Glow-worm Swift flow 75e Instructions For Use Installation And Servicing
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Glow-worm Swift flow 75e Instructions For Use Installation And Servicing

Glow-worm Swift flow 75e Instructions For Use Installation And Servicing

Fanned flue combination boiler
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Installation and Servicing

75e
Fanned Flue Combination Boiler
With Honeywell gas control
The instructions consist of three parts, User, Installation and Servicing Instructions, which include 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)
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
Supplied By www.heating spares.co Tel. 0161 620 6677

Instructions for Use

To b e l e f t w i t h t h e u s e r
G.C. No. 47 313 16
This is a Cat I
Appliance
2H
Regulations, be handed to the user on completion of the installation.

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.
Customer Services:
Tel: (01773) 828100
Fax: (01773) 828070
REGISTER YOUR GLOW-WORM APPLIANCE
FOR 1ST YEAR GUARANTEE PROTECTION
CALL 0181 380 2555
Nottingham Road, Belper, Derbyshire. DE56 1JT
General/Sales enquiries:
Tel: (01773) 824141 Fax: (01773) 820569
221422A.10.98
Hepworth Heating Ltd.,

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  • Page 1: Instructions For Use

    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 The colours of three core flexible cable are, blue - neutral, brown Introduction - live, green and yellow - earth. Please read these instructions and follow them carefully for the As the markings on your plug may not correspond with these safe and economical use of your Combination boiler.
  • Page 4 Instructions for Use Setting Instructions for Electro/mechanical Setting the Clock Clock - if fitted 1. With both AUTO and RUN switches set to the central position, press R reset button, the display will flash. This clock has a twenty four hour dial, that is, 1pm is 13. 2.
  • Page 5 Instructions for Use Maintenance and Servicing To Light the Boiler To ensure the continued efficient and safe operation of the 1. Check that all five isolating valves are open, the slots in line with the length of the valve, see diagram 3. appliance it is recommended that it is checked and serviced as necessary at regular intervals.
  • Page 6 Instructions for Use Clearances Cleaning The boiler requires a clearance in front, below and at the sides WARNING. This appliance contains metal parts (components) of the casing for safety, servicing and maintenance access, see and care should be taken when handling and cleaning with diagram 2.1.
  • Page 7 1 General 1.1 Installation 1.7 Gas Supply Materials and equipment should be fit for their purpose and of The gas installation shall be in accordance with the rules in force suitable quality and workmanship. in the countries of destination. The supply from the governed meter must be of adequate size 1.2 Important Notice to provide a steady inlet working pressure of 20mbar (8in wg) at the boiler.

  • Page 8: Boiler Position

    1 General TABLE 2 Lift Weight 37.0kg (81.4lb) D.H.W 0.5 to 10bar working pressure (7.25 to 188lbf/in Total Weight 50.4kg (111lb) Maximum Heating 119 litres Gas connection in BSPT) system water (26.2 gallons) content using with a cold Heating and return 22mm compression fitted expansion fill pressure...

  • Page 9: Flue And Ventilation

    3 Flue and Ventilation 3.1 Flue 3.3 Terminal Position The flue must be installed in accordance with the rules in force The minimum acceptable siting dimensions for the terminal in the countries of destination. from obstructions, other terminals and ventilation openings are shown in diagram 3.5.
  • Page 10 3 Flue and Ventilation 3.5 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 11: Heating System 4

    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 FLOW RATE GRUNDFOS Diagram 4.1 REMAINING CONVEYING CAPACITY OF PUMP Btu/h x 1000 SHOWING RELATIVE SYSTEM DIFFERENTIAL AT VARIOUS SYSTEM HEATING LOADS.
  • Page 12 4 Heating System Glow-worm Wilo Pump 4.1 General Notes The pump adjuster should normally be left at maximum (2) but The boiler is intended for use in a sealed system only. in some cases it is permissible to adjust to a lower setting (1), see diagram 4.1A.

  • Page 13: Heating System

    4 Heating System 4.9 Filling Sealed Systems Provision for filling the system at a low level must be made. Three methods of filling are shown in diagram 4.3. There must be no permanent connection to the mains water supply, even through a non-return valve. NOTE: It is important that fittings used for connection to potable water comply with the water undertakers requirements.

  • Page 14: Domestic Hot Water System

    5 Domestic Hot Water System 5.1 General The domestic hot water service must be in accordance with the rules in force in the countries of destination. 5.2 Water Pressure For the minimum and maximum working pressures of the domestic hot water circuit of the boiler refer to Section 1.6 Data. If the cold water supply pressure exceeds the maximum, a governor must be fitted in the supply to the boiler to reduce the pressure to within the limits given.
  • Page 15 6 Installation Preparation For a side flue, mark the horizontal flue centre line at the sides 6.4 Wall Sleeve of the template. Extend the flue centre line horizontally left or Note: If required, an optional Wall Sleeve Kit, Part No. 900862, right to the internal corner where the flue is required to exit to is available, complete with fixing instructions.

