TAbLE Of CONTENTS I NT R O D U C T IO N Instructions guidance .........................3 1.1 Product documentation................... 3 1.2 Associated documents ..................3 1.3 Explanation of symbols................... 3 1.4 Guarantee registration .................... 3 Appliance description .........................3 2.1 Safety devices .......................3 2.2 Data label .......................4 2.3 Gas category ......................4 2.4 Regulation and statutory requirements ..............4 2.5 Hydraulic schematic ....................
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TAbLE Of CONTENTS Commissioning ..........................23 12.1 Switching on ......................23 12.2 Filling the CH system (Central heating) ..............23 12.3 Filling DHW Circuit ....................23 12.4 Filling the Condensate Trap ................. 23 12.5 Initial lighting ......................24 12.6 Gas rates ......................24 12.7 Testing heating system ..................25 12.8 Testing domestic hot water system............... 25 12.9 Completion ......................25 Specified Adjustment ........................26 13.1 Heating circuit adjustment ..................26 Installation settings ..........................26 14.1 CO measurement ....................29 14.2 Re-check and restart ....................29 User information .
INTRODUCTION INTRODUCTION 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 Instructions guidance Comprehensive 12 month Guarantee. We recommend you complete and return as soon as possible Product documentation your guarantee registration card. If your guarantee registration card is missing you can obtain a copy or record your registration The instructions are an integral part of the appliance and must by telephoning the Glow-worm Customer Service number be handed to the user on completion of the installation in order 01773 828100. to comply with the current regulation. • Carefully read the manual, to understand all the information to enable safe installation, use and servicing. No liability can Appliance description be accepted in the event of damage for not complying with the guidance in this instruction manual. Safety devices These instructions consist of, Installation, Servicing, Fault Finding, Replacement of Parts and Spares. The instructions are an integral part of the appliance and must, to comply with the current issue of 2.1.1 Overheating safety the Gas Safety (Installation and Use) Regulations, be handed to The appliance is designed to recognise the potential for an the user on completion of the installation. overheat lockout and will shutdown before this happens. Associated documents 2.1.2...
- The maximum power rating the requirements of the appropriate Building Regulations. The Benchmark Checklist can be used to demonstrate - The electrical protection class compliance with Building Regulations and should be provided to - The minimum and maximum heat input (Q) the customer for future reference. - The minimum and maximum power output (P) Installers are required to carry out installation, commissioning and servicing work in accordance with the Benchmark Code - The CE number and logo of Practice which is available from the Heating and Hotwater Industry Council who manage and promote the Scheme. The appliance shall only be connected to the gas Visit www.centralheating.co.uk for more information. • type(s) indicated on the data label. 0020105022_01 - 12/10 - Glow-worm - 4 -...
“Domestic Gas Installations”, the current Building Regulations The basic safety instructions must be followed before and reference should be made to the current ETCI rules for attempting to maintain or replace spare parts: Electrical Installation. • Stop the appliance. GB: the following Codes of Practice apply: BS4814, BS6798, BS5440 Part 1 and 2, BS5546 Part 1, BS5449, BS6891, • Electrically isolate the appliance from the power supply. BS6700, BS7074 Part 1 and 2, BS7593, BS7671. IE: I.S.813, BS5546, BS 5449, BS 7074, BS 7593. • Turn off the appliance gas isolation valve. NOTE: For further information, see the current issue of the • Hydraulically isolate the appliance using the isolation valves Building Regulations, approved document L1 ( in the UK) and if provided. the following current issues of: 1) Central heating system specification (CheSS) and • Should you need to replace hydraulic components, drain the 2) Controls for domestic central heating system and hot water. appliance. BRECSU. • Protect all the electrical components from water while working on the appliance. • Use only original spare parts. 0020105022_01 - 12/10 - Glow-worm - 6 -...
