTERNAL CORNERS 25 300 300 600 1200 1200 1500 300 600 300 1000 300 Diagram 3 5 3 4 Terminal Position The minimum acceptable siting dimensions for the terminal from obstructions other terminals and ventilation openings are shown in diagram 3 5 For Ireland the minimum distances for flue terminal positioning must be those detailed in 1 5 813 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 ihe position for the terminal Seediagram 3 5 These dimensions comply with the building regulations but they may need to be increased to avoid wall staining and nuisance from plu
27. OUSLY b pan br Lb EU CHASSIS EARTH Ko gh gly g y E ly r 630mAT g y b DAD 230V 50Hz PERMANENT k BLACK r RED E NH trs ORANGE mh MAINS SUPPLY g y GREEN gn GREEN ON OFFN___ FUSED AT 3A YELLOW y YELLOW SWITCH Diagram 13 2 35 0020008155A 13 Fault Finding NO 2 Is the system pressure displayed Check there is no demand YES Is it flashing indicating zero Adjust system pressure Replace pressure sensor YE NO P Set controls for a demand S NO NO Is there temperature indicated on LCD Is F displayed YES Ensure external controls Check wires between are calling for demand main pcb and interface Wait 60 seconds YES YES Does F flash YE REFER TO DIAGRAM 13 4 NO Does boiler modulate YES before desired set point is reached Differential is too high Current flow rate too low NO Does boiler go off YES before desired set point is reached NOTE If the system pressure is too high i e greater than 3 bar the LCD will flash to indicate this COMPONENT Temperature rise too high Current flow rate too low CH thermistor 10K Q 25 C NO Fan 24V DC across blue and red at fan Gas Valve 24V DC 55 0 Diagram 13 3 0020008155A 36 13 Fault Finding DESCRIPTION POSSIBLE CAUSE Ignition fault lockout Boiler failed to light No gas Insufficient gas Incorrect gas valve adjustment Electrode Ignition lead defect
28. ROL HOSE NNECTION VALVE UNION CONNECTIO DRAIN POINT Method 1 BOILER TYPE CA BACKFLOW PREVENTION DEVICE FLOW RETURN CONTROL CONTROL VALVE VALVE SUPPLY PIPE HEATING CIRCUIT ane TUNDISH Method 2 Diagram 4 2 5 Domestic Hot Water System 5 1 General General All domestic hot water circuits connections fittings must be in accordance with the relevant standards and water supply regulations For GB Guidance G17 to G24 and recommendation R17 to R24 of the Water Regulations Guide For lE The current edition of S 813 Domestic Gas Installations The domestic water hot service must be in accordance with the current issue of BS5546 refer also to the current issue of BS6700 0020008155A 16 5 2 Domestic Hot Water Cylinder SINGLE FEED INDIRECT CYLINDERS ARE NOT SUITABLE AND SHOULD NOT BE USED The domestic hot water cylinder must be of the double feed indirect coil type It must be suitable for working at a gauge pressure of 0 35bar above the safety valve setting 6 Installation Preparation 6 1 Appliance Pack IMPORTANT With regards to the Health and Safety Manual Handling requirements two persons shall be required to lift the appliance refer to manual handling on page 5 Please check the contents of packs as shown in diagram 6 1 NOTE The fixing pack is located in the base polystyrene packing under the boiler base Remove the polystyrene end packing pieces then carefu
29. Replacement of Parts 14 8 Front Insulation For access refer to section 14 1 Refer to section 12 3 for removal of the fan gas valve and burner assembly Remove burner as described in section 14 7 Remove spark electrode see section 14 2 NOTE THE BURNER WILL REQUIRE A NEW GASKET WHEN REFITTED 14 9 Rear Insulation For access refer to section 14 1 Refer to section 12 3 for removal of the fan gas valve and burner assembly Remove securing screw and washer in the centre of the insulation and withdraw insulation see diagram 14 6 14 10 Viewing Window For access refer to section 14 1 Refer to diagram 14 7 Remove circlip Remove steel washer Remove glass Remove fibre washer Replace in reverse order SECURING SCREW a A K RE INSULATION EXCHANGER Diagram 14 6 e FIBRE WASHER GLASS CIRCLIP n E 77 STEEL crest UD Diagram 14 7 SECURING UPPER SUPPORT BOLT B BRACKET 11488 c EXPANSION VESSEL o T KA EZ COUPLING Diagram 14 8 0020008155A 40 14 Replacement of Parts 14 11 Expansion Vessel For access refer to section 14 1 Refer to section 12 8 and drain the boiler heating circuit Undo the coupling at the base of the vessel see diagram 14 8 While holding the vessel remove the securing bolt on the top panel of the boiler and upper support bracket on top of the expansion vessel Lift the vessel up draw botto
30. TS PANEL RETAINING STRAP CONTROL BOX MAIN PCB o oe l TORX SCREWS 3 12411 PCB RETAINING CLIPS FUSE Diagram 14 22 230V CONTROLS INTERFACE BOARD 11419 USER INTERFACE Diagram 14 24 SECURING SCREWS USER INTERFACE Diagram 14 23 47 14 35 Fuse Main PCB Control Box For access refer to section 14 33 The fuse rated 630mAT is located at bottom right hand side of the PCB see diagrams 13 2 or 14 22 14 36 230V Controls Interface For access refer to section 14 29 Disconnect the electrical connection from the 230V controls board and the electrical connection from the Main PCB see diagram 14 24 Remove the 230V controls interface retaining screw Remove the 230V controls interface board 0020008155A 15 Spare Parts When ordering spare parts contact Glow worm s own service organisation using the telephone number on the front cover of this booklet Please quote the name of the appliance and serial number to be found on the data label see diagram 1 2 If ordering from British Gas also quote the G C number of the part Key No Part No Description GC Part No 1 801724 Overheat Thermostat E83996 2 801911 Pressure Sensor E83997 3 801637 Spark Electrode E83999 4 2000801904 Safety Discharge Valve E84000 5 2000801898 Automatic
31. ace on bracket Ensure safe lifting techniques are used keep back straight bend using legs when lifting load from floor level Do not twist reposition feetinstead Keep boiler as close as possible to body 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 0020008155A Positioning of Appliance for Final Installation above worktop foreseeable obstructions etc Recommend 2 persons lift appliance to position into place 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 notlean forward sideways Always use assistance if required Recommend wear sui
32. all amount of water place a water container beneath the boiler connections before removing the protective caps Position gasket sealing washers supplied in the fittings pack as shown in diagram 7 1 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 and engage onto the hanging bracket Pivot the boiler to engage the fixing jig connections ensuring thatthe previously positioned washers gaskets are not disturbed see diagram 7 1 Make good the final connections N D r acy IE ZN OI q MN e A Central Heating Cock C Gas Cock with Pressure Test Point J Central Heating Tube 22mm Gas Tube 15mm co N O GASKET FIBRE SEALING WASHER FIBRE GASKET POLYACETAL Diagram 7 1 19 0020008155A 8 Safety Discharge Valve and Condensate Connections 8 1 Safety Discharge Valve SAFETY The pipe from the safety discharge valve must not discharge DISCHARGE above an entrance window or any type of public access area VALVE YO PA d 11694 A short discharge tube is supplied loose in the wall mounting pack This must be extended using not less than 15mm o d pipe to discharge in a visible position outside the building facing downwards preferably over a drain see diagram 8 1 The pipe must have a continuous fall and be routed to a position
