Glow-worm Swift flow 80 Instructions For Use Installation And Servicing
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Glow-worm Swift flow 80 Instructions For Use Installation And Servicing

Fanned flue combination boiler g.c. no. 47 313 10 honeywell g.c. no. 47 313 09 s.i.t
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Installation and Servicing
80
Fanned Flue Combination Boiler
The instructions consist of three parts, User, Installation and Servicing Instructions which includes the
Guarantee Registration Card. 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.
Glow-worm appliances' are manufactured to the very highest standard so we are pleased
In the center pages are to be found your Guarantee Registration Card, which we recommend you complete and
If this card is missing you can obtain a copy or record your registration by telephoning the Heatcall Customer
Our Guarantee gives you peace of mind plus valuable protection against breakdown by covering the cost of:
All replacement parts
All labour charges
All call-out charges
One Contact Local Service
Instructions for Use
T o b e l e f t w i t h t h e u s e r
G.C. No. 47 313 10 Honeywell
G.C. No. 47 313 09 S.I.T
This is a Cat I
Appliance
2H
Guarantee Registration
Thank you for installing a new Glow-worm appliance in your home.
to offer our customers' a Comprehensive First Year Guarantee.
return as soon as possible.
Service number 01773 828100.
REGISTER YOUR GLOW-WORM APPLIANCE
FOR 1ST YEAR GUARANTEE PROTECTION
CALL 0181 380 2555
Customer Services:
Tel: (01773) 828100
Fax: (01773) 828070
Hepworth Heating Ltd.,
Nottingham Road, Belper, Derbyshire. DE56 1JT
General/Sales enquiries:
Tel: (01773) 824141 Fax: (01773) 820569
221469B.03.99

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Summary of Contents for Glow-worm Swift flow 80

  • Page 1 Guarantee Registration Thank you for installing a new Glow-worm appliance in your home. Glow-worm appliances' are manufactured to the very highest standard so we are pleased to offer our customers' a Comprehensive First Year Guarantee. In the center pages are to be found your Guarantee Registration Card, which we recommend you complete and return as soon as possible.

  • Page 2: Table Of Contents

    Important Information Testing and Certification This boiler is tested and certificated for safety and performance. It is therefore important that no alteration is made to the boiler, without permission, in writing, from Hepworth Heating Ltd. Any alteration not approved by Hepworth Heating Ltd., could invalidate the certification, boiler warranty and may also infringe the current issue of the Statutory Requirements, see Section 1.4.

  • Page 3: Introduction

    Instructions for Use Introduction Boilers Installed in Compartments Please read these instructions and follow them carefully for the If the boiler has been fitted into a compartment or cupboard, do safe and economical use of your Combination boiler. not obstruct the compartment air supply vents. This boiler must have been installed by a competent person in Do not use the compartment for storage.
  • Page 4 Instructions for Use Setting Instructions for the 7 Day Digital Setting Instructions for Electro/mechanical Clock/Timer Clock - if fitted CLOCK FACE OVERRIDE SWITCH AUTO W Th F S Su POINTER TAPPETS CONSTANT OFF PROGRAMMED CONSTANT ON Diagram 1 Diagram 2 This is a 24 hour clock/timer, that is 1pm is 13:00, and has 8 This clock has a twenty four hour dial, that is, 1pm is 13.
  • Page 5 Instructions for Use 10. Check that the pilot is alight and stable. Setting Timed Programmes 11. Set switch “C”, clock/timer (if fitted) and any remote controls With the clock set to the correct time, see SETTING THE as required. CLOCK paragraphs 1-4, and then continue as follows: Close the door.
  • Page 6 Instructions for Use Central Heating Selector Switch COLD WATER GAS SERVICE HOT WATER SUPPLY IN COCK For central heating set switch “C” to “On” as shown in diagram 4, white flash showing. The main burner will light. When the heating is controlled by a room thermostat and/or a HEATING HEATING time switch, switch “C”...
  • Page 7 If in doubt seek advice from the local gas company or your installation/servicing company. Replacement Parts If replacement parts are required apply to your local supplier or British Gas. Please quote the name of the appliance, Swift flow 80 with Honeywell or SIT gas control valve. 221469B...