By complying with this directive, you will contribute Connection of the whole electrical system of the boiler, including to the preservation of natural resources and the any heating controls, to the electrical supply MUST be through protection of human health. one common isolator and must be fused 3 Amp maximum. Packaging Isolation should be by a double pole switched fused spur box, with a minimum gap of 3mm for both poles. The fused spur We recommend that you recycle the packaging of the appliance in a responsible fashion. box should be readily accessible and preferably adjacent to the appliance. It should be identified as to its use. • Sort the waste in order to separate those elements which can be recycled (cardboard, plastics ...) and those which Alternatively connection can be made through an unswitched cannot be recycled. shuttered socket and 3A fused 3-pin plug both to the current issue of BS 1363, provided they are not used in a room • Dispose of waste in accordance with existing regulations. containing a bath or shower. Wiring to the boiler must be PVC 85OC insulated cable, not less than 0.75mm2 (24/0.20mm). 0020105022_01 - 12/10 - Glow-worm - 7 -...
In Gb this is the current I.E.E. WIRING REGULATIONS and supporting the load. BUILDING REGULATIONS. - The minimum clearances from the boiler case are In IE reference should be made to the current edition of I.S.813 maintained. “Domestic Gas Installations” and the current ETCI rules. Timber Frame Buildings Ventilation If the boiler is to be installed in a timber frame building it should be fitted in accordance with the Institute of Gas Engineers 6.3.1 Room Ventilation document IGE/UP/7/1998. If in doubt seek advice from local gas undertaking or Glow-worm. The boiler is room sealed so a permanent air vent is not required. 6.3.2 Cupboard or Compartment Ventilation Clearances Due to the high efficiency and low casing temperature of this • To allow periodic maintenance, ensure the distances boiler, cupboard or compartment ventilation is not necessary. indicated on the diagram. • Existing ventilation should be investigated for its purpose Additional clearances may be beneficial around the boiler for before removing. installation and servicing. For flue installations where external access is not practicable, consideration should be given for the space required to insert the flue from inside the property, which may necessitate clearance larger than those specified in diagram below.
Drain point Instructions for use (x1) External bypass (if required) Extended guarantee leaflet (x1) Domestic hot water out Guarantee envelope pack (x1) Domestic cold water supply in Magnetic lighting instruction label (x1) boiler Gas conversion label (x1) 0020105022_01 - 12/10 - Glow-worm - 10 -...
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Filling the sealed system New system- For optimum performance after installation, the boiler and its associated central heating system should also be flushed. The boiler does not contain any filling loop, an external one must be fitted. Flushing shall be carried out in accordance with BS 7593, a chemical cleanser can be used either Sentinel X300, X400 or Suitable external filling systems are shown diagrammatically, Fernox F3 are suitable. see diagram below. It is recommended to flush existing systems first before fitting the new boiler. • Ensure all cleanser is removed from the whole system before adding an inhibitor. For long-term corrosion protection after flushing, an inhibitor suitable for stainless steel heat exchangers can be used. Either Sentinel X100 or Fernox F1 inhibitor can be used. The boiler is suitable for use on systems using softened water. 0020105022_01 - 12/10 - Glow-worm - 11 -...
7 4 0 3 4 6 4 1 8 3 3 8 Mounting • Make sure that the equipment used for implementing the installation is compatible with that of the appliance. • Determine the assembly location. See the "Appliance location" chapter. 80/125 flue ► Ø150mm 80/125 flue ► Ø130mm *** 80/125 flue ► 156mm • Take the wall template and place in the desired position on the wall, giving due consideration to the required boiler clearances, see chapter "Appliance location ► Clearances", and the flue you are fitting. 0020105022_01 - 12/10 - Glow-worm - 12 -...