33. alve Preset 3bar 43 5lIbf in Safety valve discharge 15mm copper Expansion vessel capacity Charge pressure 8 litres 1 76 gallons 0 5bar 7 3Ibf in System min pressure 0 7bar 10 1Ibt in B Maximum system content using fitted expansion vessel 130 litres 28 6 gallons at 75 C average system temperature Electrical supply 230V 50Hz Electrical rating 180W fused 3A IP classification X4D Internal Fuse rating On PCB 630mAT Ball valves are fitted in water and gas connections Wi For larger systems use an additional expansion vessel TABLE 2 18sxi BURNER Case Off CO Case On 9 1 0 2 0 5 9 3 0 3 0 5 APPROXIMATE 1 1 GAS RATE after 10 mins from cold ft h MIN MAX 0 53 2 00 18 7 71 30 BURNER Case Off eCO Case On 9 1 0 2 0 5 9 3 0 3 0 5 APPROXIMATE m h GAS RATE after 10 mins from cold MIN MAX 0 53 3 0 18 7 107 0020008155A 2 Boiler Location and Ventilation 2 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 RE
34. am 12 7 Turn on the mains electrical supply and turn on the gas service cock Switch the boiler on Ensure external controls are calling for heat The boiler should fire automatically Using an electrical screwdriver rotate the service potentiometer to the mid point or 3 o clock position See diagram 12 7 The fan speed should now reduce to minimum and 12 should be shown flashing on the digital display Check the CO value If necessary refer to diagram 11 3 and using a 2mm allen key carefully adjust the offset screw until a CO reading of 10 5 0 2 is achieved Turning the offset screw clockwise increases the CO reading 10 After setting combustion rotate the service potentiometer fully anti clockwise so that the display indicates the water temperature Check that the CO combustion remains between 9 8 and 10 8 CO Further adjustment should not be necessary however if required carefully adjust the gas valve throttle see diagram 11 3 until this is achieved 11 Remove analyser probe fromthe test point and replace the cap Refit the control panel 12 Fitthe LPG conversion label supplied in the documentation pack to the inner front panel alongside the data label Refit the inner door and outer door 27 INNER CASING 9 A SECURING SECURING SEREW 2 SCREWS Diagram 11 1 N AUTOMATIC CAP AIR VENT PUMP S Diagram 11 2
35. am 14 21 Remove the switch retaining screw Remove switch from housing Remove electrical leads 14 31 Mains Reset Knob Refer to section 14 29 for access Remove actuator by springing back retaining clips see diagram 14 21 Spring back knob retaining clips and push knob out from the back 14 32 User Interface Refer to section 14 29 for access and diagram 14 23 Remove electrical plug Remove the two securing screws Withdraw the board When replacing the board refer to instructions supplied with replacement PCB on setting it up 14 33 Main PCB For access refer to section 14 1 Hinge down the control box Remove three TORX screws and unhook the rear panel Remove the electrical connections to the PCB Prise back the two PCB retaining clips and withdraw the PCB When refitting the rear panel ensure the leads are not trapped 14 34 Control Box For access refer to section 14 33 Remove relevant plugs and connectors refer to wiring diagram 13 2 Withdraw grommets and leads so they are hanging loose Unthread the retaining strap and remove the control box by drawing it outwards away from its retaining slots see diagram 14 22 0020008155A 46 RETAINING LATCHES 11505 CONTROLS FASCIA Diagram 14 20 KNOB RETAINING CLIPS MAINS RESET e KNOB MAINS RESET SWITCH Diagram 14 21 14 Replacement of Parts RETAINING REAR SLO
36. am 6 3 Drill the four fixing holes 2 for the hanging bracket and 1 each for the top hole of the fixing jig wall brackets and insert suitable wall plugs If gas and or water pipes are to be connected through the rear wall the holes must be drilled as marked on the wall template prior to securing the fixing jig Secure the fixing jig wall brackets to the wall using suitable Screws NOTE Due to the varied site conditions we do not supply fixings and advise that the installer should supply those which are suitable Locate the jig plate between the wall brackets and secure with the No 8 self tapping fixing screws supplied in the fittings pack 0020008155A 18 12075 90 125 WALL TEMPLATE EXTENDED SIDE FLUE Diagram 6 2 WALL TEMPLATE a WALL PLUG HANGING BRACKET WALL PLUG SCREW 2 OFF FIXING JIG PLATE FIXING JIG WALL BRACKETS 2 OFF Handed as shown Diagram 6 3 7 Gas Water amp Appliance Connection 7 1 System Connection The system can now be connected without the boiler being mounted All water and gas connections are on the fixing jig with the exception of the condense drain and safety discharge the positions of these are shown on the wall template The gas supply pipe must be chased into the wall if routed up the back of the boiler A Vertical Piping Kit can be used to route the central heating or DHW pipes see se
37. arily protects the boiler Any other exposed areas of the system should be protected by a separate frost thermostat 29 11 11 Instruct the User Instruct and demonstrate the lighting procedure and advise the user on the safe and efficient operation of the boiler Instruct on and demonstrate the operation of any heating System controls Advise the user on the use and maintenance of any scale reducer and pass on any relevant instructional documents Advise thatto ensure the continued efficient and safe operation of the boiler it is recommended that it is checked and serviced at regular intervals The frequency of servicing will depend upon the installation conditions and usage but in general once a year should be enough Draw attention if applicable to the current issue of the Gas Safety Installation and Use Regulations Section 35 which imposes a duty of care on all persons who let out any property containing a gas appliance in the UK The user shall not interfere with or adjust sealed components It is the Law that any servicing is carried out by a competent person 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 Advise the user of the precautions necessary to prevent damage to the system boiler and the building in the event of the heating
38. ch off and on If the boiler does not resume normal operation after this the overheat stat may have operated Overheating Safety In the event of the boiler overheating the safety devices will cause a safety shutdown If this happens call your Installation Servicing company Frost Protection The appliance has a built in frost protection programme as long as the electricity and gas are left switched on This device operates the burner and system pump when the temperature inside the boiler falls to 3 C Any other exposed areas of the system should be protected by a separate frost thermostat 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 Contact your installation servicing company if the fault persists Maintenance and Servicing User Instructions Maintenance and Servicing To ensure the continued efficient and safe operation of the appliance it is recommended that it is checked and serviced as necessary at regular intervals The frequency of servicing will depend upon the particular installation conditions and usage refer to guarantee registration on the inside front cover of this literature If this appliance is installed in a rented property