  • Page 8: General Data

    1 General Data SAFETY VALVE MOUNTING DISCHARGE WALL 82mm ALL DIMENSIONS in MILLIMETRES 107 107 22mm COMPRESSION 15mm COMPRESSION in. BSPT) CENTRAL HEATING DOMESTIC WATER GAS CONNECTION Diagram 1.1 TABLE 1 D.H.W. C.H. WATER THROTTLE AUTOMATIC NOMINAL 19.71 29.3 10.6 AIR VENT MINI HEAT...

  • Page 9: Boiler Position

    1 General Data 1.4 Requirements 1.7 Gas Supply The installation of this boiler must be carried out by a competent The gas installation shall be in accordance with the rules in force person in accordance with the rules in force in the countries of in the countries of destination.

  • Page 10: Flue And Ventilation

    3 Flue and Ventilation 3.1 Flue WALL THICKNESS 'X': 75 TO 400mm The flue must be installed in accordance with the rules in force in the countries of destination. 3.2 Flue Position and Length The air and flue ducting connect to the top of the boiler using the elbow which can be positioned in one of three possible directions: Rearward, left or right.
  • Page 11 3 Flue and Ventilation 3.6 Terminal Guard A terminal guard is required if persons could come into contact with the terminal or the terminal could be subject to damage. If a terminal guard is required, it must be positioned to provide a minimum of 50mm clearance from any part of the terminal and be central over the terminal.

  • Page 12: Heating System

    4 Heating System Btu/h x REMAINING CONVEYING CAPACITY OF PUMP 1000 SHOWING RELATIVE SYSTEM DIFFERENTIAL AT VARIOUS SYSTEM HEATING LOADS. 30.6 19.8 FEET ACCEPTABLE DIFFERENTIAL RANGE LITRES/Min GALLONS/Min Diagram 4.1 FLOW RATE GRUNDFOS REMAINING CONVEYING CAPACITY OF PUMP Btu/h x 1000 SHOWING RELATIVE SYSTEM DIFFERENTIAL AT VARIOUS SYSTEM HEATING LOADS.
  • Page 13 4 Heating System 4.1 General Notes Glow-worm Wilo Pump The boiler is intended for use in a sealed system only. The pump adjuster should normally be left at maximum (2) but in some cases it is permissible to adjust to a lower setting (1), 4.2 Safety Valve...
  • Page 14 4 Heating System 4.11 Draining A draining tap must be provided at the lowest points of the system, which will allow the entire system to be drained. An additional draining tap MUST be fitted close to the boiler. The flow and return isolation valves are provided with drain points for boiler heat exchanger drainage.

  • Page 15: Domestic Hot Water System

    5 Domestic Hot Water System 5.1 General 5.3 “Hard” Water Areas The domestic hot water service must be in accordance with the In areas where the water is “hard”, more than 200mg/litre, it is rules in force in the countries of destination. recommended that a proprietary scale reducer is fitted in the cold water supply to the boiler.
  • Page 16 6 Installation Preparation 6.2 Marking MIN. 115Dia. The boiler mounting frame is the same width as the boiler but the CLEARANCE flue connection sticks out above it. FLUE Place the boiler mounting frame on the wall in the required CENTRELINE position, see diagram 2.1 to maintain minimum clearances.

  • Page 17: Flue Preparation

    7 Flue Preparation 7.1 Flue Length For a rear flue, measure the distance from the outside wall face to the boiler mounting wall. Check that the flue length will be suitable, see diagram 3.1 for a standard flue system or diagram FLUE 3.3 for a 1, 2 or 3metre flue system.
  • Page 18 7 Flue Preparation 7.4 Air Duct 3.3 DIA FLUE DUCT HOLE IN EACH SIDE Locate the flue duct and air duct in the flue elbow, making sure FLUE that the flue duct is located in the flue terminal and the flue elbow OF THE AIR DUCT TERMINAL but is free to move to allow for expansion.

  • Page 19: Gas And Water Connections

    8 Gas and Water Connections 8.1 Gas Connection BOILER 'NOTCH' MARKING POSITION OF MOUNTING SAFETY VALVE DISCHARGE Provision is made for the gas supply to be connected from FRAME below or through the wall at the rear of the boiler, see diagram 8.1 for position.