44mm/metre (2.5 • Lower the boiler slowly and engage onto the hanging bracket towards the boiler. • If fitting a side flue, extend the flue centre line into the corner then 130mm along the adjacent wall. • If fitting an extended side flue, determine the flue hole centre by extending the dashed inclined line on the template to the side wall. This dashed line is drawn at 44mm/metre (2.5 rise from the boiler. Where this line reaches the side wall, a horizontal line should be marked. The vertical centre line of the flue should then be marked at 130mm from the back wall. To allow for the flue passing through the wall at this angle a 125mm hole should be drilled irrespective of internal or external installation. Hanging bracket fixing Due to the varied site conditions the fixings supplied may not be suitable, please make sure that those used are. • Drill the holes for the fixing screws in accordance with the wall template. • Fix the hanging bracket on the wall. 0020105022_01 - 12/10 - Glow-worm - 13 -...
Domestic hot water outlet isolating valve + sealing washer ½" or steam cannot create any danger to persons, damage to Heating flow isolating valve + sealing washer ¾" property or external electrical components and wiring. Connection Ø O.D. 22 mm Connection Ø O.D. 15 mm Gas connection Ø O.D. 15 mm • Use only the original gas cock GER/1 DN15, CE-0085 CL 0082. • Use only the olive and flat seal washer supplied with the gas cock. 0020105022_01 - 12/10 - Glow-worm - 14 -...
Connect the condensate pipe (1) to the condensate outlet (2). The pipe should have a fall of a least 2.5° 44mm/ metre away from the boiler. Condensate should, if possible be discharged into the household internal drainage system. • If this is not practicable, discharge can be allowed into the external household drains or a purpose designed soak away, refer to diagram overleaf. It is recommended that any external condensate drain pipe is protected and also preferably of 32mm diameter, to prevent freezing in adverse weather conditions. • Always ensure the pipe is installed with the correct fall 0020105022_01 - 12/10 - Glow-worm - 15 -...
INSTALLATION Evacuation of combustion gas Regulation Only flue accessories supplied by Glow-worm must be used. Different flue outlet configurations can be carried out. • Consult your supplier for more information about the other possibilities and associated accessories. 44 mm/m • Standard flue terminal kits have an in-built fall back to the boiler to drain the condensate. These can be fitted level between the appliance and the termination position. All other extended flues must have a fall of at least 44mm/m The maximum length of the flue outlet is defined according to its type (for example C13). • Whatever the kind of flue system chosen, observe the minimum distances indicated in the chart below to position the flue terminals. • To install the flue, refer to the separate flue instruction supplied with your appliance. • Explain these requirements to the user of the appliance. If necessary, you must install a flue terminal guard.
1200 into dwelling vertical from a terminal 1500 horizontally from a terminal Vertical flues from another terminal above roof level from adjacent opening window 1000 from adjacent wall to flue (*) 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. 1 Gasket (fitted) Type Max length Ø 60/100 Ø 80/125 10 m Each time an additional 90° bend is necessary (or 2 at 45°), the length (L) must be reduced by 1 m. 0020105022_01 - 12/10 - Glow-worm - 17 -...
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Exhaust mass rate (g/s) At min thermal load (40°C/30°C) C43 type flue systems must have their At max thermal load (80°C/60°C) 11.3 own condensate drain fitted and not allow condensate to mix into other appliances Exhaust temperature (°C) At min thermal load (40°C/30°C) At max thermal load (80°C/60°C) 65.7 63.4 0020105022_01 - 12/10 - Glow-worm - 18 -...
• Keep a distance of a maximum of 30 mm between connector engineer. (1) and the start of the insulation (3). The appliance must be connected directly to an accessible, fixed, switched, electrical outlet. • If using single core wires are used(2) ensure that the are wrapped together in an insulating sheath. The external wiring must be earthed, with correct polarity and in accordance with current standards. • Fix the cables in the cable-clamp on the eBox. The manufacturer declines any responsibility for damages to persons or others caused by the incorrect installation of the appliance earthing. This includes failure to comply with current standards. Electrical components have been tested to meet the equivalent requirements of the BEAB. • Do not use cable greater than 10 mm in diameter for the electrical connections. All system components must be of an approved type. • Do not interrupt the mains supply with a time switch or programmer. The boiler is suitable for installation in bathroom zones 2 and 3. 0020105022_01 - 12/10 - Glow-worm - 19 -...