39. ction 1 6 Make connections to fixing jig gas water and heating cocks with the tube assemblies supplied in fixing pack as shown in diagram 7 1 7 2 Gas Connection The gas supply can be connected from below or through the wall at the rear of the boiler the position is shown on the wall template Refer also to section 1 2 Fit the sealing washer into the securing nut and make good the final connection to the gas service cock on the wall mounting jig see diagram 7 1 Do not subject the gas service cock to heat Make sure the on off lever is accessible The whole of the gas installation including the meter should be inspected tested for soundness and purged in accordance with the current issue of BS6891 and in IE the current edition of 1 5 813 Domestic Gas Installations 7 3 Water Connections Flush out the heating system before connecting to the boiler refer to section 4 6 Make the connections to the heating system by fitting the sealing washers into the securing nuts and make good the final connection to the isolating valves on the fixing jig see diagram 7 1 Do not subject the isolation valves to heat Make sure the drain point is accessible refer diagram 12 11 7 4 Appliance Connection IMPORTANT Withregards to the Manual Handling Operations 1992 Regulations the following lift operation exceeds the recommended weight for a one man lift refer to manual handling on page 5 The appliance will contain a sm
40. e two screws on the underside of the front casing and lift off Undo the two screws on the front of the inner front panel and lift off The side panels can be hinged sideways to aid replacement of parts Undo and remove the three screws securing each side panel to the boiler two at the front and one at the top 14 2 Spark Electrode For access refer to section 14 1 Remove the spark plug lead earth lead and two securing screws Withdraw the spark electrode carefully from the combustion chamber see diagram 12 2 14 3 Igniter Unit For access refer to section 14 1 Remove ignition lead and electrical connections then remove igniter unit by removing two securing screws see diagram 14 1 14 4 Ignition Lead For access refer to section 14 1 Refer to diagram 12 5 Pull the spark plug style connector off the spark electrode and the spade connector connected to the igniter unit see diagram 14 1 0020008155A 38 SECURING SCREWS 2 IGNITER UNIT S SPADE CONNECTOR ELECTRICAL IGNITION LEAD CONNECTIONS Diagram 14 1 14 Replacement of Parts 14 5 Gas Valve For access refer to section 14 1 Remove the electrical plug from the gas valve see diagram 14 2 Refer to section 12 3 for removal of the fan gas valve and burner assembly Before removing the gas valve note its position on the fan Remove the three securing screws which fix the gas valve plastic swirl plate to t
41. e standard 1 4 Technical Data All dimensions are given in millimetres except as noted Refer to diagrams 1 1 1 3 and Tables 1 and 2 The data label is positioned on the inner door refer to diagram 1 2 The Seasonal Efficiency Domestic Boilers UK SEDBUK is 18 and 30 sxi Class A Thevalueis usedinthe UK Government s Standard Assessment Procedure SAP for energy rating of dwellings The test data from which it has been calculated has been certified by B S I 1 5 Condensation 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 8 2 for more details 1 6 Vertical Plumbing Kit Where the heating flow and return pipes come from above the boiler a vertical plumbing kit is available Central Heating Kit Pt No 2000460477 Contact Glow worm for further details Do not route any pipes behind the boiler unless a vertical plumbing kit is used or the pipes are chased into the wall 0020008155A 10 CE low worm BELPER DERBYSHIRE DE56 1JT 18sxi HIGH EFFICIENCY CONDENSING SYSTEM BOILER 230V 50Hz 180W Fused at For use on I 2 G20 20 mbar This boiler is intended exclusively to be installed on a gas supply with a governed met
42. eam of Sink Waste 44mm FOR EVERY 1M External Soil and Vent Pipe or Rainwater Pipe EXTERNAL MAX 3M EXTERNAL SOIL AND VENT STACK MIN DIA 21MM NO RESTRICTION ON LENGTH SINK CONSTITUTES AIR BREAK MIN DIA 21MM NO RESTRICTION La ON LENGTH 44 21 TERMINATION FROM APPLIANCE NOTE FOR EXTENDED PIPE RUNS 32MM DIA PIPE SHOULD BE USED 2 5 FALL CEMENT MORTAR SEALING 12333 Internal Termination into Combined Sink Waste Y 25MM i 100MM PLASTIC TUBE BOTTOM OF TUBE SEALED HOLE DEPTH 400MM 300MM 2 ROWS OF 3 x 12MM HOLES AT 25MM CENTRES 50MM FROM BOTTOM OF TUBE HOLES TO FACE AWAY FROM HOUSE External Termination into Soakaway NOTE PIPEWORK SHOULD ALWAYS FALL AWAY FROM BOILER BY AT LEAST 2 5 Diagram 8 3 21 0020008155A 9 Flue Preparation Telescopic and Standard Flue 9 1 Flue Components Additional flue accessories are available to suit your site nm conditions see diagram 9 2 The components supplied in the Standard and Telescopic kit are shown in diagram 9 1 The Glow worm Flue Options Guide available on request or through the web site describes in detail the necessary accessories Top Outlet Horizontal Concentric Flue Packs FLUE d A2043600 Horizontal telescopic flue pack ELBOW EE A2043400 Standard horizo
43. eating water can be adjusted by turning the central heating water temperature control to desired setting between 1 Min and gy Max Maximum setting is appoximately 82 C Set the control to O to switch off heating If the boiler fails to light reset the controls see paragraph below TO RESET If a fault occurs the running lamp will flash red and a fault code will appear on the digital display TO RESET 2 Turn the Mains Reset Switch to 0 wait for 5 seconds turn Mains Reset Switch to 1 the boiler is reset If the fault persists contact your installer service provider using the telephone number on the inside font cover of this booklet TO TURN THE BOILER OFF 3 Turn the Mains Reset Switch to the OFF 0 position Turn the gas supply OFF at the gas service cock if the boiler is to be out of use for some time 0020008155A 8 1 Technical Information THIS DIMENSION CAN BE INCREASED TO 600mm MAX CENTRAL HEATING GAS CONNECTION Standard Flue Q N 14 FLUE Pm I CENTRE LINE ____ 1 FLUE 715 SAFETY DISCHARGE DRAIN 177 Y 22 D 18 i sll p GAS 156 EET 450 Diagram 1 1 1 1 IMPORTANT NOTICE The boiler is supplied in one pack the flue and fixing jig are supplied seperately This boiler is for use only on G20 natural gas but the 30sxi may be converted for use on G31
44. ection 14 14 NOTE It is not necessary to disconnect the electrical lead but put pump head in a convenient place where it will not strain the lead Remove the bypass tube refer to section 14 21 Remove the electrical connection to the low water pressure sensor refer to section 14 20 Remove the water connection clip 2 below the hydroblock see diagram 14 19 Remove the central heating filter refer to section 12 7 Remove the retaining clip to remove the drain point refer to section 14 24 Undo two securing screws on underside of the right hand hydroblock Remove screw in back plate Lift out the right hand hydroblock Remove the remaining components for refitting into the replacement right hand hydroblock Refill vent and pressurise the boiler Check for leaks 45 g SECURING CLIP 1 e HEATING FLOW SECURING CLIP 2 CENTRAL HEATING RETURN Diagram 14 19 0020008155A 14 Replacement of Parts 14 29 Access to Switches and User Interface For access refer to section 14 1 Release the front of the fascia by carefully prising up the two retaining latches see diagram 14 20 Do not allow the front of the controls fascia to swing down and be loosely held by the electrical connections to the mainsreset switch user interface and programmer Either remove the connections or support the fascia 14 30 Mains Reset Switch Refer to section 14 29 for access and diagr
