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05
24cxi
12175
G.C. No. 47-047-23
30cxi
G.C. No. 47-047-24
38cxi
G.C. No. 47-047-27
High Efficiency
Condensing
Combination Boilers
0020008154A 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.
Important Information 4
INTRODUCTION General Information 5
Manual Handling 5
Technical Information 1 10
Boiler Location and Ventilation 2 13
Flue Location and Ventilation 3 14
Heating System 4 16
Domestic Hot Water System 5 17
INSTALLATION Installation Preparation 6 18
Gas/Water & Appliance Connection 7 20
INSTRUCTIONS Safety Discharge Valve and
Condensate Connection 8 21
Flue Preparation Telescopic and Standard Flue 9 23
Electrical Connection 10 26
Commissioning 11 28
Servicing 12 31
SERVICING Fault Finding 13 35
INSTRUCTIONS Replacement of Parts 14 39
Spare Parts 15 51
3 0020008154A
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.
2. Directive 73/23/EEC on the harmonisation of the Laws of the Connection of the whole electrical system of the boiler, including
any heating controls, to the electrical supply must be through
Member States relating to electrical equipment designed for
one common isolator and must be fused 3 Amp maximum.
use within certain voltage limits.
Isolation should be by a double pole switched fused spur box,
3. Directive 89/336/EEC on the approximation of the Laws of with a minimum gap of 3mm for both poles. The fused spur box
the Member States relating to electromagnetic compatibility. should be readily accessible and preferably adjacent to the
appliance. It should be identified as to its use.
Alternatively connection can be made through an unswitched
shuttered socket and 3A fused 3-pin plug both to the current
issue of BS 1363 may be used, provided they are not used in a
room containing a bath or shower.
Wiring to the boiler must be PVC 85OC insulated cable, not less
than 0.75mm2 (24/0.20mm).
0020008154A 4
General Information
Clearances
If fixtures are positioned close to the boiler, space must be
left as shown in section 2. Enough space must also be left in
front of the boiler to allow for servicing.
Manual Handling
IMPORTANT. With regards to the Manual Handling Operations, Removal of carton from delivery van
1992 Regulations, the following lift operation exceeds the Recommend 2 person lift or 1 person with use of sack truck. If
recommended weight for a one man lift. 1 person is performing lift, straddle the load, tilt and place carton
into position on truck. Recommend secure appliance onto truck
General recommendations when handling with suitable straps. Ensure safe lifting techniques are used –
Clear the route before attempting the lift. keep back straight – bend using legs. Keep load as close to
body as possible. If 2 persons performing lift, ensure co-
Ensure safe lifting techniques are used – keep back straight – ordinated movements during lift. Always use assistance if
bend using legs. required.
Keep load as close to body as possible.
Do not twist – reposition feet instead.
Carriage of carton from point of delivery to
point of installation – ground floor
If 2 persons performing lift, ensure co-ordinated movements
Recommend 2 person lift or 1 person with use of sack truck. If
during lift.
1 person is performing lift, straddle the load, tilt and place carton
Avoid upper body/top heavy bending - do not lean forward/ into position on truck. Recommend secure appliance onto truck
sideways. with suitable straps. Ensure safe lifting techniques are used –
Recommend wear suitable cut resistant gloves with good grip keep back straight – bend using legs. Keep load as close to
to protect against sharp edges and ensure good grip. body as possible. If 2 persons performing lift, ensure co-
ordinated movements during lift. Clear the route before
Always use assistance if required. 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.
5 0020008154A
Manual Handling
Carriage of carton from point of delivery to Positioning of Appliance for Final Installation
point of installation – first or higher floor, – above worktop, foreseeable obstructions
cellar.
etc.
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 Recommend 2 persons lift appliance to position into place. Fit
into position on truck. Recommend secure appliance onto truck bracket securely onto wall before lifting appliance into position.
with suitable straps. Ensure safe lifting techniques are used – Obtain firm grip on front and sides of appliance, lift upwards,
keep back straight – bend using legs. Keep load as close to onto worktop if practicable. Ensure stable balance achieved
and lift upwards to position in place on bracket. If 2 persons
body as possible. If 2 persons performing lift, ensure co-
positioning onto bracket obtain firm grip at front and sides/base
ordinated movements during lift. Avoid upper body/top heavy
of boiler. Ensure co-ordinated movements during 2 person lifts
bending - do not lean forward/sideways. Clear the route before to ensure equal spread of weight of load. Ensure safe lifting
attempting the lift. If removing boiler from truck straddle the load techniques are used – keep back straight – bend using legs -
and tilt forwards to facilitate secure grip. Ensure safe lifting when lifting load from floor level. Do not twist – reposition feet
techniques are used – keep back straight – bend using legs. Do instead. Keep boiler as close as possible to body throughout lift
not twist – reposition feet instead. Take care to avoid trip to minimise strain on back. Avoid upper body/top heavy
hazards, slippery or wet surfaces and when climbing steps and bending - do not lean forward/sideways. Always use assistance
stairs. Always use assistance if required. if required. Recommend wear suitable cut resistant gloves with
good grip to protect against sharp edges and ensure good grip
Carriage of carton from point of delivery to when handling appliance.
point of installation – roofspace.
Positioning of Appliance for Final Installation
Recommend 2-person lift. Ensure co-ordinated movements
during lift. Avoid upper body/top heavy bending - do not lean
– within compartment etc. restricting
forward/sideways. Clear the route before attempting the lift. installation.
Take care to avoid trip hazards, slippery or wet surfaces and Recommend 2 persons lift appliance to position into place,
when climbing steps and stairs. When transferring appliance space permitting. Fit bracket securely onto wall before lifting
into roofspace, recommend 1 person to be in roofspace to appliance into position. Obtain firm grip on front and sides of
receive the appliance and other person to be below to pass up appliance, lift upwards, onto worktop if practicable. Ensure
and support appliance. Ensure safe lifting techniques are used stable balance achieved and lift upwards to drop into place onto
– keep back straight – bend using legs. Keep load as close to bracket. If 2 persons positioning onto bracket obtain firm grip at
body as possible. Always use assistance if required. It is front and sides/base of boiler. Ensure co-ordinated movements
assumed safe access, flooring and adequate lighting are during 2 person lifts to ensure equal spread of weight of load. If
provided in the roof space. It is recommended a risk assessment 1 person positioning onto bracket recommend obtain firm grip
of the roof space area be carried out before moving the supporting base of boiler. Ensure safe lifting techniques are
appliance into the area to take into account access, stability of used – keep back straight – bend using legs - when lifting load
flooring, lighting and other factors, and appropriate measures from floor level. Do not twist – reposition feet instead. Keep
taken. boiler as close as possible to body throughout lift to minimise
strain on back. Always use assistance if required. Recommend
Unpacking of appliance from carton. wear suitable cut resistant gloves with good grip to protect
against sharp edges and ensure good grip when handling
Recommend 2 persons unpack appliance from carton. Always
appliance.
keep working area clear. Recommend cut base end of carton
and open carton flaps, then tilt boiler forwards from its side onto
its base and remove carton by sliding up over the boiler. Ensure Positioning of Appliance for Final Installation
safe lifting techniques are used – keep back straight – bend – in roof space restricting installation.
using legs. Keep load as close to body as possible. Always use
assistance if required. Dispose of packaging in a responsible Recommend 2 persons lift appliance to position into place,
manner. Recommend wear suitable cut resistant gloves with space permitting. Fit bracket securely onto wall before lifting
good grip to protect against sharp edges and ensure good grip appliance into position. Obtain firm grip on front and sides of
when handling appliance outside packaging. appliance, lift upwards, ensure stable balance achieved and lift
upwards to drop into place onto bracket. If 2 persons positioning
onto bracket obtain firm grip at front and sides/base of boiler.