A fused three pin plug and shuttered socket outlet may be used instead of a fused spur box provided that it is not used in a room containing a fixed bath or shower. 230V permanent supply Main board terminal block = Mains earth N = Mains neutral L = Mains live Power supply cable fuse Double pole connector • Connect the appliance's power cable to the 230 V single- • Connect mains supply as described. phase network + earth. • Connect the appliance in accordance with the live and neutral connections. 0020105022_01 - 12/10 - Glow-worm - 20 -...
Carry out preliminary electrical system checks as below: = Mains earth N = Mains neutral • Resistance to earth (<1 Ohm) L = Mains live Junction box • Short circuit test (L-N) fuse Double pole connector • Resistance to earth (L-E) • Connect the mains supply and system heating controls e.g. • Polarity check room thermostat as described. • When installing a 230v controller, the link fitted to the 24v terminals (RT/24v) must be removed. RT 24V T° ext 0020105022_01 - 12/10 - Glow-worm - 21 -...
13 Gas valve Internal timer 14 fan User interface 15 Three way valve fuse 2A 16 Thermal fuse Connector for 230 V option 17 Water flow sensor Main supply 230V 18 Water pressure sensor 0020105022_01 - 12/10 - Glow-worm - 22 -...
12.2 filling the CH system (Central heating) 12.4 filling the Condensate Trap • Make sure that the installation's cold water inlet isolating valve is open. • Open the isolating valves located on the connections: they must be positioned in the direction of the flow. Air vent Pump Screw for the pump shaft • Open the plug on the air vent located on the pump and automatic air vents on the installation. If the (CH.) pressure falls below 0.4 bar, the display will flash the current pressure and the boiler will not operate. To increase the pressure, the CH circuit requires " Topping up". filling trap Condensate trap 0020105022_01 - 12/10 - Glow-worm - 23 -...
12.5.2 Adjusting the temperature • Activate the test mode "P.01" and set the value to HI in order to force the burner at P. max. See chapter "Specific adjustment ► Appliance technical settings and parameter list ► Test modes". Analogue clock Reset button Selection of functioning mode Temperature adjustment Display 0020105022_01 - 12/10 - Glow-worm - 24 -...
Gas rates (G20) Gas rates (G31) (approx) after 10 mins from cold IE: it is necessary to complete a “Declaration of Conformity” to indicate compliance to I.S.813. An example of this is given in Model the current edition of I.S.813. kg/h kg/h 0.85 2.54 89.7 0.62 1.87 0.98 34.6 2.96 104.05 0.72 2.17 In communal or LPG installations where the gas rate cannot be measured it is acceptable to measure the combustion rate as described in the servicing section. • On completion, press the "reset" button to reset the boiler. • Gas rates for both central heating and hot water can be verified using the test program P.03 and P.01 respectively. 0020105022_01 - 12/10 - Glow-worm - 25 -...
INSTALLATION 13 Specified Adjustment 13.1 Heating circuit adjustment By pass operation is automatic and not adjustable. If necessary, fit an external by-pass. BETACOM 24a Available pressure between heating flow and return (kPa) Heating circuit flow rate (l/h) BETACOM 28a Available pressure between heating flow and return (kPa) Heating circuit flow rate (l/h) 14 Installation settings • Push in and hold the...
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0 = open (no heating), 1 = closed (heating mode). d.09 Flow temperature set point from external eBus control °C External eBus set value. 0 = off d.10 Heating pump status 1 = on 0 = open (no heating), d.16 Current state of the 24V room thermostat °C 1 = closed (heating mode) Temperature regulation on flow (radiator) or return d.17 Flow or Return temperature control °C (under-floor heating) temperature sensor. 0 = off d.22 DHW demand active (tapping) 1 = on 0 = CH not available (summer mode) d.23 Central heating mode 1 = CH available (winter mode) Fan speed is displayed between 0 and 99. d.33 Speed setpoint of fan Multiply the displayed value by 100. Display the digitalized ionisation voltage. Multiply d.44 Digitalized ionisation voltage the displayed value by 100. 0020105022_01 - 12/10 - Glow-worm - 27 -...