45. efit the inner casing panel NOTE Ensure the seal is fitted correctly giving an airtight joint 14 26 Condense Drain Refer to diagram 14 18 Remove the clips securing the flexible tubes to the siphon adapter by twisting the clips slightly to disengage the clip jaws from each other Remove black flexible tubes from siphon adapter Lift off the siphon adapter Remove the drain connection downstream of the condense trap Remove the two condense trap securing screws Lift up and carefully remove the condense trap taking care not to spill any water which may be left in the unit As the unit is lifted remove the flexible pipe on the outlet Remove the cap at the base of the condense trap Remove any solids found Remove the float to clean it Flush water through the trap to remove any remaining solids Check for any debris in the outlet pipe of the condensate drain and clean as necessary Reassemble and refit the condense trap When refitting the cap ensure that a watertight seal is achieved but do not use excessive force Remove the siphon adaptor from the flexible tubes using a suitable container flush the heat exchanger until the water appears clear in the container 0020008155A 44 RETAINING CLIP 11533 DRAIN POINT Diagram 14 16 FRONT CASING PANEL b 10063 INNER CASING PANEL x Diagram 14 17 SIPHON 9948 SEAL Diagram
46. er GC No 41 047 72 EN437 IP X4D NOx Class 5 WATER CIRCUIT PMS 3 bar GB IE Pr EN483 677 EN625 87 B0 41 HEAT OUTPUT CONDENSING MODE 20 02kW INJECTOR N A DOES NOT APPLY MAXIMUM MINIMUM HEAT INPUT NETTQ kw 1890 5 00 HEAT OUTPUTP kW SERIAL No 2000460254 12341 Glow worm HEPWORTH HEATING LTD BELPER DERBYS DE561JT 30sxi HIGH EFFICIENCY CONDENSING SYSTEM BOILER 230V 50Hz 180W Fused at 3A GC No 41 047 62 For use on TYPE Cis Css Css Cos Adjusted for use on EN437 IP X4D natural gas G20 20 mbar NOx Class5 This boiler is intended exclusively NOx Class 5 CE 0086 to be installed on a gas supply with a governed meter WATER CIRCUIT PMS 3 bar GB IE Pr EN483 677 EN625 87 B0 41 HEAT OUTPUT CONDENSING MODE 30 58kW INJECTOR N A DOES NOT APPLY MAXIMUM MINIMUM HEAT INPUT NETT Q HEAT OUTPUT P SERIAL No 2000460455 12531 Diagram 1 2 1 Technical Information LO LO EXPANSION 5 HEAT EXCHANGER VESSEL FLOW THERMISTOR RETURN OVERHEAT UTOR THERMISTOR FAN GAS CONTROL VALVE SAFETY BYPASS C H INLET FILTER DRAIN C H C H E FLOW DISCHARGE RETURN SCHEMATIC LAYOUT OF BOILER Diagram 1 3 11 TABLE 1 Total Weight 18sxi 41kg 9010 30sxi 44 5kg 9810 Gas connection Re BSPT Water connection 22mm copper Safety v
47. er using a soft brush and vacuum cleaner Carefully flush by spraying water any remaining debris through the condensate trap Ensure the water is kept away from electrical components COMBUSTION CHAMBER 12343 Diagram 12 3 12402 GAS PIPE RETAINING CLIP 11480 GAS SUPPLY AT GAS SERVICE K iini Diagram 12 4 HEAT NUT EXCHANGER 5 OFF SPADE J CONNECTOR g E 11531 ELECTRODE LEAD Diagram 12 5 31 0020008155A 12 Servicing 12 5 Condensate Drain The condense drain does not normally need removing during servicing To flush the condense drain carefully pour water into the heat exchanger and check that water flows freely to drain If the condense drain is blocked refer to section 14 27 for removal 12 6 Combustion Check Once the appliance has been re assembled apart from the front and inner casing panels connect a CO combustion analyser to the test point on the flue elbow see diagram 12 1 IMPORTANT NOTE Products of combustion willbe discharged when the cap is removed It is important to replace the cap immediately Turn on the gas service cock see diagram 7 1 With the power off and the appliance cold unclip the controls fascia and hinge it down to reveal the potentiometers on the rear of the User interface see diagram 12 7 Take care not to allow the fascia to drop down and damage the wiring Tu
48. erature can be adjusted on the boiler Once the controls are set the boiler operates automatically Please read these instructions and follow them carefully for the correct and economical use of your boiler Water Treatment Inthe case of an existing installation it is ESSENTIAL that prior to installing the new boiler the system is thoroughly flushed For optimum performance after installation of a new system the boiler and its associated central heating system should also be flushed Flushing should be carried out in accordance with BS7593 1992 using acleanser such as Sentinel X300 or X400 Fernox Superfloc or Salamander corrosion guard cleaner For long term corrosion protection after flushing an inhibitor suitable for stainless steel exchangers should be used refer to the current issue of BS 5449 and BS 7593 on the use of inhibitors in central heating systems Examples are Sentinel X100 Fernox or Salamander corrosion guard inhibitor Compartment or Cupboard Installations If the boiler is fitted into a compartment or cupboard it does not require ventilation openings Do not use the compartment or cupboard for storage Clearances If fixtures are positioned close to the boiler space must be left as shown in diagram 2 1 Enough space must also be left in front of the boiler to allow for servicing Condensate Drain The condensate drain see section 8 2 must not be modified or blocked Pluming from flue terminal Li
49. erial Electrical Supply The boiler must be earthed All system components shall be of an approved type and shall be connected in accordance with the current issue of BS7671 and any applicable local regulations External wiring must be correctly earthed polarised and in accordance with the relevant standards In GB this is BS 6891 In IE this is the current edition of 1 5 813 Domestic Gas Installations 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 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 an unswitched shuttered socket outlet and 3A fused 3 pin plug both to the current issue of BS1363 may be used provided that they are not used in a room containing a bath or shower Wiring to the boiler must be PVC 85 C insulated cable not less than 0 75mm 24 0 20mm Sealed System Draining refilling and pressurising MUST be carried out by a competent person General Information General Note This condensing system boiler is designed to provide central heating from a sealed water system with a fully indirect cylinder The central heating water temp
50. gas Propane L P G Where no British Standards exists materials and equipment should be fit for their purpose and of suitable quality and workmanship Refer to Manual Handling Operations 1992 Regulations The installation of this boiler mustbe carried out by a competent person in accordance with the rules in force in the countries of destination Manufacturer s instructions must not be taken as overriding statutory requirements 1 2 Statutory Requirements In GB the installation of the boiler must be carried out by a competent person 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 and installed in accordance with the current edition of 1 5 813 Domestic Gas Installations the current Building Regulations and reference should be made to the current ETCI rules for Electrical Installation In GB the following Codes of P