Positioning of Appliance for Final Installation Ensure co-ordinated movements during 2 person lifts to ensure
– no obstructions. equal spread of weight of load. If 1 person positioning onto
bracket recommend obtain firm grip supporting base of boiler.
Recommend 2 persons lift appliance to position into place. Fit
Ensure safe lifting techniques are used - keep back straight –
bracket securely onto wall before lifting appliance into position.
bend using legs - when lifting load from floor level. Do not twist
Obtain firm grip on front and sides of appliance, lift upwards,
– reposition feet instead. Keep boiler as close as possible to
ensure stable balance achieved and lift upwards to position in
body throughout lift to minimise strain on back. Always use
place on bracket. Ensure safe lifting techniques are used – keep
assistance if required. Recommend wear suitable cut resistant
back straight – bend using legs - when lifting load from floor
gloves with good grip to protect against sharp edges and ensure
level. Do not twist – reposition feet instead. Keep boiler as close
good grip when handling appliance. It is recommended a risk
as possible to body throughout lift to minimise strain on back.
assessment of the roof space area be carried out before moving
Ensure co-ordinated movements to ensure equal spread of
the appliance into the area to take into account access, stability
weight of load. Always use assistance if required. Recommend
of flooring, lighting and other factors, and appropriate measures
wear suitable cut resistant gloves with good grip to protect
taken.
against sharp edges and ensure good grip when handling
appliance.
0020008154A 6
Appliance Safety Devices - User Instructions
Electrical Supply Failure Reset Switch Frost protection
The boiler will not work without an electrical supply. The appliance has a built in frost protection device that protects
Normal operation of the boiler should resume when the electrical the boiler from freezing. With the gas and electric supplies ON
supply is restored. and irrespective of any room thermostat setting, the frost
protection device will operate the pump when the temperature
Reset any external controls, to resume normal operation of the of the boiler water falls below 7OC.
central heating.
The burner will fire if the temperature inside the boiler falls to
If the boiler does not resume normal operation turn the mains 3OC.
reset switch off and on. If the boiler does not resume normal
operation after this the overheat stat may have operated. When the temperature reaches 10OC the boiler stops.
Any other exposed areas of the system should be protected by
Overheating safety a separate frost thermostat.
In the event of the boiler overheating the safety devices will Condensate Drain Blockage
cause a safety shutdown. If this happens, call your Installation/
Servicing company. 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
Safety Discharge Valve
house. Release an ice blockage by the use of warm cloths on
A safety discharge valve and discharge pipe is fitted to the the pipe. The boiler should then restart. Contact your installation/
boiler. This valve must not be touched. Should there be any servicing company if the fault persists.
discharge from the pipe, isolate the boiler electrical supply and
call your installer or Glow-worm’s own service organisation
using the telephone number on the inside front cover of this
booklet.
7 0020008154A
Operating the Boiler - User Instructions
9934
CONTROLS
DIGITAL NO PRE-HEAT ECONOMY POSITION
FASCIA CONTROL
DISPLAY POSITION APPROX 55O WITH PRE-HEAT
LIGHT
MAINS
RESET
SWITCH
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 heating water can be adjusted by turning the central heating water temperature
control to desired setting between 1 'Min' and 'Max'. Maximum setting is appoximately 82°C.
Set the control to '0' 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.
DOMESTIC HOT WATER CONTROL
2. Position 0 - hot water OFF. Turn hot water temperature control between 0 to for hot water 62oC with no
pre-heat. Turn hot water temperature control between and for hot water, 40oC - 62oC with pre-heat.
Pre-heat is a function that provides hot water with minimum delay.
The ECO setting is recommended and ideally suited to normal family use (showers, washing up etc.).
Positions between ECO and are for occasional use, for water above 55oC approx.
TO RESET
3. 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
4. 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.
0020008154A 8
Operating the Boiler - User Instructions
11474
The digital display normally shows the operating temperature
of the unit when there is a central heating demand and gives a
pressure reading when there is no demand or when the appliance
is in the domestic hot water mode.
If the digital display shows pressure less than 0.7bar, re-
pressurise the system to 1bar by gently opening the built in
filling tap underneath the boiler, see diagram 2. A tap extension
tool is provided to facilitate this. Ensure the tap is closed. If the
system repeatedly loses pressure, YOU MUST CONTACT
YOUR INSTALLER OR GLOW-WORM'S OWN SERVICE
ORGANISATION USING THE TELEPHONE NUMBER ON
THE INSIDE FRONT COVER OF THIS BOOKLET.
FILLING
To Turn the Boiler Off LOOP TUBE FILLING LOOP TAP
There is a mains reset switch on the right hand side of the
AND EXTENSION TOOL
controls fascia, which will isolate the boiler. However, it is
preferable to leave the electrical supply on whenever possible
to permit operation of the built-in frost protection (see 'Protection
Diagram 2
Against Freezing') and daily pump and valve exercise.
To turn off the central heating use the room thermostat or
programmer.
To turn off the domestic hot water turn the hot water temperature
control knob to the minimum setting.
For holiday mode turn both of the temperature knobs to the
minimum setting.
To turn off the boiler for servicing, isolate it from the electrical
supply. To turn it on again follow the instructions given in
'Operation of the Boiler'.
9 0020008154A
1 Technical Information
12848
87 334
176
14 FLUE
CENTRE LINE
CL
FLUE
76
CL
BOILER
715
SAFETY
DISCHARGE
DRAIN
177
77 44
48
GAS 86
156 134
450
1.1 IMPORTANT NOTICE The Health and Safety at Work Act, Control of Substances
The boiler is supplied in one carton, which includes a fittings and Hazardous to Health (COSHH).
documentation pack, see diagram 6.1. The Current I.E.E. Wiring Regulations.
The flue and fixing jig are supplied seperately. Where no specific instructions are given, reference should be
This boiler is for use only on G20 natural gas, but the 30cxi may made to the relevant British Standard Code of Practice.
be converted for use on G31 gas (Propane L.P.G.). In IE, the installation must be carried out by a competent person
Where no British Standards exists, materials and equipment and installed in accordance with the current edition of I.S.813
should be fit for their purpose and of suitable quality and "Domestic Gas Installations", the current Building Regulations
workmanship. and reference should be made to the current ETCI rules for
The installation of this boiler must be carried out by a competent Electrical Installation.
person in accordance the rules in force in the countries of In GB the following Codes of Practice apply:
destination.
BS4814, BS6798, BS5440 Part 1 and 2, BS5546 Part 1,
Manufacturer's instructions must not be taken as overriding BS5449, BS6891, BS6700, BS7074 Part 1 and 2, BS7593,
statutory requirements. BS7671.