  • Page 20: Electrical Connections

    9 Electrical Connections INTEGRAL CLOCK EXTERNAL CLOCK TO BOILER TO BOILER RED LINK. 5 POLE CONNECTOR ON 5 POLE CONNECTOR ON REMOVE WHEN MOUNTING FRAME MOUNTING FRAME CONNECTING ANY HEATING SYSTEM CONTROLS (3) (L) (3) (L) LINK MAINS POTENTIAL FROST STAT. SWITCH CONTACTS CLOCK...
  • Page 21 9 Electrical Connections 9.1 Supply Cable Connection 9.4 Frost Thermostat CAUTION: To prevent an induced current from switching the If the installation requires protection by a “frost thermostat”, central heating on, when not required, it is important that the connect a single pole type, to the appropriate terminals of the heating system control cables are separated from the other connector.

  • Page 22: Boiler Fixing

    10 Boiler Fixing 10.1 Mounting the Boiler CONTROL HOUSING FASCIA COVER SECURING After installing the boiler mounting frame, domestic and heating SCREW water systems, making the electrical connections and preparing FASCIA the flue components, continue as below: SECURING SCREW (3) Lift the boiler into position, hooking it onto the boiler mounting frame at the top, then loosely fit the two boiler securing screws at the top, see diagram 6.3.
  • Page 23 10 Boiler Fixing 10.7 Flue Fixing FLUE ELBOW Fit the self-adhesive gasket, supplied in the loose items pack, (REAR FLUE to the flue elbow, see diagram 10.3. SHOWN) GASKET Pass the prepared ductings through the wall, the longest protrusion of the flue terminal is positioned at the top. If it is impractical to gain access to the outside wall face, the optional wall liner kit may be used as described in Section 7.6 “Internal Access”.

  • Page 24: Commissioning

    11 Commissioning 11.1 Filling Domestic Water Circuit PIEZO BUTTON Check that the boiler is isolated from the electrical supply, at the PILOT/IGNITION external isolator. MAIN BURNER Fully open the domestic water supply stop cock or valve in the GAS CONTROL supply to the boiler.
  • Page 25 11 Commissioning 11.4 Initial Lighting of Pilot - Honeywell Identify the boiler controls, see diagram 11.1. Check that the boiler is isolated from the electrical supply at the external isolator. TEST Fully depress and hold in gas control knob “D”. LARGE POINT Press and release piezo button “E”...
  • Page 26 11 Commissioning Check the soundness of the boiler gas joints, with the main 11.4 Initial Lighting of Pilot - SIT burner on, using a leak detection fluid. Take care not to splash Identify the boiler controls, see diagram 11.1. any of the electrical components. Check that the boiler is isolated from the electrical supply at the Fully open the hot water throttle, (clockwise), see diagram 11.5.
  • Page 27 11 Commissioning equivalent to 16.5 seconds to fill a 1Litre container (9.5 seconds 11.6 Gas Rate Modulation - Honeywell to fill a 1pint container). If this flow rate cannot be achieved, The minimum gas rate is factory preset and no adjustment check that there is no partial blockage and that the supply is of should be required.
  • Page 28 11 Commissioning 11.10 Heating System - Commissioning Check that all remote controls and integral clock are calling for heat. Fully open all radiator valves, flow control valve “A” and bypass valve “B”, see diagram 4.2. HINGE PIN RETAINING Set the heating system in operation and balance the radiators. BRACKET Adjust the control valve “A”...

  • Page 29: General Data

    1 General Data This boiler will be fitted with either a Honeywell or SIT gas control valve. It can be identified as shown:- HONEYWELL 1.1 Servicing or Replacing Parts 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.

  • Page 30: Servicing

    2 Servicing Assemble the following parts only, in the reverse order of 2.1 Pilot Check removal. Check if the pilot flame is burning correctly and of the correct Make sure that the main burner is located on the main injector size, see diagram 4.4.