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Post run pump "PX" and "On". Status Specific messages Default status, no request for heating or domestic water. If - The test mode will be automatically stop after 15 minutes. an EBUS controller is connected to the boiler, check that S.30 a wiring link is present on terminals 3 and 4 of the boiler's • When you have finished, press the reset button to exit the main board. test modes. S.31 "Hot water only" mode Control cycle: the speed of the fan in the functioning phase S.32 is outside tolerance. S.34 "Frost protection" mode S.41 Water pressure too high Waiting cycle: temperature differential between heating flow S.53 and return is too high. If ∆T > 30, forcing to Pmin. Waiting cycle: lack of water in the installation/temperature S.54 rise between heating flow and return is too high. S.96 Test temperature sensor for heating return. Test temperature sensors for heating flow and return, or the S.98 appliance has a fault. 0020105022_01 - 12/10 - Glow-worm - 28 -...
• Advise the User if the mains electricity and gas are to be turned off for any long periods during severe weather, it is • Start the appliance to ensure that any adjustments operate recommended that the whole system, including the boiler, correctly and check that the appliance operates safely. should be drained to avoid the risk of freezing. • Check the gas-tightness and water-tightness of the appliance and eliminate any leaks. Sealed system: The system must be refilled and to the correct pressure as indicated in these • Check that the flue joints are tested for tightness and fitted in instructions accordance with the instructions. • Leave these instructions and the ‘Benchmark’ Installation, • Check the entire control and safety system, its settings and Commissioning and Service Record with the user. its operation. 0020105022_01 - 12/10 - Glow-worm - 29 -...
Check the electrical installation To ensure the continued efficient and safe operation of the boiler it is recommended that it is checked and serviced at regular intervals. The frequency of servicing will depend upon the particular installation and usage, but in general once a year should be enough. It is the Law that any servicing is carried out by a competent person approved at the time by the Health and Safety Executive. • Before commencing with a service or replacement of parts isolate the boiler from the electrical supply and turn off the gas supply at the gas isolation valve. • 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. • If any electrical connections have been disconnected and after their connection, checks to the earth continuity, polarity, short circuit and resistance to earth must be repeated using a suitable multimeter, as described in chapter "Trouble-shooting ► Fault diagnosis ► Check the electrical installation". • After servicing, complete the relevant Service Interval Main board Record section of the Benchmark Checklist located in the Neutral Live back pages of this document. Multimeter • Remove the front casing panel 16 Trouble-shooting • Check the external electrical supply to the boiler is on and a...
• In order to display the fault code memory, simultaneously press the buttons and for more than 7 seconds. • The screen will display the first fault "1." (record) and after "XX" (fault code). • To display the other faults registered by the appliance, press the button or . • Press button for more than 3 seconds to exit this menu. Record fault code Description Consult the “Fault codes” chapter. Consult the “Fault codes” chapter. Consult the “Fault codes” chapter. Consult the “Fault codes” chapter. Consult the “Fault codes” chapter. Consult the “Fault codes” chapter. Consult the “Fault codes” chapter. Consult the “Fault codes” chapter. Consult the “Fault codes” chapter. Consult the “Fault codes” chapter. • To erase the fault memory registered by the appliance, consult the “Installation adjustments” chapter and use code “d.94”. 0020105022_01 - 12/10 - Glow-worm - 31 -...