  • Page 16: Flue Preparation

    7 Flue Preparation 7.1 Flue Length X + 173 ( AIR DUCT ASSEMBLY) 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 3.3 for a 1, 2 or 3metre flue system.

  • Page 17: 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 18: Electrical Connections

    9 Electrical Connections 9.1 Supply Cable Connection 9.5 Cable and Connector Securing CAUTION: To prevent an induced current from switching the After completing all the connections to the boiler, secure the central heating on, when not required, it is important that the cable(s) with the cover, using the two screws previously removed, heating system control cables are separated from the other see diagram 9.1.
  • Page 19 9 Electrical Connections INTEGRAL CLOCK TO BOILER EXTERNAL CLOCK 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 20: 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, carry on as below: SECURING SCREW (3) Lift the boiler into position, hooking it on the boiler mounting frame at the top, then loosely fit the two boiler securing screws at the top, see diagram 6.3.

  • Page 21: Commissioning

    10 Boiler Fixing 10.7 Flue Fixing FLUE ELBOW (REAR FLUE Fit the self-adhesive gasket, supplied in the loose items pack, GASKET SHOWN) to the flue elbow, see diagram 10.3. Push the prepared ductings into and through the wall sleeve, the longest protrusion of the flue terminal is positioned at the top.
  • Page 22 11 Commissioning Check the burner pressure is within +/-0.35mbar (+/-0.14in wg). of 15.6mbar (6.3in wg). If this is incorrect, the burner pressure SWITCH 'ON' SWITCH 'OFF' may be adjusted to the correct setting by turning the hot water CONTROL gas pressure adjuster (potentiometer), using an insulated RESET screwdriver, see diagram 11.4 .
  • Page 23 11 Commissioning 11.7 Burner Pressure - Heating TEST POINT The burner pressure is factory preset and no adjustment should be required. Check that all remote heating system controls, room thermostats, integral clock and the like are switched on/programmed and calling for heat. Set switch “C”...
  • Page 24 11 Commissioning If required, fit the plastic covers to hide the bracket securing DOMESTIC screws. WATER Change the position of the “Push” label to suit the new door THROTTLE opening. Clock/timer, if fitted, remove the screws, nuts and washers to release the cover plate, see diagram 11.6.

  • Page 25: General Data

    1 General Data boiler will be under the supply water pressure. Before any parts 1.1 Servicing or Replacing Parts of this circuit are disconnected, turn the domestic cold water To ensure the continued efficient and safe operation of the isolating valve off, open the hot water taps to reduce the water boiler it is recommended that it is checked and serviced as pressure in the boiler, close the hot water isolating valve and necessary at regular intervals.

  • Page 26: Servicing

    2 Servicing 2.1 Isolation and Access 2.6 Operational Checks Before commencing, refer to Section 1.1. Light the boiler, carry out operational checks and any necessary adjustments as described in “Commissioning” in the Installation Isolate the boiler from the electrical supply and close the gas Instructions.

  • Page 27: Fault Finding

    3 Fault Finding 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 the fuses are in order. CABLE TO NOTE: THE BOILER CONTROL BOARDS CAN BE DAMAGED REMOTE BY INCORRECT TESTING WITH THE POWER ON.
  • Page 28 3 Fault Finding 3.3 Electrical PERMANENT Preliminary electrical system checks, as outlined in a Multimeter LIVE 230V~50Hz Instruction book, are the first checks to be carried out during a fault finding procedure. Isolate the boiler from the electrical supply, refer to Section 1.3. Gain access to the boiler controls by removing the outer case, refer to Section 1.4.
  • Page 29 3 Fault Finding GREY GREY CVI IGNITION UNIT TERMINAL No's 9 10 11 12 CVI IGNITION UNIT CONTROL BOARD GREY GAS VALVE BLACK MODUREG YELLOW GREY Fuse rating WHITE 630 mA Fuse TRANSFORMER GREY TERMINAL No's GREY WATER TRANSFORMER PRESSURE SWITCH BLOCK 1 GREY...
  • Page 30 3 Fault Finding Carry out the initial fault finding checks described in Section 3.1. Check that gas, water and electricity are available at the boiler. Before starting tests isolate the boiler, make sure that the remote controls are not calling for duty and there is no domestic hot water demand. Remove the outer case, control housing and it's cover.
  • Page 31 3 Fault Finding Check for shorting check lead connections to electrodes. Press reset switch wait 15 seconds between attempts. Are there sparks Check lead connections at electrode ? to electrodes Check dimensions of Does burner light ? spark electrode, if ok replace CVI gas valve unit.
  • Page 32 3 Fault Finding Is there between Faulty main 15 - 30 V DC on the two PCB. greys on CN1 main PCB ? Is there between Faulty CVl 15 - 30 V DC on the ignition unit. Modureg coil ? Faulty coil.
  • Page 33 3 Fault Finding If mains potential room thermostat is connected, make sure 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, make sure that remote controls are calling for heat. Isolate the boiler from electrical supply, remove outer case.