  • Page 31: Fault Finding

    3 Fault Finding 3.1 Initial Checks If the boiler fails to operate, first check the following and put the problem right, if possible. Check that the electrical supply is available at the boiler and that the fuses are in order. CABLE TO REMOTE Make sure that the system pressure gauge registers 0.7bar...
  • Page 32 3 Fault Finding 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 any air. Does pilot light? knob is released? Apply match to pilot burner instead of pressing piezo unit button.
  • Page 33 3 Fault Finding With the boiler cold, check connections of the thermocouple, boiler overheat cut-off and gas valve. Disconnect overheat cut-off connectors at points A and B at the gas valve, see diagram. Test continuity of the overheat cut-off. Is there continuity ? Faulty boiler overheat cut-off, renew Re-connect boiler overheat cut-off to points A...
  • Page 34 3 Fault Finding 3.4 Clock/Timer PERMANENT If the clock has failed it can be bypassed by disconnecting the LIVE plug at the wall frame. Gain access to the control box, refer to 240V~50Hz Section 4.12, disconnect the clock wiring harness from the four way terminal block.
  • Page 35 3 Fault Finding BLOCK 1 BLOCK 4 6 BLOCK 6 CONTROL BOARD MAIN GAS VALVE PURPLE PURPLE SOLENOID PRESSURE ORANGE SWITCH YELLOW YELLOW T630mA D.H.W. WHITE TRANSFORMER CUT-OFF TERMINAL No's CONTROL FUSE 2 GREY GREY MODULATOR D.H.W. FLOW SWITCH YELLOW REMOTE HEATING PURPLE...
  • Page 36 3 Fault Finding Carry out the initial fault finding checks described in section 3.1 and 3.4. Check that gas, water and electricity are available at the boiler. There must be no external voltage applied to the control board via the central heating controls to the P.C.B. Before commencement of test, isolate the boiler from the electricity supply, ensure that the remote controls are not calling for duty (no red link in plug and socket).
  • Page 37 3 Fault Finding Continued Continued Continued Reduce D.H.W. flow to Isolate supply. Is there Restore supply. Is there Is there 24V AC across 3.7 litres/minute. Does continuity between 24V AC across 'main terminals on main P.C.B. and modulator? burner pressure reduce? solenoid' pins on block solenoid on gas valve? 1 on P.C.B?
  • Page 38 3 Fault Finding Continued from diagram 3.7 Does pump operate? Isolate supply. Isolate external controls from terminals 1 and 2 of the five pole Check wiring of external controls, connector. Link terminals 1 and 2 in the 5 rectify as necessary. pole connector.
  • Page 39 3 Fault Finding 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. Isolate the boiler from electrical supply remove outer case.

