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Glow-worm SwiftFlow 120 Servicing Instructions
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Glow-worm SwiftFlow 120 Servicing Instructions

Glow-worm SwiftFlow 120 Servicing Instructions

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221045A.05.97

Servicing Instructions

To b e l e f t w i t h t h e u s e r
120
G.C. No. 47 313 13
Fanned Flue Combination Boiler
This is a Cat I
appliance
2H
Hepworth Heating Ltd.,
Customer Services:
Nottingham Road, Belper, Derbyshire. DE56 1JT
Tel: (01773) 828100
General/Sales enquiries:
One Contact Total Service
Fax: (01773) 828070
Tel: (01773) 824141 Fax: (01773) 820569
Supplied By www.heating spares.co Tel. 0161 620 6677

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  • Page 1: Servicing Instructions

    221045A.05.97 Servicing Instructions To b e l e f t w i t h t h e u s e r G.C. No. 47 313 13 Fanned Flue Combination Boiler This is a Cat I appliance Hepworth Heating Ltd., Customer Services: Nottingham Road, Belper, Derbyshire.
  • Page 2 1 G e n e r a l The instructions consist of three parts, Installation, COLD WATER GAS SERVICE HOT WATER Servicing and Instructions for Use which includes the SUPPLY IN COCK Guarantee Registration Card. The instructions are an integral part of the appliance and must, to comply with HEATING HEATING the current issue of the Gas Safety (Installation and Use)
  • Page 3 1 G e n e r a l 1.3 Isolation of Boiler SECURING SCREW (4) Before commencing any servicing or the replacement of parts, isolate the boiler from the electrical supply at the external isolator and close the gas service cock, see diagram 1.1.
  • Page 4 2 S e r v i c i n g 2.1 Pilot Check SPARK GAP 4.5mm to 5.5mm Check that the pilot flame is burning correctly and of the correct size, see diagram 2.1. If the pilot flame is not correct, the pilot injector will require removing, as detailed later.
  • Page 5 2 S e r v i c i n g 2.3 Heat Exchanger Place a sheet of paper or similar in the combustion chamber, to act as a collector for deposits removed. HEAT Brush the heat exchanger with a suitable brush, remove EXCHANGER paper together with any debris.
  • Page 6 2 S e r v i c i n g STEP 1 STEP 3 WING NUT BURNER BURNER BRACKET WING NUT BURNER BRACKET SECURING SCREW STEP 2 STEP 4 BURNER GUIDE SIDE GUIDES MAIN INJECTOR BURNER Diagram 2.5 221045A Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 7 3 F a u l t F i n d i n g 3.1 Initial Checks If the boiler fails to operate, first check the following: 1. That the electrical supply is available at the boiler and CABLE TO the fuses are in order. REMOTE HEATING NOTE: THE BOILER CONTROL BOARDS CAN BE...
  • Page 8 3 F a u l t F i n d i n g PILOT WILL NOT LIGHT START HERE Check gas line - open all cocks, Does pilot stay alight when rectify any blockages, purge out multi-functional control knob any air. Does pilot light? is released? Apply match to pilot burner instead of pressing piezo unit button.
  • Page 9 3 F a u l t F i n d i n g With the boiler cold, check connections of the thermocouple, boiler overheat cut-off and multifunctional control. Disconnect overheat cutoff connectors at points A and B at the multifunctional control, see diagram 3.5.
  • Page 10 3 F a u l t F i n d i n g 3.4 Clock/Timer - if fitted PERMANENT LIVE If the clock has failed it can be bypassed by 240V~50Hz disconnecting the plug at the wall frame. Disconnect the plug at the control box and connect this plug to the connection at the wall frame.
  • Page 11 3 F a u l t F i n d i n g MAIN MULTIFUNCTIONAL CONTROL SOLENOID DHW CUT OFF CONTROL 240V~ TRANS- WATER PRESSURE FORMER 26V~ SWITCH (SHOWN IN PRESSURISED TO REMOTE STATE) HEATING CONTROL 5 WAY PLUG/SOCKET SELECTOR FLOW SWITCH SWITCH...
  • Page 12 3 F a u l t F i n d i n g Carry out the initial fault finding checks described in Section 3.1. Check that gas, water and electricity are available at the boiler. Before commencing tests isolate the boiler, make sure that the remote controls are not calling for duty and there is no domestic hot water demand.
  • Page 13 3 F a u l t F i n d i n g After about 30 seconds from Isolate supply disconnect central heating thermistor, “switch on” does fan go to low is resistance of thermistor between 8KΩ and 11KΩ? speed? Faulty thermistor.
  • Page 14 3 F a u l t F i n d i n g Isolate supply disconnect Red in line connectors to flow switch, is there continuity across flow switch? Reconnect flow switch, Faulty flow switch. disconnect Purple in line Replace. connectors to DHW thermistor.
  • Page 15 3 F a u l t F i n d i n g If a mains potential room thermostat is connected, ensure that the switch live is connected to PIN 1 in the 5 pole connector. Check continuity of clock/timer harness, ensure an electrical supply is available, ensure that remote controls are calling for heat.