1.2 Statutory Requirements In IE: I.S.813, BS5546, BS 5449, BS 7074, BS 7593.
In GB the installation of the boiler must be carried out by a Manufacturer's instructions must not be taken as overriding
competent person as described in the following regulations: statutory requirements.
The manufacturer's instructions supplied. Note: For further information, see the current issue of the
The Gas Safety (Installation and Use) Regulations. Building Regulations, approved document L1 ( in the UK) and
the references:
The appropriate Buildings Regulations either The Building
Regulations, The Building Regulations (Scotland),The Building 1) GIL 59, 2000: Central heating system specification (CheSS)
Regulations (Northern Ireland). and
The Water Fittings Regulations or Water byelaws in Scotland. 2) GPG 302, 2001: Controls for domestic central heating
system and hot water. BRECSU.
0020008154A 10
1 Technical Information
TABLE 1
11976
24cxi 30cxi 38cxi
Lift Weight 41kg(90lb) 42kg(92.5lb) 44kg(97lb)
Total Weight (installed) 44kg(97lb) 45kg(99lb) 47kg(103.5lb)
Diagram 1.2
11 0020008154A
1 Technical Information
Certification
9165
This boiler certificated to the current issue of EN 483 : 2000 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.
0020008154A 12
2 Boiler Location and Ventilation
2.1 Location
12344
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 5 5
the relevant requirements.
In GB this is the current I.E.E. WIRING REGULATIONS and
BUILDING REGULATIONS.
In IE reference should be made to the current edition of I.S.813
"Domestic Gas Installations" and the current ETCI rules. 600
+
2.2 Clearances
The boiler should be positioned so that at least the minimum
operational and servicing clearances are provided, see diagram
2.1.
5
Additional clearances may be beneficial around the boiler for 150
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.
13 0020008154A
3 Flue Location and Ventilation
3.1 Flue Options 3.2 Flue Length
This boiler is suitable for concentric Horizontal and Vertical The maximum permissable horizontal flue length is 10 metres
flues, elevated horizontal and vertical twin, all are fitted onto the plus the flue terminal, this can be achieved by use of the
top of the boiler. accessories, however should additional 90o or 2 x 45o elbows
The Glow-worm Flue Options Guide, available on request or be used then the length MUST be reduced by 1metre.
through the web site, describes in detail the necessary When extension pipes are used the flue system must be
accessories. designed to have a continuous fall to the boiler of at least 2.5o
These instructions describe the use of the standard and 44mm/metre to allow condensate to run back into the boiler and
telescopic horizontal flues. out via the drain.
The instructions for all other flues will be contained in those The flue can be installed from inside the building, when access
packs. 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.
12837
12839
75 min. to 540 max. 208 min. to 413 max.
WALL THICKNESS WALL THICKNESS
176 176
TOP REAR FLUE - STANDARD Diagram 3.1 TOP REAR FLUE - TELESCOPIC Diagram 3.3
12838
NOTE. If necessary, it is permitted to NOTE. If necessary, it is permitted to
12840
increase this dimension to 600mm max. increase this dimension to 600mm max.
87min Max flue length 717mm 87min Max flue length 589mm
20mm 20mm
min. min.
239 211 clearance 239 211
clearance
CL CL
FLUE A FLUE
A
A
A
Max. distance from outside Min. distance from outside
Max. distance from outside Min. distance from outside
wall face to min clearance. wall face to min clearance.
wall face to min clearance. wall face to min clearance.
LH - 330mm LH - 125mm
LH - 458mm LH/RH - 75mm
RH - 358mm RH - 153mm
RH - 486mm
TOP SIDE FLUE - STANDARD Diagram 3.2 TOP SIDE FLUE - TELESCOPIC Diagram 3.4
0020008154A 14
3 Flue Location and Ventilation
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 I.S.813
"Domestic Gas Installations".
The terminal must be exposed to the external air, allowing free
passage of air across it at all times.
Being a condensing boiler some pluming may occur from the
flue outlet. This should be taken into consideration when
selecting the position for the terminal.
* *
H and J See diagram 3.5 . 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.
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
MINIMUM SITING DIMENSIONS FOR wall, require special consideration with respect to any openings,
FANNED FLUE TERMINALS POSITION MM doors, vents or windows under the roof. Care is required to
protect the roof if made of plastic sheeting. If the carport
HORIZONTAL FLUES comprises of a roof and two or more walls, seek advice from the
local gas supply company before installing the boiler.
A DIRECTLY BELOW AN OPENING, AIR BRICK,
OPENING WINDOWS 300 * *
H and J See diagram 3.5 . These dimensions comply with
the building regulations, but they may need to be increased to
B ABOVE AN OPENING, AIR BRICK, avoid wall staining and nuisance from pluming depending on
OPENING WINDOWS 300 site conditions.
C HORIZONTALLY TO AN OPENING,
AIR BRICK, OPENING WINDOWS 300
3.5 Terminal Guard
D BELOW GUTTER, DRAIN/SOIL PIPE 25 A terminal guard is required if persons could come into contact
with the terminal or the terminal could be subject to damage.
E BELOW EAVES 25
If a terminal guard is required, it must be positioned to provide
F BELOW A BALCONY OR CAR PORT 25
minimum of 50mm clearance from any part of the terminal and
G FROM VERTICAL DRAIN PIPES AND be central over the terminal.
SOIL PIPES 25 The guard should be similar to that shown in diagram 3.6.
H FROM INTERNAL/EXTERNAL CORNERS 25 A suitable guard is manufactured by: -
*
H TO A BOUNDARY ALONGSIDE THE
Tower Flue Components
TERMINAL 300
Morley Rd.
I ABOVE ADJACENT GROUND OR
Tonbridge
BALCONY LEVEL 300
Kent
*
J FROM SURFACE OR A BOUNDARY
TN9 1RA.
FACING THE TERMINAL 600
K FACING TERMINALS 1200 Size: 280mm x 280mm x 270mm.
L FROM OPENING (DOOR/WINDOW)
IN CAR PORT INTO DWELLING 1200 TERMINAL GUARD
M VERTICAL FROM A TERMINAL 1500
N HORIZONTALLY FROM A TERMINAL 300
VERTICAL FLUES
P FROM ANOTHER TERMINAL 600
Q ABOVE ROOF LEVEL 300
R FROM ADJACENT OPENING WINDOW 1000
S FROM ADJACENT WALL TO FLUE 300
15 0020008154A
4 Heating System
4.1 General 4.3 Flow Rate
The boiler is for use only with sealed central heating systems. If it is necessary to alter the flow rate, the system can be fitted
The safety valve is an integral part of the boiler and it cannot be with a lockable balancing valve in the main flow or return pipes
adjusted. shown as valve "A" in diagram 4.1. The flow rate through the
boiler must not be allowed to fall below that given in table 3.
The digital readout on the controls fascia indicates the system
pressure when there is no central heating demand.
4.4 Bypass
The circulation pump is integral with the boiler.