51. ge air from the gas supply Turn onthe gas isolation valve slotin line with the length of the valve see diagram 7 1 11 4 Initial Lighting The lighting procedure of the boiler is fully automated Ensure that the central heating water temperature control knob is turned OFF Turn on the mains electrical supply and the mains reset knob to 1 on the controls fascia The digital display will show system pressure Turn the central heating water temperature control knob to 1 MINIMUM The digital display will now show water temperature The fan should start and after a few seconds the ignition will commence If the burner fails to light the fan will stop Initially this may be due to air in the gas supply line The boiler will automatically have three attempts at ignition If necessary turn the reset switch to the off position O then back to the on position I and the boiler will restart After the boiler has lit allow to warm at minimum temperature Setting to purge any air from the system NOTE If the appliance is operated above MINIMUM on initial lighting there is a possibility that the overheat thermostat will trip and F5 will be displayed on controls fascia this is due to air not having been completely purged See diagram 14 15 for reset switch Oncethe system has been purged of air turn the central heating water temperature control knob to the desired temperature The appliance will then continue to fire until
52. he venturi on the fan Remove the gas valve Remove the flexible gas supply pipe from the gas valve When refitting the gas valve take care as it can be fitted more than one way After assembly test for gas soundness and purge in accordance with the current issue of BS6891 or in IE the current edition of 1 5 813 Domestic Gas Installations 14 6 Fan For access refer to section 14 1 Refer to section 12 3 for removal of the fan gas valve and burner assembly Remove the gas valve as described in the relevant parts of section 14 5 Remove the venturi plate secured with four screws and remove the two screws securing the fan to the gas manifold see diagram 14 3 Check the gasket and replace if necessary NOTE The 30sxi fan is secured through an extension piece with two securing screws check and replace any seals or gaskets if necessary 14 7 Burner NOTE THE BURNER WILL REQUIRE A NEW GASKET WHEN REFITTED For access refer to section 14 1 Refer to section 12 3 for removal of the fan gas valve and burner assembly Remove the four screws that secure the burner see diagram 14 5 VENTURI PLATE SECURING SCREW 3 Diagram 14 3 11485 Diagram 14 4 12402 GAS VALVE ELECTRICAL PLUG PRESSURE TEST POINT Diagram 14 2 SECURING SCREW 4 11487 INSULATION Diagram 14 5 39 0020008155A 14
53. in the UK 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 Please be advised that the Benchmark logbook should be completed by the installation engineer on completion of commissioning and servicing All CORGI Registered Installers carry a CORGI ID card and have a registration number Both should be recorded in your benchmark Logbook You can check your installer is CORGI registered by calling CORGI direct on 01256 372300 Spare Parts Remember when replacing a part on this appliance use only spare parts that you can be assured conform to the safety and performance specification that we require Do not use reconditioned or copy parts that have not been clearly authorised by Glow worm Ifa partis required 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 this infomation will be on the name badge on the front of the appliance If in doubt seek advice from the local gas company or Glow worm s own service organisation using the tele
54. ing collar behind the locating lugs on the flue terminal see diagram 9 1 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 duct to be drawn back into the flue elbow after the boiler has been mounted 9 4 Flue Attachment To Boiler Secure the flue elbow in position on top of the boiler with four torque headed screws supplied Draw the flue assembly from wall and engage the flue duct into the elbow and butt fit the air duct then fit the collar and secure with screws provided see diagram 9 9 NOTE If the air and flue ducts have been correctly cut to the instructions given in section 9 2 the rubber sealing collar should fit flush with the outside wall check this Slide the internal trim ring back against the wall securing in place with a small amount of sealant if required 0020008155A 24 N AIR DUCT TELESCOPIC TOP TELESCOPIC AIR DUCT SECURING Diagram 9 7 N Cp AIR DUCT BD gt a L gt 13mm TERMINAL CATCH 4 FLUE DUCT NEN L 11mm DUCT CUTTING LENGTHS Diagram 9 8 Diagram 9 9 10 Electrical Connections WARNING This appliance must be wired in accordance with these instructions
55. ke 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 It is normal and not a fault indication Cleaning The boiler casing can be cleaned using a mild liquid detergent with a damp cloth then a dry cloth to polish Do not use any form of abrasive or solvent cleaner as you may damage the paintwork Electrical Supply 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 Make sure that if fitted the immersion heater in the cylinder is switched off Manual Handling IMPORTANT With regards to the Manual Handling Operations 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 using legs Keep load as close to body as possible Do not twist reposition 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
56. lly lay the boiler on its back remove the two front casing panel securing screws and lift off the panel from two retaining lugs Remove the transit packaging behind the front panel and discard Carefully place front panel and screws to one side FITTINGS PACK FLUE CONDENSATE CONNECTOR N o SCREW SEALING VALVE TUBE 4 OFF C 2 WASHER FILLING DEVICE TUBING EXTENSION NUT FLOW RESTRICTOR POACETAL MAINS VOLTAGE GASKET OFF HEATING CONTROL CONNECTION PLUG DOCUMENTATION PACK NOT ILLUSTRATED Installation and Servicing Instructions inclusive Guarantee Registration Card Service Plan Leaflet Benchmark Logbook FIXING JIG PACK Part No A20055 supplied seperately A Central Heating Cock C Gas Cock with Pressure Test Point L H WALL WALL BRACKET E Gasket BRACKET F Gasket J Central Heating Tube 22mm SECURING K Gas Tube 15mm R H WALL BRACKET VO SECURING SCREW WALL TEMPLATE ON OFF LEVER O GASKET FIBRE SEALING WASHER FIBRE Diagram 6 1 17 0020008155A 6 Installation Preparation 6 2 Wall Template Remove the wall template from the wall mounting pack and place in the desired position on a flat wall giving due consideration to boiler clearances see section 2 2 and the flue you are fitting 6 3 Flue Hole Cutting The standard horizontal flues are designed with an internal fall of 44mm metre towards the boiler for disposal of condensate If