Gas valve closure fault • Check the main boards connections. Fault in the main board memory • Check the main board. Fault in the main board Rapid fluctuation of return or flow • Check the appliance DSN number is correct. heating sensor. • Reset the appliance. Excessive main board temperature Flame signal fault in the main board • Check the return gas circuit (gas valve open). No return gas / Insufficient gas flow • Check the observe the flame picture and check Gas valve incorrectly adjusted Fluctuation of flame signal the CO setting. Defective firing electrode and flame • Check the igniter unit connections. control / Defective igniter unit • Check the state of the electrode (corrosion). • Check that the appliance DSN code on the screen matches the product code of the nameplate (in the User interface incompatible with the main Incorrect product code event of a fault and the appliance DSN does not board appear, consult menu.d.93 reserved for the code). • Check the boards reference. Flow heating temperature sensor • Check the sensor connections. Flow heating temperature sensor fault unclipped or defective (no • Make sure that the sensor is clipped to the tube. temperature variation) 0020105022_01 - 12/10 - Glow-worm - 32 -...
• Check the pump connections. Pump disconnected does not increase when the burner is lit • Check the flow and return heating sensor Leak in the installation connections. • Check that there are no leaks. Inverted or disconnected flow and Permanent temperature difference between • Check temperature sensors connections. return heating temperature sensors flow and return heating sensors • Replace faulty sensors. Defective temperature sensors Flow and return heating temperature Flow and return heating sensors fault • Check temperature sensors connections. sensor connected to same tube • Check the sensor connections. Floor heating contact open Underfloor heating contact fault • Check that the sensor is connected to the main Sensor disconnected or defective board and the shunt is removed. • Check connection from user interface PCB to main User interface fault Defective user interface PCB. • Replace user interface. 16.4 functional flow diagram 16.4.1 Central Heating 0020105022_01 - 12/10 - Glow-worm - 33 -...
- the gas service isolation valve is opened. The person carrying out a combustion measurement should have been assessed as competent in the use of a flue gas analyser and the interpretation of the results. The flue gas analyser used should be one meeting the requirements of BS7927 or BS-EN50379-3 and be calibrated in accordance with the analyser manufacturers’ requirements. Competence can be demonstrated by satisfactory completion of the CPA1 ACS assessment, which covers the use of electronic portable combustion gas analysers in accordance with BS 7967, parts 1 to 4. 17.1 Settings Steps "Switching on" to "Re-pressurising System" will need to be completed before the appliance can be converted (See chapter "Commissioning"). Tools required to make the conversion are a 4mm Allen key and an electricians screwdriver. 0020105022_01 - 12/10 - Glow-worm - 34 -...
Adjusting the gas valve • Press the on/off button to turn the appliance off. • Turn the screw in the direction and the number of times Serial number stickers indicated in the following table. Data label location • Firmly attach the gas replacement label to the appliance in Gas adjustment Model G20 ► G31 G31 ► G20 the corresponding location (1) on the electrical box. 2 turns 17.2 Restart - re-check commissioning 3 turns • Before putting the appliance into operation, follow the 2 turns instructions within the chapter Specific adjustment. 3 turns 0020105022_01 - 12/10 - Glow-worm - 35 -...
MAINTENANCE 18 Draining Safety Executive in accordance with the rules in force in the countries of destination. • To obtain service, please call your installer or Glow-worm’s 18.1 Heating circuit own service organisation. PLEASE NOTE: During routine servicing, and after any maintenance, we recommend that the following must be checked: - The integrity of the flue system and the flue seals, - The integrity of the boiler combustion circuit and the relevant seals, - The operational (working) gas inlet pressure at maximum rate, - The gas rate, - The combustion performance. • See the "Safety instructions" chapter for a list of operations to be performed prior to the maintenance of the application. • Once the maintenance operations have been completed, consult the ¨Start Up¨ chapter to restart the appliance. 19.1 Annual Maintenance Length of hose (not supplied) Drain valve 19.1.1...