The boiler is fitted with an adjustable automatic bypass. Ensure
that under no circumstances does the flow rate drop below the
4.2 Expansion Vessel figure specified, refer to table 3 and section 11.6.
The boiler has an integral expansion vessel with a capacity of The installation of the boiler must comply with the requirements
8 litres (1.76 gallons), with a charge pressure of 0.5bar. of the current issue of BS6798, in Ireland, refer also to the
NOTE: The expansion vessel volume depends on the total current edition of I.S.813 "Domestic Gas Installations".
water system volume and the initial system design pressure. In GB it is necessary to comply with the Water Supply (Water
Guidance on vessel sizing is also given in the current issue of Fittings) Regulations 1999 (for Scotland, the Water Byelaws
BS5449 and BS7074 Part 1, for IE refer to the current edition of 2000, Scotland).
I.S.813 "Domestic Gas Installations".
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.
Table 3. Flow Rate In IE the requirements given in the current edition of I.S.813
"Domestic Gas Installations" and the current Building Regulations
must be followed.
MODEL MINIMUM FLOW RATE
4.5 Filling the Sealed System
24 cxi 774 litres/hr.
NOTE: The water pressure at the boiler must be at least 1.2bar
30 cxi 1032 litres/hr. to enable filling the boiler to a minimum pressure. If not
pressurisation must be carried out by an alternative filling loop.
38 cxi 1289 litres/hr. The boiler has a built in filling device, see diagram 4.2. A push-
on extension is supplied in the loose items pack to ease access
This is equal to 20OC differential at maximum heat input. to the filling device tap.
This filling device is designed to enable the re-pressurisation of
the system in the event of loss of pressure. It is not intended to
be used to completely fill the system. If so used, it may take a
9168
FILLING LOOP
REDUCED TAP
PRESSURE FILLING LOOP TAP
* Refer to section 11.6 ZONE VALVE EXTENSION Diagram 4.2
Diagram 4.1
0020008154A 16
4 Heating System
4.6 Water Treatment
12253
In the 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 a cleanser 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.
Diagram 4.3
17 0020008154A
6 Installation Preparation
6.1 Appliance Pack Remove the polystyrene end packing pieces then carefully lay
the boiler on its back, remove the two front casing panel
IMPORTANT: With regards to the Health and Safety Manual securing screws and lift off the panel from two retaining lugs.
Handling requirements, two persons shall be required to lift the
Remove the transit packaging behind the front panel and
appliance, refer to Manual Handling section on page 5.
discard.
Please check the contents of packs as shown in diagram 6.1.
Carefully place front panel and screws to one side.
NOTE: The fittings pack is located in the base polystyrene
packing under the boiler base.
12332
Diagram 6.1
0020008154A 18
6 Installation Preparation
12075
2.5° 44mm/metre
Take the wall template from the fixing jig pack and place in the Inclined Extended
desired position on a flat wall, giving due consideration to boiler
clearances, see section 2, and the flue you are fitting. flue length
176
template.
127
For standard side flues the horizontal flue centre line on the
2.5
°
16
Ø 125
wall template should be extended to the side wall, and the Standard
0
13
vertical centre of the flue hole marked at 176mm from the back 13
0
flue length
wall.
Horizontal
For installations with external access, a 105mm diameter core
drill can be used.
For installations with internal access only a 125mm diameter
core drill should be used.
WALL
When using extension pipes with the horizontal rear flue, a core
drill size of 125mm should be used to allow the extension pieces
TEMPLATE
to slope at 44mm/metre (2.5°) towards the boiler.
For extended side flues, the flue hole centre should be EXTENDED SIDE FLUE Diagram 6.2
determined by extending the dashed inclined line on the template
to the side wall. This dashed line is drawn at 44mm/metre (2.5o)
rise from the boiler. Where this line reaches the side wall, a
12049
horizontal line should be marked. The vertical centre line of the
flue should then be marked at 176mm from the back wall, see WALL WALL
diagram 6.2. TEMPLATE PLUG
To allow for the flue passing through the wall at this angle a
125mm hole should be drilled irrespective of internal or external
installation.
Remove the wall template whilst drilling the flue hole. HANGING
BRACKET
6.4 Fixing Jig and Hanging Bracket
Reposition the wall template over the flue hole and mark the
position of the fixing holes for the jig and the hanging bracket,
see diagram 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 SCREW
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 WALL
and advise that the installer should supply those which are
suitable. PLUG
Locate the jig plate between the wall brackets and secure with SCREW
the No. 8 self tapping fixing screws supplied in the fittings pack. (2 OFF)
SCREW
FIXING JIG
WALL BRACKETS
(2 OFF)
FIXING JIG
(Handed as shown)
PLATE
Diagram 6.3
19 0020008154A
7 Gas/Water & Appliance Connection
12349
C
A B D A
ALL ISOLATION
VALVES ARE SHOWN
IN CLOSED POSITION
12347
Diagram 7.1
0020008154A 20
8 Safety Discharge Valve and Condensate Connections
8.1 Safety Discharge Valve
11694
The pipe from the safety discharge valve must not discharge SAFETY
above an entrance, window or any type of public access area. DISCHARGE
Take the short safety discharge tube, union nut and seal, VALVE
supplied loose in the boiler fittings pack and fit as shown in
diagram 8.1
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.
The pipe must have a continuous fall and be routed to a position
so that any discharge of water, possibly boiling, or steam cannot
create any danger to persons, damage to property or external
electrical components and wiring.
To ease future servicing it is advisable to use a compression
type fitting to extend the safety discharge valve tube.
11482
It is recommended that any external condensate drain pipe is CONDENSATE
insulated and also preferably of 32mm diameter, to prevent TRAP
freezing in adverse weather conditions.
The condensate is discharged periodically in 'slugs' by siphonic
action.
It is not necessary to provide air breaks or extra traps in the
discharge pipe as there is already a 75mm high trap inside the
boiler. Fitting an extra trap may cause the boiler siphon to work
incorrectly.
Refer to BS5546 or BS6798 for advice on disposal of boiler
condensate.
CONDENSATE
CAP
DRAIN
CONNECTOR
Diagram 8.2
21 0020008154A
8 Safety Discharge Valve and Condensate Connections
INTERNAL SOIL
AND VENT STACK EXTERNAL SOIL
12333
AND VENT STACK
BOILER BOILER
EXTERNAL
MAX. 3M
BOILER
EXTERNAL LENGTH SINK
OF PIPE 3M MAX. * (CONSTITUTES BOILER
AIR BREAK)
External Termination to a Gulley or Hopper Internal Termination into Combined Sink Waste
300MM
100MM PLASTIC TUBE
NOTE: PIPEWORK SHOULD ALWAYS FALL AWAY FROM BOILER BY AT LEAST 2.5 0
44mm FOR EVERY 1M.
Diagram 8.3
0020008154A 22
9 Flue Preparation Telescopic and Standard Flue
9.1 Flue Components Additional flue accessories are available to suit your site
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.