57. low the figure specified refer to table 3 and section 11 6 The installation of the boiler must comply with the requirements of the current issue of BS6798 in Ireland refer also to the current edition of 1 5 813 Domestic Gas Installations In GB it is necessary to comply with the Water Supply Water Fittings Regulations 1999 for Scotland the Water Byelaws 2000 Scotland To comply with the Water regulations your attention is drawn to The Water Regulations guide published by the Water Regulations Advisory Service WRAS gives full details of the requirements In IE the requirements given in the current edition of 1 5 813 Domestic Gas Installations and the current Building Regulations must be followed 4 5 Filling the Sealed System Provision for filling the system at low level must be made see diagram 4 2 There must be no permanent connection to the mains water supply even through a non return valve NOTE Itis importantthat fittings used for connection to potable water comply with the water undertakings requirements 15 Table 3 Flow Rate MODEL MINIMUM FLOW RATE 18sxi 774 litres hr 30sxi 1289 litres hr This is equal to 20 C differential at maximum heat input KR BOILER ADDITIONAL EXPANSION VESSEL if required l BYPASS if required HEATING CIRCUIT FLOW CONTROL DRAIN VALVE N POINT Refer to section 11 6 Diagram 4 1 00
58. m out to the left lower and remove Fit the replacement unit Refill vent and pressurise the boiler Check for leaks 14 12 Heat Exchanger For access refer to section 14 1 Refer to section 12 3 for removal of the fan gas valve and burner assembly Drain the boiler heating circuit see section 12 8 Remove the clip securing the clear condense pipe to heat exchanger Pull to remove the condense pipe out of the bottom of the heat exchanger Undo the two nuts of the flow and return pipes from the heat exchanger Move the pipes away from the heat exchanger Loosen the three heat exchanger securing screws and clamps two at the top and one at the bottom to remove the heat exchanger see diagram 14 9 CAUTION There will be water in the heat exchanger Remove condense pipe connector from bottom of heat exchanger Carefully ease heat exchanger out 14 13 Flue Hood For access refer to section 14 1 Refer to diagram 14 10 Remove heat exchanger as per section 14 12 Remove the two securing screws and pull the flue hood down and away from the flue hood bracket and flue elbow see diagram 14 10 14 14 Pump head only For access refer to section 14 1 Refer to section 12 8 and drain the boiler heating circuit Refer to diagram 14 11 Remove the four cap head screws Carefully remove the pump head together with cable do not strain cable Support the pump head unscrew cable cover at the side of pump head
59. mand Replace inner casing panel and front casing panel see diagram 11 1 11 Commissioning 11 6 Testing Heating System Check that all remote controls are calling for heat The boiler will fire automatically Fully open all radiator valves and flow control valve A if fitted see diagram 4 1 Balance the radiators as required and if fitted adjust valve A to give the required system differential Turn off all radiators that can be shut off by the user and check to see if less than the maximum differential allowed of 20 C can be achieved across flow and return This boiler has a built in bypass see diagram 11 4 and 14 17 The boiler is supplied with the bypass open half a turn It should not be necessary to adjust the bypass but if required turn the adjustment screw clockwise to close the valve see diagram 11 4 Allowthe systemto reach maximumtemperature then switch off the boiler by isolating from the electrical supply Drain the entire system rapidly whilst hot using the drain tap at the lowest part of the system Fill and vent the system as described previously in section 11 2 Lock or remove the handle from control valve A to prevent unauthorised adjustment 11 7 Completion Adjust the boiler temperature control and any system controls to their required settings In addition it is necessary to complete the Benchmark logbook 9531 AUTOMATIC BYPASS VALVE BYPASS TUBE Diagram 11
60. ment work Always check for gas soundness after any service work Electrical Testing Shouldthere be any doubt aboutthe voltage supply to any ofthe components it is possible to carry out a simple electrical test IMPORTANT On completion ofthe Service Fault Finding tasks which have required the breaking and remaking ofthe electrical connections the earth continuity polarity short circuit and resistance to earth checks must be repeated using a suitable multimeter To carry out the electrical test gain access as follows Hinge down the control box and remove Torx screws and unhook the rear panel refer diagram 13 1 Refer to the Wiring diagram 13 2 and fault finding charts diagrams 13 3 and 13 4 0020008155A 34 RETAINING SLOTS RETAINING CORD TORX SCREWS 3 9808 REAR PANEL CONTROL BOX Diagram 13 1 13 Fault Finding i N IGNITION ELECTRODE IGNITE WATER PRESSURE SENSOR OVERHEAT THERMOSTAT THERMISTOR CH FLOW THERMISTOR CH RETURN Wiss MAINS VOLTAGE HEATING CONTROLS PLUG Lula ut REMOVE VOLTAGE FREE LINK 230V SWITCHED LIVE FROM OPTIONAL FROST STAT 0 230V SWITCHED LIVE FROM HEATING CONTROLS HE TH x DO NOT CONNECT REMOVE THE LINK IF FITTING VOLTAGE FREE NG 230V OR 230V SYSTEM br m CONTROLS CONTROLS IF THE m INTERFACE w LINK IS NOT REMOVED b THE BOILER WILL RUN gn CONTINU
61. ming depending on site conditions Increased siting flexibility can be achieved by using the Glow worm Plume Management Kit A2044000 black or A2044100 white NOTE If necessary it is permitted to increase the terminal protrusion through the outside wall to greater than the minimum dimension of 87mm but no more than 600mm see diagram 1 1 Carports or similar extensions of a roof only or a roof and one wall require special consideration with respect to 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 Seediagram3 5 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 3 5 Terminal Guard A terminal guard is required if persons could come into contact with the terminal or the terminal could be subject to damage In 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 3 6 A suitable guard is manufactured by Tower Flue Components Morley Rd Tonbridge Kent TN9 1RA Size 280 x 280 x 270mm TERMINAL GUARD sat AS
62. mistor connection Software incompatibility Incorrect user interface or Main PCB Lack of water fault pressure is less than 0 5bar System leak or faulty pressure sensor Upper water pressure is greater than 2 7bar Filling device open Central heating return temperature is greater than 90 C System fault Possible pump failure Check Thermistor on return Maximum temperature rise slope Possible pump failure Air in system Maximum delta temperature 37 Check Thermistor on return System too restrictive Diagram 13 4 12355 0020008155A 14 Replacement of Parts 14 1 Important Notes 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 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 service cock on the boiler see diagram 7 1 Unless stated otherwise parts are replaced in the reverse order to removal After replacing any parts always test for gas soundness and if necessary carry out functional test of the controls For replacement of parts the front casing and the inner casing panel of the boiler will need to be removed To remove undo th
63. ntal flue pack SECURING SCREW x 4 COLLAR SEALING TAPE telescopic only SCREW x 2 GASKET SEALING fitted COLLAR T SCREW x 1 TELESCOPIC TERMINAL ASSEMBLY SEALING COLLAR STANDARD TERMINAL ASSEMBLY Diagram 9 1 45 D 2000460485 X m 20ff 90 Bend 2000460484 0 5m EXTENSION 2000460481 im EXTENSION 2000460482 m VERTICAL 4 FLUE ADAPTOR 2m A2024600 EXTENSION 2000460483 Diagram 9 2 0020008155A 22 9 Flue Preparation Telescopic and Standard Flue 9 2 Flue Length Top Rear flue Telescopic with the flue elbow temporarily fitted measure the distance from the outside wall to the butt joint see diagram 9 4 Ifthe measurement Y exceeds 525mm then the appropriate length of extension pipe is required if the dimension is less than 320mm DO NOT cut the flue it can project to a maximum of 600mm if this is not desirable then a Standard flue MUST be used and cut to length Top Rear flue Standard with the flue elbow temporarily fitted measure the distance from the outside wall to the butt joint see diagram 9 3 Ifthe measurement Y exceeds 652mm then the appropriate length of extension pipe is required The minimum dimension is 187mm to suita 75mm min wall thickness Top Side flue Telescopic with the flue elbow temporarily Top Side flue Standard with the flue elbow temporarily fitted