Safe combustion can only be verified by measuring CO/CO ratio. This must not exceed the value shown in the table opposite. 19.3.2 Preliminaries Prior to, during servicing and after any maintenance or changed parts, the following inspection must be carried out. • The integrity of the flue system and flue seals. • The integrity of the appliance combustion circuit and relevant front panel seals. front panel retaining screw • A visual inspection of the flame quality. 0020105022_01 - 12/10 - Glow-worm - 37 -...
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2b Vertical flue adaptor If after servicing and adjustment of the appliance the combustion values are still unacceptable and after further remedial work has been carried out, the appliance must be 19.3.3 Maximum rate check and adjustment disconnected until the CO/CO ratio is acceptable. • Advice can be sought from the Glow-worm Technical To verify the maximum gas rate CO setting the Helpline. appliance must be checked at the maximum rate. • Activate the test mode "P.01" and set the value to HI in order to force the burner at P. max. See chapter "Specific adjustment ► Appliance technical settings and parameter list ► Test modes".
Service interval record • Refer to benchmark Service Interval Record at the rear of this manual. 19.5 Silencer Expansion vessel Expansion vessel pressure inlet • Check the expansion vessel's supply pressure (see « Technical Data » chapter) by means of the pressure inlet located on the expansion vessel. Adjust the pressure if necessary. • Following the installation of a new expansion vessel, fill and purge the appliance or installation, if necessary. Silencer retaining screw fixed silencer Removable silencer • Remove the silencer retaining screws (1) and remove the silencer (3). • Clean the interior of the silencer with a dry cloth if necessary, taking care not to damage the internal foam. • Repeat the operation in reverse order to replace the silencer. 0020105022_01 - 12/10 - Glow-worm - 39 -...
Condensate cleaning cap Condensate pipe Condensate outletv Condensate retaining screw Condensate trap Hose • Place a container under the condensate trap (5). • Remove the condensate from the reservoir (1). • Disconnect the condensation discharge (2). • Disconnect the heat exchanger hose (6). The condense trap will contain water, lift taking care not to spill the water. • Remove the condensate trap (5) using the retaining screw (4). • Clean the hose, the trap and the siphon, remove any accumulated dirt. • Reassemble the components, taking care to position the gaskets correctly. • Start the siphon (3) and fill with water. 0020105022_01 - 12/10 - Glow-worm - 40 -...
19.8.2 Dismantling the burner 20 Replacement of Parts Warning: The gasket (12) must be replaced each • Do not use reconditioned or copy parts, only use original time the burner is dismantled. parts supplied by Glow-worm. • Disconnect the spark electrode connector (6) from the igniter • If a part is required, contact the Glow-worm service unit. organisation. • Remove the gas pipe (17). • Please quote the name of the appliance, this information will be on the name badge on the front of the appliance. • Remove the connectors from the gas valve (1) and the fan (15). • If in doubt seek advice from the local gas company or Glow- worm’s own service organisation.
Upper support bracket Retaining screw Gasket Drain the boiler heating circuit as described in the appropriate chapter "Draining". • Remove the two screws (4). • Undo the connector (1) at the base of the vessel. • Remove upper support bracket (3). • Remove the expansion vessel (2). • Fit a new gasket between the expansion vessel and connector. • Refill, vent and pressurise the boiler. fibre washer Steel washer Glass Steel washer Circlip • Remove the circlip (5). • Remove the steel washer (4). • Remove fibre washer (1). • Remove the glass (3). 0020105022_01 - 12/10 - Glow-worm - 43 -...
• Fit the new low water pressure sensor. • Remove the two securing screws (23). • Refill vent and pressurise the boiler. • Remove the plate-to-plate heat exchanger (17). 20.4.4 Safety discharge valve • When replacing the plate-to-plate heat exchanger, ensure that the four rubber sealing washers are fitted into the • Drain the boiler heating circuit as described in the hydroblock. appropriate chapter "Draining". NOTE: The plate-to-plate heat exchanger only fits one way. • Remove the low water pressure sensor as described in the previous section. • Refill, vent and pressurise the boiler. • Undo the safety discharge valve union and remove the pipe. • Disconnect the Central Heating isolation valve. • Remove the securing clips and withdraw the safety discharge valve plastic housing (29). • Remove the safety discharge valve. • Fit new ‘O’ ring. Refill, vent and pressurise the boiler. 0020105022_01 - 12/10 - Glow-worm - 45 -...