12841
Top Outlet Horizontal Concentric Flue Packs: FLUE
A2043600 Horizontal telescopic flue pack. ELBOW
A2043400 Standard horizontal flue pack. SECURING SCREW x 4
COLLAR
SEALING SCREW x 2
TAPE (telescopic only)
SCREW x 2 GASKET
SEALING (fitted)
COLLAR
SCREW x 1
TELESCOPIC
TERMINAL ASSEMBLY
SEALING
COLLAR
STANDARD
TERMINAL ASSEMBLY
Diagram 9.1
12842
45o Bend
2000460485
(2off)
90o Bend
2000460484
0.5m
EXTENSION
2000460481
1m
EXTENSION
2000460482
VERTICAL
FLUE
ADAPTOR
2m A2024600
EXTENSION
2000460483 Diagram 9.2
23 0020008154A
9 Flue Preparation Telescopic and Standard Flue
9.2 Flue Length Top Side flue - Standard - with the flue elbow temporarily fitted,
measure the distance from the outside wall to the butt joint, see
Top Rear flue - Telescopic - with the flue elbow temporarily diagram 9.5. If the measurement 'Y' exceeds 652mm, then the
fitted, measure the distance from the outside wall to the butt appropriate length of extension pipe is required. The minimum
joint, see diagram 9.4. If the measurement 'Y' exceeds 525mm, dimension for Lhd is 270 and Rhd 242 to suit a minimum wall
then the appropriate length of extension pipe is required, if the thickness of 75mm.
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. If the measurement 'Y' exceeds 652mm,
then the appropriate length of extension pipe is required. The
minimum dimension is 187mm to suit a 75mm min wall thickness.
Top Side flue - Telescopic - with the flue elbow temporarily
12843
fitted, measure the distance from the outside wall to the butt Y
joint, see diagram 9.6. If the measurement 'Y' exceeds 525mm,
then the appropriate length of extension pipe is required, if the OUTER FLUE
DUCT AIR COLLAR
dimension is less than 320mm DO NOT cut the flue, it can RUBBER
COLLAR DUCT
project to a maximum of 600mm, if this is not desirable then a DRILL AND
Standard flue MUST be used and cut to length. SCREW
12658
OUTSIDE
WALL FACE
DRILL AND INNER CL
SCREW PLASTIC FLUE
COLLAR
COLLAR
TOP SIDE FLUE - STANDARD Diagram 9.5
OUTSIDE BOILER
WALL FACE MOUNTING WALL
12851
Y
TOP REAR FLUE - STANDARD Diagram 9.3 OUTER FLUE
RUBBER DUCT AIR
COLLAR DUCT COLLAR
Y
12850
DRILL AND
SCREW
WALL THICKNESS 112
DRILL AND
SCREW
OUTSIDE
WALL FACE
INNER CL
PLASTIC FLUE
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
0020008154A 24
9 Flue Preparation Telescopic and Standard Flue
9.2 (cont'd) Flue and Air Ducts
12852
Telescopic:
The Telescopic Flue system MUST NOT be cut.
Adjust the flue 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. AIR DUCT - TELESCOPIC
The terminal plastic duct MUST be cut at the opposite end to the TOP TELESCOPIC
catch. Diagram 9.7
AIR DUCT SECURING
The plastic flue duct extensions MUST be cut at the opposite
end to seal.
12847
The cut ducts must be de-burred and all filings and debris
removed. L
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.
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.
Diagram 9.9
25 0020008154A
10 Electrical Connection
WARNING: This appliance must be earthed.
10181
This appliance must be wired in accordance with these
instructions. Any fault arising from incorrect wiring cannot be
put right under the terms of the Glow-worm guarantee.
All system components must be of an approved type.
Electrical components have been tested to meet the equivalent
requirements of the BEAB.
Do not interrupt the mains supply with a time switch or
programmer.
Connection of the whole electrical system and any heating
system controls to the electrical supply must be through a
common isolator.
Isolation should preferably be by a double pole switched fused
spur box having a minimum contact separation of 3mm on each CONTROL CABLE
pole. The fused spur box should be readily accessible and EXIT
preferably adjacent to the boiler. It should be identified as to its PANEL REAR
use. COVER SECURING
SCREW (3)
A fused three pin plug and shuttered socket outlet may be used
instead of a fused spur box provided that:
11506
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.
12442
BOILER TO MAIN PCB
CONNECTOR J15
CONTROLS
INTERFACE PCB
3
2
X 1
VOLTAGE FREE
DO NOT
HEATING
CONNECT
CONTROLS
CONNECTION
(ON CONTROLS
BOX COVER)
ON/OFF
SWITCH
PROGRAMMER
ROOM
THERMOSTAT
3 AMP FUSE
DOUBLE POLE
ISOLATOR
PROGRAMMER L N E
230V~ 50Hz
VOLTAGE FREE PERMANENT
ROOM THERMOSTAT MAINS SUPPLY
Diagram 10.2
0020008154A 26
10 Electrical Connection
10.3 Mains Voltage System Controls
12406
CABLE
WARNING: UNDER NO CIRCUMSTANCES MUST ANY EXIT
MAINS VOLTAGE BE APPLIED TO ANY OF THE TERMINALS
ON THE VOLTAGE FREE HEATING CONTROLS
CONNECTION PLUG. MAINS
Remove the MAINS VOLTAGE HEATING CONTROLS CABLE
CONNECTION PLUG from the fittings pack and install on the
control interface PCB as follows. SYSTEM
Gain access to the control and user interface PCB's by unclipping CONTROLS
the fascia panel and hinging forward, see diagram 10.3. CABLE
Route the system controls cable and connect to the plug, see
diagram 10.3.
Insert plug onto controls interface PCB, see diagram 10.3. STRAIN
Close the fascia panel and remove the screws to open the rear RELIEF
cover of control panel, see diagram 10.1.
Secure the system control cable in the strain relief, and thread
the cable through rear of the control panel and out of the cables
exit, see diagram 10.4.
Close and secure rear cover of control panel.
Remove the wire link from the voltage free heating controls Diagram 10.4
connector, see diagram 10.1.
Connect system controls as diagram 10.5.
12441
External controls should be fitted in accordance with the rules
in force.
RETAINING
LATCHES
12440
27 0020008154A
11 Commissioning
Please ensure the "Benchmark" logbook is completed and left The water flow rate is restricted to a maximum 10 l/min (24cxi)
with the user and the magnetic lighting instruction label is 12 l/min (30cxi) and15.5 l/min (38cxi) by a restrictor fitted during
placed on the surface of the boiler casing. boiler installation, see diagram 7.1.
LPG CONVERSION - 30cxi only
11.2 Filling the Heating Circuit
NOTE: Steps 11.1 to 11.3 will need to be completed before the Refer to section 4 to fill the system.
appliance can be converted.
Open the two central heating isolating valves and domestic cold
The 30cxi can be converted to run on LPG-Propane (G31). water inlet valve, slots in line with the length of the valve, see
This conversion should only be carried out by a competent diagram 7.1
person. To enable the system pressure to be viewed, turn the Central
During the conversion to Propane use of a suitable flue gas heating temperature knob and hot water temperature knob to
analyser is necessary. the off position.
Turn the mains electricity supply on to the appliance and ensure
As an option a chargeable boiler only commissioning service that the mains switch on the appliance fascia is set to the on
can be provided by Glow-worm Service by calling telephone position.
No. 01773 828100.
