Glow-worm 30si Instructions For Use Manual

Fanned flue combination boiler

Hide thumbs Also See for 30si:

Instructions for use installation and servicing (60 pages)

Instructions for use, installation & servicing (56 pages)

Table Of Contents

Quick Links

Download this manual

Installation and Servicing

30ci

Fanned Flue Combination Boiler

G.C. No. 47 - 047 - 20

30si

System Boiler

G.C. No. 41 - 047 - 70

This is a Cat I

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 to offer our customers' a

This product is guaranteed for 24 months from the date of installation or 30 months from the date of manufacture,

whichever is the shorter, for parts. In addition this product is guaranteed for 12 months from the date of intallation or

18 months from the date of manufacture, whichever is the shorter, for labour.

The second year of the parts guarantee, from the beginning of the 13th month onwards after installation or

manufacture, is conditional upon the boiler having been serviced by a CORGI registered gas installer, in accordance

with the manufacturer's recommendations. We strongly recommend regular servicing of your gas appliance, but where

the condition is not met, any chargeable spare parts or components issued within the applicable guarantee period still

benefit from a 12 month warranty from the date of issue by the manufacturer.

We recommend you complete and return as soon as possible your guarantee registration return literature, supplied in

If your guarantee registration return literature is missing you can obtain a copy or record your registration by

One Contact Local Service

Instructions for Use

To b e l e f t w i t h t h e u s e r

Appliance

Guarantee Registration

Thank you for installing a new Glow-worm appliance in your home.

Comprehensive Guarantee.

the document envelope.

telephoning the Heatcall Customer Service number 01773 828100.

CALL 0208 247 9857

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

4000122703-1.05.02

Table of Contents

Need help?

Do you have a question about the 30si and is the answer not in the manual?