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When reconnecting, the polarity of the wiring to thermistors is not important. • Fit the new burner and the new gasket. 20.5.9 Gas valve 20.5.5 Heat exchanger • Remove the burner door (11) refering to chapter "Dismantling There will be water in the heat exchanger. the burner door". Carefully ease heat exchanger out. • Remove the two gas valve retaining screws (30). • Drain the boiler heating and hot water circuits as described in • Remove the gas valve (31) and the gasket (32). the appropriate chapter "Draining". 0020105022_01 - 12/10 - Glow-worm - 47 -...
Warning: condensate is mildly acidic. Wear protective gloves. Control panel Rear panel Retainings clips Main PCb • Remove the 24V and 230V connections. • Remove the rear panel (2). • Ease back the two PCB retaining clips (3) and withdraw the PCB from the retaining lugs. • Remove the electrical connections to the PCB (appliance Condensate reservoir interface cable). Condensate discharge Condensate outlet • When refitting the rear panel, ensure the leads are not Condensate retaining screw trapped. Condensate trap Hose 0020105022_01 - 12/10 - Glow-worm - 48 -...
This appliance displays a CE Mark of conformity. Only use the manufacturer’s genuine, new spare 20.7.3 User interface PCb parts. • Ensure that spare parts are correctly mounted in the right position and direction. After fitting any spare part or servicing, the appliance must be tested for its safe operation. 21.1 Short List of Parts • When ordering spare parts, contact Glow-worm’s own service organisation. • Please quote the name of the appliance and serial number, to be found on the data label. If ordering from British Gas also quote the G.C. number of the part. Part No. Description GC Part No. 0020097277 Fan A000035144 Spark igniter...
Manual Handling IMPORTANT. With regards to the Manual Handling Operations, 1992 Positioning of Appliance for final Installation – no obstructions. Regulations, the following lift operation exceeds the recommended Recommend 2 persons lift appliance to position into place. Fit bracket weight for a one man lift. securely onto wall before lifting appliance into position. Obtain firm grip on front and sides of appliance, lift upwards, ensure stable bal- General recommendations when handling ance achieved and lift upwards to position in place on bracket. Ensure Clear the route before attempting the lift. safe lifting techniques are used – keep back straight – bend using Ensure safe lifting techniques are used – keep back straight – bend legs - when lifting load from floor level. Do not twist – reposition feet using legs. Keep load as close to body as possible. Do not twist – instead. Keep boiler as close as possible to body throughout lift to reposition feet instead. If 2 persons performing lift, ensure co-ordinated minimise strain on back. Ensure co-ordinated movements to ensure movements during lift. Avoid upper body/top heavy bending - do not equal spread of weight of load. Always use assistance if required. lean forward/sideways. Recommend wear suitable cut resistant gloves Recommend wear suitable cut resistant gloves with good grip to protect with good grip to protect against sharp edges and ensure good grip. against sharp edges and ensure good grip when handling appliance. Always use assistance if required. Positioning of Appliance for final Installation – above worktop, Removal of carton from delivery van foreseeable obstructions etc.
SERVICE INTERVAL RECORD It is recommended that your heating system is serviced regularly and that you complete the appropriate Service Interval Record Below . Service Provider. Before completing the appropriate Service Interval Record below, please ensure you have carried out the service as described in the boiler manufacturer’s instructions.
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Glow-worm Nottingham Road, Because of our constant endeavour for Belper, Derbyshire. improvement, details may vary slightly DE56 1JT from those shown in these instructions. www.glow-worm.co.uk...
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