The system pressure is displayed on the controls panel fascia
Tools required to make the conversion are a 2mm Allen key and of the appliance, see diagram 1 of the User Instructions.
an electricians screwdriver.
Fill the system until the pressure on the display reads at least
Ensure that the appliance supply pressure = 37mbar. 1.0bar. Note that on filling the system a small amount of water
(1) Access the gas valve. may be discharged from the reduced pressure zone valve, see
diagram 4.2.
(2) Refer to diagram 11.4 and turn the gas valve throttle fully Remove the two inner casing panel securing screws, lift the
clockwise. panel off the retaining lugs, refer diagram 11.1.
(3) Turn the throttle back anti-clockwise by 5 1/2 turns. Make sure that the automatic air vent works correctly and that
(4) Ensure that the gas analyser is set to the correct fuel the black cap is loosely fitted to allow air to escape, see diagram
setting - Propane. 11.2.
(5) Attach combustion analyser to the combustion test point. Check the heating system and boiler connections for water
See diagram 12.1. soundness.
12353
INNER
(7) Turn on the mains electrical supply and turn on the gas CASING
service cock. Switch the boiler on. PANEL
(8) Ensure external controls are calling for heat. The boiler
should fire automatically. CASING
PANEL
(9) Using an electrical screwdriver, rotate the service
potentiometer to the mid point or 3 o’clock position. See
diagram 12.8. The fan speed should now reduce to minimum
and ‘12’ should be shown flashing on the digital display.
Check the CO2 value. If necessary refer to diagram 11.4
and using a 2mm allen key carefully adjust the offset screw
until a CO2 reading of 10.5% ± 0.2% is achieved. Turning
the offset screw clockwise increases the CO2 reading.
(10) After setting combustion, rotate the service
potentiometer fully anti-clockwise so that the display
indicates the water temperature. Check that the CO2
combustion remains between 9.8% and 10.8% CO2. Further SECURING
adjustment should not be necessary, however if required, SECURING SCREW (2)
carefully adjust the gas valve throttle (see diagram 11.4)
until this is achieved.
SCREWS Diagram 11.1
(11) Remove analyser probe from the test point and replace the
cap. Refit the control panel. CAP
11483
0020008154A 28
11 Commissioning
THERMOSTAT GAS
VALVE
RESET OFFSET
SWITCH ADJUSTMENT
THROTTLE
ELECTRICAL
PLUG
INLET PRESSURE
TEST POINT
29 0020008154A
11 Commissioning
11.7 Completion
9531
Adjust the boiler temperature control and any system controls ADJUSTMENT
to their required settings. In addition it is necessary to complete SCREW
the "Benchmark" logbook.
BYPASS VALVE
For IE, it is necessary to complete a "Declaration of Conformity"
to indicate compliance to I.S.813. An example of this is given in
the current edition of I.S.813.
Testing Flue Gases: If any doubt exists that the flue products
are not exhausting correctly, investigate by use of a gas
analyser (FGA).
Diagram 11.5
0020008154A 30
12 Servicing
Important Notes
12853
To ensure the continued efficient and safe operation of the FLUE ELBOW
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. COMBUSTION
ANALYSER
TEST POINT
12.1 General
Refer to Table 2 Section 1 Technical Information. Measurement
of the products of combustion can be achieved by connection FLUE DUCT
of a probe to the combustion analyser test point, see diagram EXTENSION
12.1.
IMPORTANT NOTE: Products of combustion will be 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 Diagram 12.1
supply should be turned off at the gas isolation valve, see
diagram 7.1.
9808
All routine servicing requirements can be achieved by the RETAINING
removal of the front panel and inner panel only. To remove SLOTS TORX
simply undo the two screws on the underside of the front panel SCREWS (3)
and lift off, see diagram 12.2. Undo the two screws on the front
of inner panel and lift off, see diagram 12.2.
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).
RETAINING
REAR PANEL
12.2 Spark Electrode CORD CONTROL BOX
Disconnect the electrode lead and two securing screws. Diagram 12.2
Withdraw the spark electrode carefully from the combustion
chamber, see diagram 12.3 and 12.6.
HEAT
11410
31 0020008154A
12 Servicing
Withdraw the gas pipe from gas valve connection and remove.
12402
NOTE: When replacing ensure that the sealing grommet, OFFSET
situated below the gas valve is correctly re-seated. ADJUSTMENT
Disconnect the gas valve electrical plug at the gas valve.
Disconnect the electrical leads from the fan.
Remove the five combustion chamber front retaining nuts, see THROTTLE
diagram 12.6.
Gently remove the fan, gas valve and burner assembly from the
combustion chamber, see diagram 12.4. GAS VALVE
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.
GAS PIPE
Inspect the sealing rings and replace if necessary.
RETAINING CLIP
Removal of the burner is not necessary during a normal service.
NOTE: IF THE BURNER HAS TO BE REMOVED IT WILL
REQUIRE A NEW GASKET WHEN REFITTED. SEALING GROMMET
11478
12.4 Combustion Chamber and Heat GAS PIPE
Exchanger RETAINING CLIP
Refer to diagram 12.4.
Remove loose debris from combustion chamber 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).
11490
HEAT
COMBUSTION CHAMBER SECURING NUT EXCHANGER
11502
(5 OFF)
BURNER
SEALING
RING
SPADE
CONNECTOR
ELECTRODE
LEAD
FAN
GAS VALVE
0020008154A 32
12 Servicing
12.6 Combustion Check.
11472
If a gas carrying component has been replaced, the combustion RETAINING
of the appliance should be checked as follows. Once the LATCHES
appliance has been re-assembled (apart from the front and
inner casing panels) connect a CO2 combustion analyser to the
test point on the flue adapter, see diagram 12.1.
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.
Turn 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, see diagram 12.7. This will allow the digital
display to indicate the 'flashing' fan speed on the appliance
fascia. CONTROLS USER INTERFACE
11417
In the fully clockwise position the display should be indicating FASCIA
the maximum fan speed of the appliance, in central heating
mode this should be 39±1 for 24cxi, 45±1 for 30cxi and 45±1 for
38cxi. With domestic hot water max. demand this should be
51±1 for 24cxi, 57±1 for 30cxi and 57±1 for 38cxi. Check the
CO2 value, which should be 9.1% +0.2 -0.5.
Note that with the inner casing panel fitted the combustion
readings will increase slightly to 9.3% +0.3 -0.5.
If adjustment proves necessary then proceed as follows.
Any adjustment to the gas valve should only be carried out by
a competent person.
Refer to diagram 11.4.
Adjust the maximum rate CO2 with the throttle to 9.1%. (Rotate MIN.
anti-clockwise to increase).
Rotate the service potentiometer fully anti-clockwise. Hold it in SERVICE
this position for about 5 seconds before rotating the service POTENTIOMETER
potentiometer clockwise to the mid-point or 3 o'clock position.
MAX.
The fan should reduce to 1200 ± 100 rpm which will flash '12' ±1
on the digital display.
Check the CO2 value, which should be 9.1% +0.2 -0.5.
POTENTIOMETERS Diagram 12.7
For Propane the CO2 value, should be 10.5% +0.3 -0.7.
If adjustment proves necessary then proceed as follows.