64. o position Obtain firm grip on front and sides of appliance lift upwards ensure stable balance achieved and lift upwards to position 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 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 Appliance Safety Devices User Instructions Electrical Supply Failure Reset Switch 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 boiler does not resume normal operation turn the mains reset swit
65. phone number on the inside front cover of this booklet 0020008155A Operating the Boiler User Instructions eo CONTROLS MAINS RESET FASCIA CONTROL LIGHT SWITCH A C Slow worm 0 CENTRAL HEATING WATER TEMPERATURE DIGITAL CONTROL DISPLAY Diagram 1 OPERATION OF THE BOILER Check that all isolating valves on the boiler are open and that water flows from the hot water tap 2 Ifyou are in any doubt about the boiler being filled with water contact your installer or Glow worm s own service organisation using the telephone number on the inside front cover of this booklet Do not operate the boiler without water Check that the electrical supply to the boiler is ON and set any remote controls as required With the Central Heating Water Temperature Control in its OFF 0 position turn the Mains Reset Switch to the ON 1 position the running lamp will initially illuminate green then go off the system pressure will be displayed and should read on the digital display at least 0 7bar recommended 1 Obar if less you MUST contact your installation servicing company USER CONTROLS CENTRAL HEATING CONTROL 1 Turn the central heating water temperature control ON the lighting sequence will begin the running lamp will illuminate green to indicate the boiler has lit the system temperature will now be displayed instead of system pressure The temperature of the central h
66. quirements of Statutory Instrument No 3083 The boiler Efficiency Regulations and therefore is deemed to meet the requirements of Directive 92 42 EEC on the efficiency requirements for new hot water boilers fired with liquid or gaseous fuels Type test for purposes of Regulation 5 certified by Notified body 0087 Product production certified by Notified body 0086 The CE mark on this appliance shows compliance with 1 Directive 90 396 EEC on the approximation of the laws of the Member States relating to appliances burning gaseous fuels 2 Directive 73 23 EEC on the harmonization of the Laws of the Member States relating to the electrical equipment designed for use within certain voltage limits 3 Directive 89 336 EEC on the approximation of the Laws of the Member States relating to electromagnetic compatibility 0020008155A Control of Substances Hazardous to Health The adhesives and sealants used in this appliance are cured and give no known hazard in this state Insulation Pads Ceramic Fibre If you have a history of skin complaint you may be susceptible to irritation High dust levels are usual only if the material is broken Normal handling should not cause discomfort but follow normal good hygiene and wash your hands before eating drinking or going to the lavatory If you do suffer irritation to the eyes or severe irritation to the skin seek medical attention The insulation is composed of non combustible mat
67. r 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 For customer service call 01773 828100 Technical helpline 01773 828300 For General and Sales enquiries Tel 01773 824639 Fax 01773 820569 To register your Glow worm appliance call 0800 073 2142 C The code of practice for the installation commissioning amp servicing of gas central heating 0020008155A 2 Contents The instructions consist of three parts User Installation and Servicing Instructions 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 INTRODUCTION INSTRUCTIONS FOR USE INSTALLATION INSTRUCTIONS SERVICING INSTRUCTIONS DESCRIPTION Important Information General Information Manual Handling Appliance Safety Devices Maintenance and Servicing Operating the Boiler Technical Information Boiler Location and Ventilation Flue Location and Ventilation Heating System Domestic Hot Water System Installation Preparation Gas Water amp Appliance Connection Safety Discharge Valve and Condensate Connections Flue Preparation Telescopic and Standard Flue Electrical Connections Commissioning Servicing
68. ractice apply BS4814 BS6798 55440 Part 1 and 2 BS5546 Part 1 BS5449 BS6891 BS6700 BS7074 Part 1 and 2 BS7593 BS7671 In IE 1 5 813 BS5546 BS 5449 BS 7074 BS 7593 Manufacturer s instructions must not be taken as overriding statutory requirements NOTE For further information see the current issue of the Building Regulations approved document L1 in the UK and the references 1 GIL 59 2000 Central heating system specification CheSS and 2 GPG 302 2001 Controls for domestic central heating system and hot water BRECSU Certification This boiler certificated to the current issue of EN 483 for performance and safety It is important that no alteration is made to the boiler without permission in writing from Glow worm Any alteration that is not approved by Glow worm could invalidate the warranty and could also infringe the current issue of the Statutory Requirements 0020008155A 1 Technical Information 1 3 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 1 5 813 Domestic Gas Installations The supply from the governed meter must be of adequate size to provide a steady inlet working pressure of 20mbar 8in wg at the boiler On completion test the gas installation for soundness using the pressure drop method and suitable leak detection fluid purge in accordance with the abov
69. riage 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 personis performing lift straddle the load tiltand 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 lf 2 persons performing lift ensure co ordinated movements during lift Avoid upper body top heavy bending do notlean 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 sideways 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
70. rn on the electrical supply Ensure external controls are calling for heat The boiler should fire automatically Allow the boiler to fire for a minimum of 60 seconds and then using an electrical screwdriver rotate the service potentiometer fully clockwise This will allow the digital display to indicate the flashing fan speed on the appliance fascia In the fully clockwise position the display should be indicating the maximum fan speed of the appliance 57 1 for 30sxi and 41 1 for 18sxi Check the CO value which should be 18sxi 30sxi 9 1 0 2 0 5 Case Off 30sxi LPG 10 5 0 3 0 7 Case Off Note that with the inner case front panel fitted the combustion readings will increase slightly to 18sxi 30sxi 9 1 0 3 0 5 Case On 30sxi LPG 10 7 0 3 0 7 Case On If adjustment proves necessary then proceed as follows For LPG appliances refer to the begining of commissioning LPG CONVERSION 30sxi only Any adjustment to the gas valve should only be carried out by a competent person Refer to diagram 12 6 Adjust the maximum rate CO by rotating the throttle to 9 1 0 2 0 5 in small incrimental adjustments then wait for the analyser to reflect the change before continuing to 9 1 0 2 0 5 anti clockwise to increase Rotate the service potentiometer fully anti clockwise Hold it in this position for about 5 seconds before rotating the service potentiometer clockwise to the mid point or 3 o clock position The fan should reduce to