  • Page 16 4 R e p l a c e m e n t o f P a r t s Before replacing any part please read points below:- Replacement of parts must only be carried out by a CLOCK/TIMER (if fitted) competent person.
  • Page 17 4 R e p l a c e m e n t o f P a r t s 4.6 Thermocouple SECURING SCREW (2) Remove the sealing gland, secured with a single screw, see diagram 2.4. Remove the spark electrode/lead, see diagram 2.4. Disconnect the thermocouple at both ends, see diagram 2.4 and 4.2.
  • Page 18 4 R e p l a c e m e n t o f P a r t s 4.9 Pump Release the water pressure and drain the central heating PUMP circuit of the boiler, refer to Section 1.3 and 1.6. ADJUSTER PUMP Disconnect the electrical connectors at the water pressure...
  • Page 19 4 R e p l a c e m e n t o f P a r t s 4.12 Pressure Gauge SAFETY Remove the control housing assembly, see diagram 4.1. VALVE Release the water pressure and drain the central heating SEALING circuit of the boiler, refer to Section 1.3 and 1.6.
  • Page 20 4 R e p l a c e m e n t o f P a r t s 4.14 Transformer FAN DRIVER FAN DRIVER Note. Timer/clock may be removed to improve access, BOARD CONTROL see Section 4.32 or the control housing bottom half can HOUSING be removed.
  • Page 21 4 R e p l a c e m e n t o f P a r t s PRESSURE screened screened SWITCH DRIVER BOARD or y THERMISTOR gry r 230V-50Hz PERMANENT MAINS SUPPLY FUSED AT 3A MULTI-FUNCTIONAL CONTROL PUMP p p g/y b br THERMISTOR WATER...
  • Page 22 4 R e p l a c e m e n t o f P a r t s 4.15 Multifunctional Control and Gas/Air BOILER Ratio Unit Assembly: diagram 4.12 OVERHEAT CUTOFF Remove control housing, see diagram 4.1. CONNECTOR Remove the piezo bracket, see diagram 4.3. GAS/AIR RATIO UNIT Disconnect the two electrical connectors at the front of...
  • Page 23 4 R e p l a c e m e n t o f P a r t s 4.17 Domestic Hot Water Flow Switch UNION NUTS The replacement of this part can be done within the limits of “minimum clearances”. Should there be a side clearance of 150mm or more then the multifunctional control/air ratio unit assembly need not be removed.
  • Page 24 4 R e p l a c e m e n t o f P a r t s 4.18 Thermistor - Heating DISCHARGE SAFETY Release the water pressure and drain the heating circuit PIPE VALVE of the boiler, refer to Sections 1.3 and 1.6. Gain access by removing the piezo bracket, see diagram 4.3.
  • Page 25 4 R e p l a c e m e n t o f P a r t s 4.23 Mini Expansion Vessel Release the water pressure and drain the domestic hot water circuit at the boiler, refer to Sections 1.3 and 1.6 LOCATION Remove the control housing as Section 4.1.
  • Page 26 4 R e p l a c e m e n t o f P a r t s COMBUSTION FRONT CHAMBER INSULATION FRONT PANEL SECURING SCREW (4) CLIP COMBUSTION CHAMBER FRONT PANEL Diagram 4.19 4.26 Combustion Chamber Insulation Remove the combustion chamber front panel secured with four screws, see diagram 4.19.
  • Page 27 4 R e p l a c e m e n t o f P a r t s 4.27 Expansion Vessel Renewal of the expansion vessel requires the boiler to be removed from the wall. As an alternative, a separate expansion vessel of the same specification may be connected as close as possible to the boiler, leaving the original in position, refer to Section 4.5 in the...
  • Page 28 4 R e p l a c e m e n t o f P a r t s FRAME SCREWS (2) GASKET GLASS SECURING SCREW (2) AIR PRESSURE Diagram 4.23 SWITCH VIOLET 4.28 Pilot Viewing Window CLEAR Remove the pilot viewing window, secured with two ELECTRICAL screws.
  • Page 29 4 R e p l a c e m e n t o f P a r t s SECURING CLIP (2) CLOCK/TIMER MOUNTING BRACKET SPACER SECURING TIMER/CLOCK SCREWS (2) ELECTRICAL CONNECTIONS p p br b br BROWN b BLUE p PURPLE MAINS NEUTRAL (N)

  • Page 30: Part Identification

    5 S p a r e P a r t s 5.1 Part Identification The key number in diagram 5.1 and the first column of the list will help identify the spare part. 5.2 Ordering When ordering any spare part, please quote the part number and the description from the list together with the model name and serial number information from the data label.
  • Page 31 5 S p a r e P a r t s Diagram 5.1 221045A Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 32: Control Of Substances Hazardous To Health

    Control of Substances Hazardous to Health Information for the Installer and Service Engineer. Under Section 6 of The Health and Safety at Work Act 1974, we are required to provide information on substances hazardous to health. The adhesives and sealants used in this appliance are cured and give no known hazard in this state. INSULATION PADS/CERAMIC FIBRE These can cause irritation to skin, eyes and the respiratory tract.