Adjustment of the CO2 at minimum rate is very coarse so 9183
carefully adjust the CO2 with the offset adjustment to 9.1%, see
diagram 11.4.
DOMESTIC
Rotate the service potentiometer fully clockwise, see diagram SECURING COLD WATER
12.7 and re-check the maximum rate combustion, which should
be 9.1% +0.2 -0.5. CLIP INLET FILTER
After checking combustion rotate the service potentiometer
fully anti-clockwise so that the display indicates the water HOUSING
temperature.
PUMP
Replace the cap on the test point and refit the control cover rear
panel.
Diagram 12.8
33 0020008154A
12 Servicing
12.7 Domestic Cold Water Inlet Filter
9184
FIXING JIG RETAINING CLIP
If the water flow rate through the appliance has reduced it may
be necessary to clean or replace the water inlet filter.
Turn off the electrical supply to the boiler.
Refer to section 12.10 and drain the domestic hot water circuit.
Slide out the securing clip, which holds the filter in its housing
to the left of the pump, remove the filter to clean or renew if
necessary, see diagram 12.8.
Replace the filter into its housing and replace the securing clip.
Open the cold water isolating valve and test the Domestic Hot HOUSING
Water circuit for soundness.
Check for leaks.
9302
Open the heating flow and return isolating valves and refill, vent GAS SERVICE MOUNTING JIG
and pressurise the heating circuit. See section 11.2. COCK
Check for leaks.
SEAL
Diagram 12.11
0020008154A 34
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 replacement work.
Always check for gas soundness after any service work.
Electrical Testing
Should there be any doubt about the voltage supply to any of the
components, it is possible to carry out a simple electrical test.
Important. On completion of the Service/Fault Finding tasks
which have required the breaking and remaking of the 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 12.2.
Refer to the Wiring diagram 13.1 and fault finding charts
diagrams 13.2 and 13.3.
35 0020008154A
13 Fault Finding
12404
MAINS VOLTAGE HEATING CONTROLS PLUG
REMOVE VOLTAGE FREE LINK
230V SWITCHED LIVE FROM OPTIONAL FROST STAT.
230V SWITCHED LIVE FROM HEATING CONTROLS.
LINK
Diagram 13.1
0020008154A 36
13 Fault Finding
12190
Diagram 13.2
37 0020008154A
13 Fault Finding
12352
Diagram 13.3
0020008154A 38
14 Replacement of Parts
11492
Replacement of parts must be carried out by a competent SECURING
person. SCREWS (2)
SPADE
Before replacing any parts the boiler should be isolated from the CONNECTOR
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 the
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 IGNITION
parts.
LEAD
To hinge a side panel undo and remove the three screws
securing each side panel to the boiler, two at the front and one
ELECTRICAL
at the top.
CONNECTIONS Diagram 14.1
14.2 Spark Electrode
For access, refer to section 14.1.
12402
Remove the spark plug lead, earth lead and two securing
screws. Withdraw the spark electrode carefully from the
combustion chamber, see diagram 12.3.
GAS
14.3 Igniter Unit VALVE
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. ELECTRICAL
PLUG
14.4 Ignition Lead
For access, refer to section 14.1.
Refer to diagram 12.6.
Pull the spark plug style connector off the spark electrode and
the spade connector connected to the igniter unit, PRESSURE TEST
see diagram 14.1. POINT
39 0020008154A
14 Replacement of Parts
14.6 Fan
11486
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 three screws, see
diagram 14.3.
Remove the two screws securing the fan to the gas manifold,
see diagram 14.4, check the gasket and replace if necessary.
NOTE : The 30 fan is secured through an extension piece with
two securing screws, check and replace any seals or gaskets if
necessary. VENTURI
PLATE
14.7 Burner
For access, refer to section 14.1. SECURING
Refer to section 12.3 for removal of the fan, gas valve and SCREW (3) Diagram 14.3
burner assembly.
Remove the four screws that secure the burner, see diagram
24cxi Illustrated
11485
14.5.
NOTE: THE BURNER WILL REQUIRE A NEW GASKET
WHEN REFITTED.
GAS
MANIFOLD
SECURING
SCREW (2)
FAN
Diagram 14.4
11487
BURNER
SECURING INSULATION
SCREW (4)
Diagram 14.5
0020008154A 40
14 Replacement of Parts
WASHER
INSULATION Check for leaks.
11488
BOLT BRACKET
SECURING
SCREW
HEAT
EXCHANGER
Diagram 14.6
EXPANSION
11413
FIBRE VESSEL
WASHER GLASS
11489
CIRCLIP
STEEL
WASHER
COUPLING
Diagram 14.7 Diagram 14.8
41 0020008154A
14 Replacement of Parts
11490
FLOW AND SECURING SCREWS
Refer to Manual Handling section on page 5. RETURN PIPE AND CLAMPS
For access, refer to section 14.1. NUTS
Refer to section 12.3 for removal of the fan, gas valve and
burner assembly.
Drain the boiler heating circuit, see section 12.9.
Drain the boiler hot water circuit, see section 12.10.
Remove the clip securing the clear condense pipe to heat
exchanger.
Pull to remove the clear 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. Diagram 14.9
Remove condense pipe connector from bottom of heat
exchanger.
11602
Carefully ease heat exchanger out.
RETAINING CLIP
(NOTE ORIENTATION)
DIVERTER VALVE
MOTOR
ELECTRICAL
PLUG)
DIVERTER VALVE
Diagram 14.11
0020008154A 42
14 Replacement of Parts
11496
For access, refer to section 14.1.
Refer to section 12.9 and drain the boiler heating circuit.
Refer to diagram 14.12.
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 and take off.
Disconnect wiring from pump head.
Reconnect wiring to new pump head and fit cover.
Fit the new pump head with 'O' ring.
CABLE Refill, vent and pressurise the boiler.
COVER Check for leaks.
SAFETY Undo the safety discharge valve union and remove from the
DISCHARGE pipework.
VALVE Remove the securing clip and withdraw the safety discharge
valve.
Fit new 'O' ring.
Refill, vent and pressurise the boiler.
Check for leaks.
43 0020008154A
14 Replacement of Parts
14.20 Overheat Thermostat 14.24 Bypass
For access, refer to section 14.1. For access, refer to section 14.1.
Refer to diagram 14.15. Refer to section 12.9 and drain the boiler heating circuit.
Remove the electrical connections from the overheat thermostat. Refer to diagram 14.19.
Remove the retaining clip from the flow pipe. Remove the retaining clips to remove the bypass tube.
Remove the overheat thermostat from the retaining clip. Fit new 'O' rings.
NOTE: When fitting new thermostat, please ensure that it is Replace the bypass tube, refill, vent and pressurise the boiler.
located correctly onto the flat area of the pipe and the retaining Check for leaks.
clip is secure.
11503
14.21 Automatic Air Vent RETURN
For access, refer to section 14.1. PIPE
Refer to section 12.9 and drain the boiler heating circuit.
FLOW
Refer to diagram 14.16. PIPE
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. OVERHEAT
Check for leaks. THERMOSTAT
Diagram 14.16
0020008154A 44
14 Replacement of Parts
14.25 Filling Loop Tube
11497
FLOW RETAINING
SENSOR CLIP For access, refer to section 14.1.