71. section 14 1 Refer to diagram 14 13 Remove the electrical connections from the overheat stat Remove the retaining clip from the return pipe Remove the overheat stat from the retaining clip Ensure that the replacement thermostat is correctly located on the flat on the return pipe and carefully push the thermistor clip into place CAP HEAD OUTLET CABLE 5 SCREW 4 CONNECTOR COVER 2 PUMP HEAD Diagram 14 11 SAFETY DISCHARGE VALVE 11694 Diagram 14 12 FLOW PIPE OVERHEAT THERMOSTAT RESET SWITCH FLOW THERMISTOR RETURN PIPE a t 11503 RETURN THERMISTOR Diagram 14 13 0020008155A 42 14 Replacement of Parts 14 19 Automatic Air Vent For access refer to section 14 1 Refer to section 12 8 and drain the boiler heating circuit Refer to diagram 14 14 Unscrew the automatic air vent Fit the new automatic air vent and O ring ensuring the vent cap is left loose Refill vent and pressurise the boiler Check for leaks 14 20 Low Water Pressure Sensor For access refer to section 14 1 Refer to section 12 8 and drain the boiler heating circuit Refer to diagram 14 15 Disconnect the electrical lead by pushing up retaining tab and withdraw lead plug Remove the retaining clip to remove the low water pressure sensor Fitthe new low water pressure sensor Refill vent and pressurise the boiler Check for leaks
72. 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 To ease future servicing it is advisable to use a compression type fitting to extend the discharge pipe 8 2 Condensate Drain Connection The condensate drain connection is behind the pump atthe rear of the boiler see diagram 8 2 21 5mm plastic overflow pipe UNION NUT should be used to fit into the drain connection on the condensate Tighten half turn D siphon and discharge condensate to a drain The drain pipe should have a fall of at least 2 5 away from the boiler past finger tight SAFETY Condensate should if possible be discharged into the household DISCHARGE internal drainage system If this is not practicable discharge VALVE PIPE can be allowed into the external household drains or a purpose j designed soak away Diagram 8 1 It is recommended that any external condensate drain pipe is insulated or of a 32mm diameter to prevent freezing in adverse m weather conditions CONDENSATE The condensate is discharged periodically slugs by DRAIN action SPIGOT It is not necessary to provide air breaks or extra traps in the discharge pipe as there is already a trap inside the boiler Fitting an extra trap may cause the boiler siphon to work incorrectly Refer to BS5546 or BS6798 for advice on the disposal of boiler condensa
73. system being out of use during frost or freezing conditions Advise the user that the permanent mains electrical supply SHOULD NOT be switched off as the built in frost protection and pump saver program would not be operable Reminder leave these instructions and the Benchmark logbook with the user 0020008155A 12 Servicing Important Notes 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 general once a year should be enough It is the Law that any servicing is carried out by a competent person 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 12 1 General Referto Table 2 Section 1 Technical Information Measurement of the products of combustion can be achieved by connection of a probe to the combustion analyser test point see diagram 12 1 IMPORTANT NOTE Products of combustion willbe discharged when the cap is removed It is important to replace the cap immediately 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 valve
74. table 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 restricting installation Recommend 2 persons lift appliance to position into place space permitting 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 frontand 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 Recommend 2 persons lift appliance to position into place space permitting Fit bracket securely onto wall before lifting appliance int
75. te Arange of condensate fittings are available These cost effective easy to install condensate fittings when used are designed to help installers with the easy removal of condensate The fittings are available from Hepworth Plumbing Products and normal distribution channels CONDENSATE FITTINGS Description Nom Dia mm Overflow to Waste Adaptor A021 21 5 For connection to 32mm or 40mm Push Fit or Solvent Weld pipe Diagram 8 2 Overflow to Rainwater Adaptor A022 For connection to round and square section downpipe Overflow to Soil 32 or 21 5 Adaptor S117 For connection to 110mm Soil pipe Overflow to Soil 40 or 21 5 Adaptor S118 For connection to 110mm Soil pipe Conensate Soakaway S951 0020008155A 20 8 Safety Discharge Valve and Condensate Connections Typical Gravity Draining Condensate Installations INTERNAL SOIL AND VENT STACK MIN DIA 21MM NO RESTRICTION ON LENGTH Internal Soil and Vent Pipe EXTERNAL LENGTH OF PIPE 3M MAX OPEN END OF PIPE DIRECT INTO GULLEY BELOW GROUND BUT ABOVE WATER LEVEL MIN DIA 21MM NOTE FOR EXTENDED PIPE RUNS 32MM DIA PIPE SHOULD BE USED External Termination to a Gulley or Hopper MIN DIA 21MM NO RESTRICTION ON LENGTH OPEN END OF PIPE DIRECT INTO GULLEY BELOW GROUND LEVEL BUT ABOVE WATER LEVEL Internal Termination Downstr
76. to your required length Y mark the securing hole position in the air duct Drill a 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 Standard 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 8 The duct cutting lengths are shown in diagram 9 8 The air duct should be cut at the opposite end to the terminal fixing The terminal plastic duct MUST be cut at the opposite end to the 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 NOTE If you require to lubricate the seals to ease installation please do not use a mineral oil based grease we would recommend the use of water 9 3 Flue Assembly The flue assembly is a push fit design with securing collars Having adjusted the telescopic or cut the air and flue ducts as described in section 9 2 Assemble the flue elbow to the air duct ensuring the correct alignment of the terminal Fit the collar into position mark through two of the pre drilled holes in the collar Remove collar and drilltwo 3mm diameter holes in the elbow take care not to pierce the inner flue duct Insert the terminal flue duct remembering to engage the catch within the terminal check for alignment Fit the rubber seal
77. 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 provided in the roof space Itis tecommendeda 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 overthe boiler 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 Dispose 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 Recommend 2 persons lift appliance to position into place 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 pl

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