Questions and answers

Summary of Contents for Glow-worm 30si

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 Guarantee. This product is guaranteed for 24 months from the date of installation or 30 months from the date of manufacture, whichever is the shorter, for parts.
Page 2: Manual Handling Guidance
If you see any exception to this rule, please contact your nearest Glow-worm dealer. Thank you in advance for your assistance.
Page 3: Table Of Contents
Safety Devices Servicing and Maintenance Technical Data Dimensions Heating System Design Domestic Hot Water System Design Boiler Schematic 30ci Boiler Schematic 30si Boiler Location, Flue and Ventilation INSTALLATION Fixing Jig Pack Piping System Installation INSTRUCTIONS Boiler Installation Horizontal Rear Flue Installation...
Page 4: Introduction
Controls and lighting your needs but the selector should be moved nearer to the Your 30ci or 30si boiler has been factory configured to operate maximum setting in very cold weather when your home is not at the heart of an existing installation. However, because many reaching the required temperature.
Page 5 If the fault continues call your Switch ON ( I ) Installation/Servicing company or Heatcall. The running lamp will (Glow-worm’s own service organisation) using the illuminate green telephone number on the front cover of this literature. 2. Stop the boiler : 6.
Page 6: Programmer Instructions For Use
Programmer Instructions for Use Optional Clock-timers inclusive of installation and user instructions:- These are available from your nearest stockist. Electro/Mechanical Part No. 4000122022 Digital Part No. 4000120494 Draining Protection against freezing The boiler has a built in frost protection programme as long as the electricity and gas are left switched on.
Page 7: Safety Devices
The boiler switches over to safety mode, the red light will flash. Should the boiler fail to operate during Commissioning, the Call a qualified service engineer or Heatcall (Glow-worm’s own most likely fault is that the gas supply to the boiler has not been...
Page 8: Technical Data
1 Technical Data Heating Electrical Heat input (max) NET Q 32,6 kW Electrical supply 230 V ~ 50Hz 111,231 BTU/H Electrical rating 122 W fused at 3A Heat input (min) NET Q 13,3 kW Level of protection IPX4D 45,380 BTU/H Fuse rating 1,25mA Heat output (max) NET P...
Page 9: Dimensions
2 controls and lighting and diagram 3.1. • The total volume of water permitted for the heating system 3.3 Filling the system 30si depends, amongst other things, on the static head in the cold condition. The expansion vessel on the boiler is pressurised at •...
Page 10 DRAIN FLOW CONTROL POINT VALVE Diagram 3.1 30si 4 Domestic Hot Water System Design 30ci Only • Copper tubing or plastic Hep 0 may be used for the domestic Best operating comfort will be obtained from a supply pressure hot water system. Unnecessary pressure losses should be of 1 bar or greater.
Page 11: Boiler Schematic 30Ci
5 Boiler Schematic 30ci 1 - Fan. 12 - Ignition module. A - Heating flow B - Domestic hot water outlet 2 - Air pressure switch. 13 - By-pass. C - Gas 3 - Heat exchanger. 14 - Gas control valve. D - Cold water inlet 4 - Overheat thermostat.
Page 12: Boiler Schematic 30Si
5a Boiler Schematic 30si 1 - Fan. 10 - Pump. A - Heating flow. B - Gas. 2 - Air pressure switch. 11 - Heating thermistor. C - Heating return. 3 - Heat exchanger. 12 - Ignition module. 4 - Overheat thermostat.
Page 13: Boiler Location, Flue And Ventilation
PROVIDING that adequate Horizontal extended flue pack. consideration is given for Servicing/Repairs at a later date. If Vertical flue pack. any doubt exists, contact the Glow-worm's Technical Helpline 01773 828300. Twin flue pack. The minimum acceptable spacings from the terminal to Extensions, 90°...
Page 14: Fixing Jig Pack
7 Fixing Jig Pack The fixing jig is made up as follows: Other components within the fixing jig pack. A - Heating return fitting with isolating valve (v). F - Hanging bracket B (30ci Only) - Cold water inlet fitting with isolating G - wall template valve (m).
Page 15: Piping System Installation
8 Piping System Installation 8.1 Fixing jig, refer to diagram 7.1 • Note: It is important the hanging bracket and service cock 80 min. Rear top flue outlet bracket are fitted to a flat and true wall area for correct alignment with the boiler.
Page 16: Boiler Installation
9 Boiler Installation 9.1 Statutory requirements FAN RETAINING EARTH The installation of this boiler must be carried out by a qualified BOLTS LEAD registered person in accordance with the relevant requirements of the current issue of: The Gas Safety (Installation and Use) Regulations The Building Regulations The local water company Byelaws The Building Standards Regulations (Scotland)
Page 17: Horizontal Rear Flue Installation
9 Boiler Installation 9.4 Discharge safety valve, refer to diagram 9.4. DISCHARGE WARNING. It must not discharge above an entrance or window SAFETY or any type of public access area. VALVE A short discharge pipe is supplied in the fittings pack, when fitted (3 bar) to the safety valve it will end below the boiler.