  • Page 40: Replacement Of Parts

    4 Replacement of Parts 4.1 Fan FLUE ELECTRICAL CONNECTORS ELBOW Before starting refer to Section 1.1. Isolate the boiler from the electrical supply, refer to Section 1.3. Remove the outer case and the cover of the inner case, refer to Section 1.4 and 1.5.
  • Page 41 4 Replacement of Parts Remove the main burner refer to Section 4.2. SPARK ELECTRODE Remove the sealing angle, secured with a single screw, see diagram 4.3. SECURING Disconnect the ignition lead from the spark electrode. THERMO- SCREW COUPLE Remove the spark electrode, secured with a single screw. Disconnect the thermocouple nut from the pilot burner.
  • Page 42 4 Replacement of Parts Disconnect the pilot supply tube, holding the pilot injector 4.12 Pressure Gauge hexagon with another spanner, see diagram 4.3. Before starting, refer to Section 1.1. Disconnect the thermocouple at both ends, see diagram 4.3 and 4.6. Isolate the boiler from the electrical supply, refer to Section 1.3.
  • Page 43 4 Replacement of Parts 4.14 Clock/Timer - if fitted Disconnect the pressure gauge connection from the safety valve, discard the sealing washer. ELECTRO/MECHANICAL and DIGITAL clock/timer - Release Remove the pressure gauge secured with the retaining spring the mounting bracket securing screws, see diagram 4.8A. tabs.
  • Page 44 4 Replacement of Parts 4.15 Transformer Before starting, refer to Section 1.1 SECURING CLIP (2) Isolate the boiler from the electrical supply, refer to Section 1.3 Remove the outer case, refer to Section 1.4. Remove the control housing and cover, refer to Section 4.13.
  • Page 45 4 Replacement of Parts 240V-50Hz PERMANENT MAINS SUPPLY FUSED AT 3A COLOUR CODE B BR GY- GREY W- WHITE OR- ORANGE B- BLUE V- VIOLET BK- BLACK N 3(L) R-RED BR -BROWN Y- YELLOW G/Y- GREEN/ YELLOW P- PURPLE PUMP L N E THERMISTOR MULTI-FUNCTIONAL...
  • Page 46 4 Replacement of Parts 240V-50Hz PERMANENT MAINS SUPPLY FUSED AT 3A COLOUR CODE Y P G/Y B BR GY- GREY W- WHITE OR- ORANGE B- BLUE V- VIOLET BK- BLACK N 3(L) R-RED BR -BROWN Y- YELLOW G/Y- GREEN/ YELLOW P- PURPLE PUMP MULTI-FUNCTIONAL...
  • Page 47 4 Replacement of Parts WIRING AS * Note: DIAGRAM 4.10 Remove 'Yellow Link" B BR before fitting Clock/Timer CLOCK / 4 WAY TIMER TERMINAL BLOCK B BR Diagram 4.10A 221469B...
  • Page 48 4 Replacement of Parts 4.16 Gas Valve - Honeywell 4.17 Central Heating Selector Switch Before starting refer to Section 1.1. Before starting refer to Section 1.1 Isolate the boiler from the electrical supply and close the gas Isolate the boiler from the electrical supply and close the gas service cock, refer to Section 1.3.
  • Page 49 4 Replacement of Parts 4.18 Modulator - Honeywell Before starting refer to Section 1.1. PIEZO UNIT BRACKET Isolate the boiler from the electrical supply and close the gas service cock, refer to Section 1.3. IGNITION LEAD Remove the outer case, refer to Section 1.4. Disconnect the two electrical connectors at the modulator, see diagram 4.13.
  • Page 50 4 Replacement of Parts 4.20 Domestic Hot Water Flow Switch Before starting refer to Section 1.1. GAS VALVE Isolate the boiler from the electrical supply, refer to Section 1.3. Remove the outer case, refer to Section 1.4. Isolate the domestic water inlet, release the domestic water pressure and drain, refer to Section 1.3 and 1.6.
  • Page 51 4 Replacement of Parts Remove the outer case, refer to Section 1.4. 4.23 Water Inlet Filter Isolate domestic water inlet, release the domestic water pressure Before starting refer to Section 1.1. and drain, refer to Section 1.3 and 1.6. Isolate the boiler from the electrical supply, refer to Section 1.3. Remove the control housing, refer to Section 4.7 paragraph 7.
  • Page 52 4 Replacement of Parts 4.26 Pump PUMP PUMP ADJUSTER SPINDLE Before starting refer to Section 1.1. FLOW DIRECTION Isolate the boiler from the electrical supply, refer to Section 1.3. ARROW Remove the outer case, refer to Section 1.4. Release the water pressure and drain, refer to Section 1.6. Remove the control housing, refer to Section 4.7 paragraph 7.
  • Page 53 4 Replacement of Parts 4.29 Heat Exchanger 4.31 Expansion Vessel Before starting refer to Section 1.1 Renewal of the expansion vessel requires the boiler to be removed from the wall. As an alternative, in certain Isolate the boiler from the electrical supply and close the gas circumstances, a separate expansion vessel of the same service cock, refer to Section 1.3.
  • Page 54 4 Replacement of Parts FLUE ELBOW COMBUSTION FRONT CHAMBER INSULATION AIR DUCT FRONT PANEL SECURING SCREW (2) SECURING SCREW (4) CLIP BOILER/MOUNTING FRAME SCREW (2) Diagram 4.23 UNION CONNECTION AND SEALING WASHER SIDE INSULATION PIECES CLAMPING SCREWS Diagram 4.24 LOWER REAR INSULATION UPPER REAR INSULATION...

  • Page 55: Spare Parts

    5 Spare Parts 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 56 5 Spare Parts Diagram 5.1 Because of our constant endeavour for improvement, details may vary slightly from those shown in these instructions. 221469B...

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