  • Page 34: Replacement Of Parts

    4 Replacement of Parts Before replacing any part please read points below:- Replacement of parts must only be carried out by a competent ELECTRICAL person. FLUE COLLECTOR CONNECTORS 1. Refer to Section 1.1. 2. Always isolate the boiler from the electrical and as required, the gas supply, as Section 1.3.
  • Page 35 4 Replacement of Parts 4.3 Main Injector SPARK EARTH ELECTRODE ELECTRODE Remove the main burner, refer to Section 4.2. Unscrew the main injector. When fitting the main injector, fit the new sealing washer, supplied, to ensure gas soundness. 4.4 Spark Electrode Remove the inner case as Section 1.5.
  • Page 36 4 Replacement of Parts 4.9 Water Pressure Switch Release the water pressure and drain the central heating circuit of the boiler, refer to Section 1.3 and 1.6. WATER PRESSURE Remove the control housing, secured with two screws. Support SWITCH control housing on a surface or by screwing it to front edge of the base, using the outer case securing screw, see diagram 4.10.
  • Page 37 4 Replacement of Parts 4.13 Transformer Remove the transformer, noting the correct position. Reconnect the cables, refer to diagram 4.15. Before starting, refer to Section 1.1 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, refer to section 4.9.
  • Page 38 4 Replacement of Parts 4.14 Gas Valve SECURING ELECTRICAL SCREW If applicable remove the clock/timer mounting bracket, see CONNECTORS (2) (4+4) diagram 4.29 Remove control box housing, see Section 4.9. Remove the user control switch bracket, see diagram 4.6. Disconnect the ignition unit and 2 electrical connectors. see diagram 4.13.
  • Page 39 4 Replacement of Parts COLOUR CODE GY- GREY W- WHITE OR- ORANGE B- BLUE GAS VALVE V- VIOLET BK- BLACK R-RED BR -BROWN Y- YELLOW G/Y- GREEN/ YELLOW P- PURPLE KEY: MODUREG FAN/APS(C) RESET LOCKOUT NEON 4 5 6 7 8 L N E IGNITION UNIT AIR PRESSURE...
  • Page 40 4 Replacement of Parts 4.19 Thermistor - Heating Release the water pressure and drain the heating circuit of the boiler, refer to Sections 1.3 and 1.6. Disconnect the cables from the thermistor, see diagram 4.19. CONTROL RESET BUTTON Remove the thermistor, complete with its “O” ring. The polarity of the electrical connections is not important.
  • Page 41 4 Replacement of Parts UNION NUT SAFETY VALVE DISCHARGE PIPE FLOW SWITCH LOCKNUT VIEW ON ARROW 'A' UNION UNION FLOW SWITCH FLOW SWITCH FILTER ELECTRICAL UNION CABLES Diagram 4.20 WATER FILTER WATER INLET THROTTLE PIPE ADJUSTER ASSEMBLY THROTTLE UNION ISOLATING VALVE Diagram 4.18 'O' RING Diagram 4.21...
  • Page 42 4 Replacement of Parts 4.25 Pump Release the water pressure and drain the central heating circuit TERMINAL PUMP of the boiler, refer to Section 1.3 and 1.6. COVER SCREW SPINDLE Remove control housing, see Section 4.9. FLOW DIRECTION Disconnect the electrical connectors at the water pressure ARROW microswitch.
  • Page 43 4 Replacement of Parts 4.28 Combustion Chamber Insulation COMBUSTION CHAMBER FRONT Remove the fan, refer to Section 4.1. FRONT PANEL INSULATION Remove the flue collector, secured with two wing nuts and hook bolts, see diagram 4.1. Remove the combustion chamber front panel, secured with four screws, see diagram 4.2.
  • Page 44 4 Replacement of Parts 4.29 Expansion Vessel FLUE AIR DUCT ELBOW Renewal of the expansion vessel requires the boiler to be SECURING removed from the wall. As an alternative, a separate expansion SCREW (2) vessel of the same specification may be connected as close as SECURING possible to the boiler, leaving the original in position, refer to the Installation Instructions.
  • Page 45 4 Replacement of Parts 4.30 Viewing Window 4.32 Air Pressure Switch Remove the viewing window, secured with two screws. When Disconnect the two electrical connectors at the air pressure fitting a new window use the gasket provided, see diagram 1.2. switch, see diagram 4.28.

  • Page 46: 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 47 5 Spare Parts Diagram 5.1 221422A Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 48 Because of our constant endeavour for improvement, details may vary slightly from those shown in these instructions. 221422A Supplied By www.heating spares.co Tel. 0161 620 6677...

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