Page 18 10 Horizontal Rear Flue Installation RUBBER 30mm SEALING COLLAR STANDARD FLUE ASSEMBLY INNER The combined kits A20097 include (1.) WALL - Flue duct pipe ............A - Air duct pipe ............B - External rubber sealing collar ......C - Self adhesive semi rounded seal ......D PLASTIC - Self adhesive seal ...........
Page 19 10 Horizontal Rear Flue Installation SELF POWER SUPPLY LEAD PLASTIC ADHESIVE INTERNAL SELF SEAL SAMPLE FLANGE ADHESIVE POINT GASKET INNER WALL EARTH FAN RETAINING LEAD Diagram 10.8 SELF BOLT (2 OFF) ADHESIVE INTERFACE SEMI STANDARD ROUND FLUE SEAL ASSEMBLY Diagram 10.5 RESTRICTOR Diagram 10.6 SELF...
Page 20: Horizontal Telescopic Top Flue Installation
11 Horizontal Telescopic Top Flue Installation The Horizontal Telescopic Top Flue, Kit No. A2004500 is suitable for installations that require a flue length from 425 minimum to 659.5 maximum. If longer flueing is required extensions and bends are available, see note below.
Page 21: Horizontal Top Flue Installation
12 Horizontal Top Flue Installation 12.1 The Horizontal Top flue - kit 86285 is suitable for installations that require a flue Max. Std flue length 930mm length from 300 minimum to 930 maximum Min. Std flue length 300mm (without extensions). If a shorter flue length is 70mm required the flue can be cut to suit, see diagrams 12.1 and 12.2 for minimum flue...
Page 22 12 Horizontal Top Flue Installation 12.4 Installation of horizontal top flue assembly • Fit rubber sealing collar (F), see diagram 12.3, into groove at the outer end of pipe (A). • Fit air duct pipe (A) into wall with groove to the outside. •...
Page 23: Electrical Connection
Warning: This appliance must be wired in accordance with (E) Wire link these instructions. Any fault arising from incorrect wiring cannot VOLTAGE be put right under the terms of the Glow-worm guarantee. FREE Important: If a replacement supply cable is required it must be HEATING purchased.
Page 24: Commissioning
14 Commissioning Please ensure the “Benchmark” logbook is completed and left with the user. The commissioning and first firing of the boiler must only be done by a qualified registered person. Gas installation It is recommended that any air is purged from the supply at the GAS INLET gas inlet test point on the gas valve, see diagram 14.1.
Page 25: Instruct The User
14 Commissioning • Bleed each radiator to remove air, ensure all • Leave cap on automatic air vent on top bleed screws are re-tightened. of pump open. • If necessary repressurise the system, refer to procedure 4 • Open various hot water taps to bleed system •...
Page 26: Settings
16 Settings Bypass The boiler has a built-in bypass. This must be adjusted according to the requirements of the system, refer to the flow rate pressure curve (diagram 1.1). The boiler is supplied with the built-in bypass open a half a turn. It is adjusted by turning the bypass screw (a), see diagram 16.1.
Page 27 17 Routine Cleaning and Inspection To Drain the Domestic hot water circuit (30ci Only) BOILER DRAIN VALVE • Close boiler isolating valve (c). • Turn on one or more hot water taps. To Drain the boiler • Close isolating screws on the isolating valves (b), (c) and (d) turn from vertical to horizontal to close.
Page 28: Spark Gap
17 Routine Cleaning and Inspection 17.7 Combustion chamber cover 17.14 Sealed chamber cover seal check • Unscrew and remove the two screws securing combustion Check the condition of the seal, repalce as required. chamber cover to combustion chamber, see diagram 17.5. To replace remove the old seal, thoroughly clean the casing •...
Page 29 17 Routine Cleaning and Inspection BURNER RETAINING SCREWS BURNER AIR PRESSURE GUIDE SWITCH SENSING TUBE FLUE HOOD Diagram 17.7 HEAT EXCHANGER Diagram 17.9 EARTH FAN RETAINING BOLTS LEAD CLIP DOMESTIC WATER INLET FILTER HOUSING POWER SUPPLY LEADS FILTER Diagram 17.8 30ci Only Diagram 17.10 RETAINING CLIP...
Page 30: Fault Finding
18 Fault Finding IMPORTANT: On completion of the fault finding task which has Before trying to operate the boiler make sure that : required the breaking or remaking of the electrical connections, • All gas supply cocks are open and that the gas supply has the continuity, polarity, short circuit and resistance to earth been purged of air.
Page 31 18 Fault Finding COMPONENT NORMAL MEASURE CHECK Under demand during ignition sparks: If 0 Volt: the gas control valve Gas control valve Resistance of coil 116Ω 24V dc for 1 to 2 seconds, then is not faulty. 12Vdc (constant) at the gas control If 24 Volts and then 12 Volts valve electrical connection.
Page 32 18 Fault Finding FAULT: NO HEATING The setting is too low or the boiler Is the heating set high enough ? is set to summer mode. Turn the setting up by turning the central heating temperature control knob clockwise. Is the room thermostat in demand ? Adjust the setting.
Page 33 18 Fault Finding 30ci ONLY FAULT: NO HOT WATER, BUT THE HEATING IS WORKING Open it. Is the cold water inlet tap fully open ? Insufficient water pressure. Is the water pressure greater The appliance will not operate. than 0.5 bar ? Find out why the pressure is so low.
Page 34: Fault Not Found
18 Fault Finding FAULT: THE BURNER LIGHTS, THEN GOES OUT. The flame is spreading across the With the power turned off, check the whole burner, but not being detected. resistance between the spark electrode CHECK and terminal H23 on the control board (PCB).