Refer to section 12.10 and drain the boiler hot water circuit.
Refer to diagram 14.20.
Remove the retaining clips to remove the filling loop tube.
Fit new 'O' rings.
After replacing the filling loop tube open the cold-water isolation
valve and slowly open a hot water tap to remove air. Close the
hot water tap and check for any leaks.
LEAD AND PLUG valve and slowly open a hot water tap to remove air. Close the
hot water tap and check for any leaks.
AUTOMATIC BYPASS
Fit new 'O' rings.
VALVE
Replace the reduced pressure zone valve, refill, vent and
pressurise the boiler.
Check for leaks.
BYPASS TUBE
Diagram 14.19
45 0020008154A
14 Replacement of Parts
14.31 Heating Circuit Drain Point
11474
Refer to section 12.9 to drain the boiler heating circuit. RETAINING
Refer to diagram 14.22. CLIPS
Remove the retaining clip to remove the drain point.
Fit new 'O' rings.
Replace the drain point, refill, vent and pressurise the boiler.
Check for leaks.
11477
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. REDUCED
Remove the cap at the base of the condense trap. PRESSURE
Remove any solids found. ZONE
VALVE
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. Diagram 14.21
When refitting the cap ensure that a watertight seal is achieved,
but do not use excessive force.
11501
DRAIN
POINT
Diagram 14.22
0020008154A 46
14 Replacement of Parts
FLOW PIPE
CONNECTOR PLATE TO PLATE HEAT OUTLET
RH
EXCHANGER SECURING CONNECTOR
HYDROBLOCK
SCREW
SAFETY
11499
DISCHARGE
11500
VALVE
SECURING SECURING
CLIP 1 CLIP 4
11478
Diagram 14.23
14.34 Plate-to-Plate Heat Exchanger Remove the plate-to-plate heat exchanger by lifting it up and
over the top of the left hand hydroblock.
For access, refer to section 14.1.
When replacing the plate-to-plate heat exchanger ensure that
Refer to section 12.9 to drain the boiler heating circuit.
the four rubber sealing washers are fitted into the hydroblock.
Refer to section 12.10 and drain the boiler hot water circuit.
NOTE: The plate-to-plate heat exchanger only fits one way
Refer to diagram 14.23. round, 'TOP' is marked on the plate.
Remove the gas supply pipe from the gas service cock and the Refill, vent and pressurise the boiler.
gas valve, refer to relevant parts of section 12.3.
Open the cold-water isolation valve and slowly open a hot water
Undo the central heating flow pipe connection into the left hand tap to remove air.
hydroblock, see diagram 14.23.
Close the hot water tap and check for any leaks.
Undo the nut connecting flow pipe to heat exchanger.
Open the heating circuit isolation valves, re-pressurise the
Lift it up to remove it from the hydroblock with the washer and system as necessary.
rotate it forward and out of the way.
Using a TORX screwdriver remove the two screws securing the
plate-to-plate heat exchanger to the hydroblock.
47 0020008154A
14 Replacement of Parts
Remove the securing clip and withdraw the safety discharge Move the coupling out of the way.
valve, refer to section 14.16. Remove pump head, refer to section 14.15.
Remove securing clips 1 and 2 below hydroblock, see diagram NOTE: It is not necessary to disconnect the electrical lead but
14.23. put pump head in a convenient place where it will not strain the
Undo three securing screws on the underside of the left-hand lead.
hydroblock. Remove the filling loop tube, refer to section 14.25.
Remove the diverter valve motor as described in section 14.14. Remove the bypass tube, refer to section 14.24.
Remove left hand hydroblock from plate-to-plate heat exchanger Remove the electrical connections to the flow sensor and the
using a TORX screwdriver to remove the securing screw, see low water pressure sensor, refer to sections 14.23 and 14.24.
diagram 14.23. Remove the water connection clips 3 and 4 below the hydroblock,
Lift out the left hand hydroblock. see diagram 14.23.
Remove the remaining components for refitting into the Remove the central heating filter, refer to section 12.8.
replacement left hand hydroblock. Remove the retaining clip to remove the drain point, refer to
Refill, vent and pressurise the boiler. section 14.31.
Open the cold water isolation valve and slowly open a hot water Undo two securing screws on underside of the right hand
tap to remove air. Close the hot water tap. hydroblock.
Check for any leaks. Remove right hand hydroblock from plate-to-plate heat
exchanger using a TORX screwdriver to remove the securing
14.36 Diverter Valve Motor screw, see diagram 14.23.
Lift out the right hand hydroblock.
For access, refer to section 14.1.
Remove the remaining components for refitting into the
Refer to section 12.9 and drain the boiler heating circuit.
replacement right hand hydroblock.
Refer to section 12.10 and drain the boiler hot water circuit.
Refill, vent and pressurise the boiler.
Remove the diverter valve motor as described in 14.15.
Open the cold-water isolation valve and slowly open a hot water
Refer to section 14.35 to remove the left hand hydroblock. tap to remove air. Close the hot water tap.
Unscrew and remove both halves of the diverter valve from the Check for leaks.
left hand and right hand sides of the hydroblock, see diagram
14.26.
10101
DIVERTER
VALVE
L.H. HYDROBLOCK
Diagram 14.24
0020008154A 48
14 Replacement of Parts
9808
Release the front of the fascia by carefully prising up the two
retaining latches, see diagram 14.26. TORX
Do not allow the front of the fascia to swing down and be loosely SCREWS (3)
held by the electrical connections to the mains/reset switch,
user interface and clock. Either remove the connections or
support the fascia.
12411
Refer to section 14.38 for access.
Remove actuator by springing back retaining clips, see diagram
14.25.
Spring back knob retaining clips and push knob out from the
back.
SECURING SCREWS
11416
MAINS/RESET
SWITCH
KNOB
RETAINING
CLIPS
MAINS/RESET
KNOB Diagram 14.25 USER INTERFACE Diagram 14.27
49 0020008154A
14 Replacement of Parts
14.43 Main PCB 230V CONTROLS
11419
For access, refer to section 14.1. INTERFACE BOARD RETAINING
Hinge down the control box. SCREW
Remove 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,
see diagram 14.26.
When refitting the rear panel ensure the leads are not trapped,
refer to diagram 14.3.
9948
Disconnect the electrical connection from the 230V controls SIPHON
interface board and the electrical connection from the Main ADAPTER
PCB.
Remove the 230V controls interface retaining screw.
Remove the 230V controls interface board, see diagram 14.28.
FLOAT
CONDENSE
TRAP
SCREW
SEAL
CAP
Diagram 14.29
0020008154A 50
15 Spare Parts
When ordering spare parts, contact Glow-worm's own service Please quote the name of the appliance and serial number, to
organisation using the telephone number on the inside front be found on the data label.
cover of this booklet. If ordering from British Gas also quote the G.C. number of the
part.
51 0020008154A
15 Spare Parts
12379
3
2
1
5
4 8
6 9
13
11 10
12
14
15
16
17
18
21
20 19
Diagram 15.1
Because of our constant endeavour for improvement, details may vary slightly from those shown in these instructions.
0020008154A 52