Page 35 18 Fault Finding FAULT: THE RADIATORS ARE LUKE-WARM. Is the installation fitted with an The temperature of the radiators external sensor? depend on the outside temperature. If the room temperature is not sufficient, adjust Is the installation fitted with a The radiators will only be hot if the room thermostat? thermostat is demanding heat.
Page 36 18 Fault Finding FAULT: THE FAN DOES NOT START. Does the warning light flash 45 seconds Check the power from the room thermostat. after the start of the demand? Replace the interface board or control board (PCB). Check the fan (loose terminal connector, windings burnt out).
Page 37: Wiring Diagram 30Ci
19 Wiring Diagram 30ci AIR PRESSURE SWITCH PLUG IGNITOR IGNITION UNIT ELECTRODES SENSE ELECTRODE OVERHEAT PUMP WATER THERMOSTAT PRESSURE SENSOR CHASSIS THERMISTOR EARTH THREE-WAY VALVE CONTROL VALVE 230V CONTROLS BOARD THERMOSTAT 2 INPUT (FROST STAT) THERMOSTAT 1 INPUT (ROOM STAT) MAINS VOLTAGE EXTERNAL CONTROLS CONNECTION PLUG...
Page 38: Wiring Diagram 30Si
19a Wiring Diagram 30si AIR PRESSURE SWITCH IGNITION PLUG ELECTRODES SENSE ELECTRODE IGNITOR UNIT CONTROL OVERHEAT VALVE PUMP CH THERMOSTAT CHASSIS THERMISTOR EARTH WATER PRESSURE SENSOR THERMOSTAT 230V CONTROLS BOARD 2 INPUT (FROST STAT) THERMOSTAT 1 INPUT (ROOM STAT) MAINS VOLTAGE...
Page 39: Replacement Of Parts
20 Replacement of Parts To Drain the central heating circuit • Open drain valve fitted at the lowest point in the system. • Allow air into the system by opening a radiator bleed screw or the boilers drain valve (a). (30ci Only) To Drain the Domestic hot water circuit BOILER DRAIN VALVE •...
Page 40 20 Replacement of Parts 20.2 Fan, refer to Section 17.10. Before starting refer to the front of Section 20 Important information. • Remove the front panel, refer to Section 17.3. RETAINING CLIPS • Remove the sealed chamber cover, refer to Section 17.5. AIR PRESSURE •...
Page 41 20 Replacement of Parts 20.9 Burner injector assembly, refer to diagram BURNER 20.6. INJECTOR BAR Before starting refer to the front of Section 20 Important information. • Remove the front panel, refer to Section 17.3. • Lower the control panel, refer to Section 17.4. •...
Page 42 20 Replacement of Parts 20.13 Heat exchanger, refer to diagram 20.7. 20.16 User interface board, refer to diagram 20.10. Before starting refer to the front of Section 20 Important information. Before starting refer to the front of Section 20 Important information.
Page 43: Control Panel
20 Replacement of Parts CONTROL BOARD PCB (CONTROL BOARD) COVER 30ci shown Diagram 20.9 230V CONTROLS CONTROL PANEL BOARD USER INTERFACE BOARD MAINS SWITCH Diagram 20.10 30ci shown 4000122703-1...
Page 44 20 Replacement of Parts 20.19 Optional Programmer. Before starting refer to the front of Section 20 Important information. PUMP • Remove the front panel, refer to Section 17.3. ELECTRICAL CONNECTION • Unclip control panel user interface and hinge forward . Do not strain the cables.
Page 45 20 Replacement of Parts 20.23 Boiler drain point, refer to diagram 20.13. Before starting refer to the front of Section 20 Important information. BOILER • Remove the front panel, refer to Section 17.3. DRAIN VALVE • Lower the control panel, refer to Section 17.4. •...
Page 46: Air Vent
20 Replacement of Parts 20.26 Bypass valve, refer to diagram 16.1. Before starting refer to the front of Section 20 Important information. • Remove the front panel, refer to Section 17.3. AIR VENT • Lower the control panel, refer to Section 17.4. Drain down the boiler, refer to relevant part of Section 20.1.
Page 47 20 Replacement of Parts 20.30 Discharge safety valve, refer to diagram 20.19. Before starting refer to the front of Section 20 Important information. • Remove the front panel, refer to Section 17.3. PRESSURE • Lower the control panel, refer to Section 17.4. RELIEF VALVE •...
Page 48 20 Replacement of Parts 20.33 Igniter unit, refer to diagram 20.22. Before starting refer to the front of Section 20 Important information. • Remove the front panel, refer to Section 17.3. IGNITER • Lower the control panel, refer to Section 17.4. UNIT •...
Page 49 20 Replacement of Parts 20.35 Expansion vessel EXPANSION Renewal of the expansion vessel requires the boiler to be VESSEL 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 the installation instructions.
Page 50 20 Replacement of Parts 20.36 Sealed chamber cover seal, refer to diagram 20.25 Before starting refer to the front of Section 20 Important information. • Remove the front panel, refer to Section 17.3. SEALED • Remove the sealed chamber cover, refer to Section 17.5. CHAMBER COVER •...
Page 51: Spare Parts
21 Spare parts When ordering spare parts, quote the part number and description, stating the appliance model number and serial number from the data badge. Short parts list Description Part No. G.C. No. Central heating thermistor S57398 S10119 Air pressure switch S57441 30ci Only Domestic water flow sensor S57202...
Page 52 Notes Because of our constant endeavour for improvement details may vary slightly from those in the instructions. 4000122703-1...

This manual is also suitable for: