Glow-worm 30ci Instructions For Use Installation And Servicing
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Glow-worm 30ci Instructions For Use Installation And Servicing

Fanned flue combination boiler; fanned flue system boiler
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Instructions for Use

Installation and Servicing

To b e l e f t w i t h t h e u s e r
30ci
G.C. No. 47-047-20
30si
G.C. No. 41-047-70
35ci
G.C. No. 47-047-28
Hepworth Heating Ltd., Nottingham Road, Belper, Derbyshire. DE56 1JT
Fanned Flue
Combination Boiler
Fanned Flue
System Boiler
Fanned Flue
Combination Boiler
4000123923-2 07/03
30si shown

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  • Page 1: Instructions For Use

    4000123923-2 07/03 Instructions for Use Installation and Servicing To b e l e f t w i t h t h e u s e r 30ci Fanned Flue Combination Boiler G.C. No. 47-047-20 30si Fanned Flue System Boiler G.C. No. 41-047-70...

  • Page 2: Guarantee Registration

    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 3: Table Of Contents

    User Controls and Lighting Analogue Programmer 30ci Only Digital Programmer 30ci Only Technical Data General Information Heating System Design Domestic Hot Water System Design (30ci/35ci) Boiler Schematic 30ci/35ci Boiler Schematic 30si INSTALLATION Boiler Location, Flue and Ventilation Fixing jig INSTRUCTIONS...

  • Page 4: Important Information

    Important Information Gas safety (Installation and use) Regulations All external wiring between the appliance and the electrical supply and earthing requirements shall comply with the current In your interests and that of gas safety, it is the law that ALL gas IEE Regulations.

  • Page 5: Draining And Filling

    Appliance Introduction an adjacent inside wall, that is, the flue system will pass The 30ci and 35ci boilers are wall mounted modulating boilers directly to the rear or to either side to the terminal fitted on the with electronic ignition providing central heating and hot outside wall face.

  • Page 6: Appliance Safety Devices

    Servicing/maintenance should be carried out by a competent person in accordance with the rules in force in the countries of destination. To obtain service, please call the relevant service organisation or Glow-worm Service using the telephone number on the inside front cover of this literature. 4000123923-2...

  • Page 7: User Controls And Lighting

    It is supplied factory set to 38˚C to 73˚C PROGRAMMER Pressure gauge (bar) 30 ci/35 ci Only Domestic hot water temperature selector (30ci Only) and temperature minimum setting approx. 38˚C up to maximum setting 65˚C. ° gauge ( The ECO setting is ideally suited for all the requirements of normal family use (showers, washing up etc.).

  • Page 8: Analogue Programmer 30Ci Only

    Programmer Instructions for Use Analogue Programmer (30ci Only) Digital Programmer Kit. (30ci Only) Part No. A20086. Fitted as standard. Part No. A20087. Not fitted as standard. Setting the time, see diagram 3 KEYPAD DESCRIPTION • Rotate the dial clockwise, by hand, until the indicator arrow See diagram 4 for position of keypads as described below, is pointing to the current time.
  • Page 9 Programmer Instructions for Use NOTE: MULTIPLE ON OR OFF EVENTS MAY BE Programming 24 Hour or 7 Day Schedules PROGRAMMED, SEE EXAMPLE. It may be helpful to write out the programme schedules before BEFORE PROCEEDING WITH SETTING THE TIME AND beginning.
  • Page 10 Programmer Instructions for Use Event Review Troubleshooting To review the programs at any time, press Prog. key. Events PROBLEM: Days are flashing, pressing any key does nothing will appear in the order they were entered with repeated except key turns output ON and OFF. presses of the Prog.

  • Page 11: Technical Data

    1 Technical Data 30ci 30si 35ci Heating Heat input (max) NET Q 32,6 32,6 37,8 BTU/H 111,231 111,231 128,973 Heat input (min) NET Q 13,3 13,3 BTU/H 45,380 45,380 40,944 Heat output (max) NET P 29,6 29,6 34,8 BTU/H 100,995...

  • Page 12: General Information

    1 Technical Data The 30ci, 35ci and 30si are delivered in two separate packages: • The boiler including fixing jig complete with isolating valves and fittings. • The flue system Net lift weight (boiler only) 30ci 37 kg 30si 36 kg...

  • Page 13: Heating System Design

    An additional expansion vessel can be fitted to the system if required, see • The 30ci/35ci and 30si are for use with sealed central heating diagram 3.2. systems. Guidance on vessel sizing is also given in a current issue of a •...
  • Page 14 Model Minimum flow rate least 1.5 metres away from the appliance, see diagram 3.1. 30ci 21.26 litres per minute 3.2 Filling the system 30ci/35ci 30si 21.26 litres per minute 35ci 24,98 litres per minute A filling device is fitted to the boiler to initially fill the system and This is equal to 20°C differential at maximum...

  • Page 15: Domestic Hot Water System Design (30Ci/35Ci)

    4 Domestic Hot Water System Design. 30ci Only General - All domestic hot water circuits, connections, fittings • The flow restrictor, supplied in the document envelope, must must be in accordance with the relevant standards and water be fitted as diagram 7.1, limiting the flow through the boiler to supply regulations.

  • Page 16: Boiler Schematic 30Ci/35Ci

    5 Boiler Schematic 30ci/35ci 1 - Fan. 2 - Air pressure switch. 3 - Heat exchanger. 4 - Overheat thermostat. 5 - Combustion chamber. 6 - Expansion vessel. 7 - Ignition electrode. 8 - Burner. 9 - Flame sense electrode.

  • Page 17: Boiler Location, Flue And Ventilation

    6 Boiler Location, Flue and Ventilation 6.1 Boiler Location The recommended clearances are shown in diagram 6.1. Note: The boiler must be mounted on a flat wall which is sufficiently robust to take its weight when full. If in doubt, expert advice should be obtained.

  • Page 18: Fixing Jig

    The fixing jig is supplied within the boiler pack and is made up as follows : A - Heating flow isolating valve. B - 30ci Only Domestic hot water outlet. C - Gas service cock. D - 30ci Only Cold water inlet isolating valve. E - Heating return isolating valve. Wall template Documentation Pack, inclusive...

  • Page 19: Boiler Preparation And System Connections

    • IMPORTANT NOTE: Ensure that the fixing jig is fitted to a flat and true wall area for correct alignment with the boiler. If this Diagram 8.1 30ci/35ci shown cannot be achieved it is acceptable to pack out the fixing jig to obtain the correct alignment.

  • Page 20: Boiler Installation

    • Ensure the plastic plugs are removed from water and gas pipes. NOTE: There will be some spillage of water. • (30ci Only) Fit the cold water inlet restrictor (supplied in the document envelope) into cold water inlet isolating valve, see diagram 7.1.
  • Page 21 10 Horizontal Telescopic Rear Flue Installation 10.1 Horizontal Telescopic Rear flue - kit No. A2018000, refer to diagram 10.1 Suitable for installations that require a flue length "L" 193 - 510mm. For flue lengths less than 328mm the duct will need to be cut, see diagram 10.2.
  • Page 22 10.6 Restrictor, refer to diagram 10.8 SUPPLY For flue systems less than 0.5m long, fit the flue restrictor LEADS supplied in document envelope into the fan outlet (30ci/30si only), see diagram 10.8. Diagram 10.5 10.7 Fan Securing, refer to diagram 10.5 Ensure fan outlet seal is in position, see diagram 10.5, then fit...

  • Page 23: Horizontal Telescopic Top Flue Installation

    11 Horizontal Telescopic Top Flue Installation The Horizontal Telescopic Top Flue, Kit No. A2004500 SIDE FLUE Suitable for installations that require a flue length "L" from 430 minimum to 660 maximum. If longer flueing is required extensions and bends are available, see note below. If the flue length, see diagram 11.2.

  • Page 24: Restrictor

    11 Horizontal Telescopic Top Flue Installation 11.3 Installation of telescopic flue assembly STEP 1. • For flue lengths less than 0.5m fit the restrictor (supplied in the document envelope) inside the fan outlet (30ci/30si only), FLUE LENGTH Outside see diagram 11.3.

  • Page 25: Horizontal Top Flue Installation

    12 Horizontal Top Flue Installation 12a.1 The Horizontal Top flue - kit 86285H SIDE FLUE Suitable for installations that require a max. flue length "L" of 740mm. If a shorter flue length is required, the flue can be cut to a min. length"L"...

  • Page 26: Air Duct Pipe

    For each 90° flue elbow used, (or two 45° elbows) the maximum permissible length (L) must be reduced by 1 metre. Warning : The flue restrictor (a) must be fitted inside the fan outlet of 30ci and 30si for flue lenghts less than 0,5 m.

  • Page 27: Electrical Connection

    13 Electrical Connection 13.1 Mains Cable WARNING: This appliance must be earthed. This appliance must be wired in accordance with these instructions. Any fault Important: If a replacement supply cable is required it must be arising from incorrect wiring cannot be put right under the purchased.
  • Page 28 13 Electrical Connection 13.3 Mains Voltage External Controls WARNING: UNDER NO CIRCUMSTANCES MUST ANY MAINS VOLTAGE BE APPLIED TO ANY OF THE TERMINALS ON THE VOLTAGE FREE HEATING CONTROLS CONNECTION STRAIN TERMINAL. RELIEF When mains voltage external controls are used, remove the MAINS VOLTAGE HEATING CONTROLS CONNECTION PLUG from the fittings pack and install on the control interface PCB as follows.

  • Page 29: Commissioning

    3. • Undo cap on automatic air vent on top of pump • Turn the switch ON ( I ) • 30ci Only Open the tap on the filling device and leave undone. • Fill the system until the pressure indicated on the display is 1 bar.
  • Page 30 The central heating output is factory preset to approximately : see diagram 13.3. The potentiometer P3, is shown in diagram 12.2,to adjust to - 15 kW for 30ci/30si. the required heating output, insert a small flat edge screw - 20 kW 35ci.
  • Page 31 1 bar is indicated when system is COLD. of the heating system being out of use during frost or freezing conditions. 30ci Only Flush the domestic hot water system by opening Advise the user that the permanent mains electrical supply the hot water taps for several minutes.

  • Page 32: Changing Gas Type

    1. in section 3 (turn clockwise 'A' to close the valve). Diagram 16.1 30ci/35ci shown 4000123923-2...

  • Page 33: Routine Cleaning And Inspection

    Switch on the electrical supply and gas supply, then operate the • Isolate boiler from the gas and electrical supplies. boiler. • (30ci Only) Drain the Domestic hot water circuit, refer to diagram 17.2. To Drain the Domestic hot water circuit (30ci Only) BOILER DRAIN VALVE •...
  • Page 34 • Left hand side panel only disconnect the control panel retaining strap at the control panel. • Unhook each panel from the front retaining tabs. • Pull each panel forward from the rear retaining tabs to remove. Diagram 17.3 30ci shown Diagram 17.4 4000123923-2...

  • Page 35: Servicing

    Diagram 17.5 DO NOT USE ANY TOOL LIKELY TO DAMAGE PAINTED FINISH OF HEAT EXCHANGER. 3.5mm 17.12 Domestic water inlet filter 30ci Only, refer to diagram 17.10 3.5mm If the water flow rate through the appliance has reduced it may be necessary to clean or replace the domestic water inlet filter.

  • Page 36: Screws

    FLUE HOOD Diagram 17.7 HEAT EXCHANGER Diagram 17.9 FAN RETAINING EARTH BOLTS LEAD CLIP DOMESTIC WATER INLET FILTER HOUSING POWER SUPPLY LEADS FILTER Diagram 17.8 30ci/30si shown 30ci Only Diagram 17.10 FLAT FILTER RETAINING CLIP 30ci shown Diagram 17.11 4000123923-2...

  • Page 37: Fault Finding

    RESET BUTTON 30ci/ shown Diagram 18.1 DISPLAY FAULT '01' and 'F' and 'flashing red LED'...
  • Page 38 No display on control panel • 230V supply • PCB fuse • Connection between PCBs No domestic hot water (30ci Only) • Loose connections on control board (PCB), No central heating • Connections on air pressure switch (electrical or tubes)
  • Page 39 Connect 1 and 2 on J10, Faulty main PCB. does boiler fire in central heating? Faulty 230V controls board. 30ci Only FAULT: NO HOT WATER, BUT THE HEATING IS WORKING Insufficient water pressure. Is the water pressure greater The appliance will not operate.
  • Page 40 18 Fault Finding F1 FAULT DISPLAYED FAULT: THE BURNER LIGHTS BUT THEN GOES OUT. THERE IS NO FLAME DETECTED. The flame is not spreading across the whole burner and is not reaching • Check that the gas taps are fully open the sensing electrode.
  • Page 41 Turn up settings - Check set point P3. (Refer to Commissioning) - Check the adjustment of the by-pass internal and external (If fitted). - 30ci/35ci Only Check the 3-way valve is not passing into the domestic hot water heat exchanger. 4000123923-2...
  • Page 42 18 Fault Finding 30ci Only FAULT: THE WATER AT THE TAPS IS LUKE-WARM. Is the temperature higher if you reduce Check the 3-way valve is not passing the flow through the taps? into the radiators. (The radiators should stay cold in Summer setting) Check that the flow restrictor on the cold water inlet is fitted.

  • Page 43: Wiring Diagram 30Ci

    19 Wiring Diagram 30ci AIR PRESSURE SWITCH IGNITION PLUG ELECTRODES IGNITOR UNIT SENSE ELECTRODE PUMP CONTROL OVERHEAT VALVE THERMOSTAT CHASSIS THERMISTOR EARTH WATER PRESSURE SENSOR THREE-WAY VALVE MAINS VOLTAGE HEATING CONTROLS PLUG 230V SWITCHED LIVE FROM OPTIONAL FROST STAT. 230V SWITCHED LIVE FROM HEATING CONTROLS.

  • Page 44: Wiring Diagram 30Si 19A

    19a Wiring Diagram 30si AIR PRESSURE SWITCH IGNITION PLUG ELECTRODES SENSE ELECTRODE IGNITOR UNIT CONTROL VALVE OVERHEAT PUMP CH THERMOSTAT CHASSIS THERMISTOR EARTH WATER PRESSURE SENSOR MAINS VOLTAGE HEATING CONTROLS PLUG 230V SWITCHED LIVE FROM OPTIONAL FROST STAT. 230V SWITCHED LIVE FROM HEATING CONTROLS. REMOVE VOLTAGE FREE LINK CONTROLS VOLTAGE FREE...

  • Page 45: Wiring Diagram 35Ci

    19b Wiring Diagram 35ci AIR PRESSURE SWITCH IGNITION PLUG ELECTRODES IGNITOR UNIT SENSE ELECTRODE SENSOR PUMP CONTROL OVERHEAT VALVE THERMOSTAT CHASSIS THERMISTOR EARTH WATER PRESSURE SENSOR THREE-WAY VALVE MAINS VOLTAGE HEATING CONTROLS PLUG 230V SWITCHED LIVE FROM OPTIONAL FROST STAT. 230V SWITCHED LIVE FROM HEATING CONTROLS.

  • Page 46: Replacement Of Parts

    • 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 (f). (30ci Only) To Drain the Domestic hot water circuit BOILER DRAIN VALVE • Close boiler isolating valve (d).
  • Page 47 COLD WATER INLET UNION NUT RESTRICTOR 20.4 (30ci Only) Domestic water inlet filter If the water flow rate through the appliance has reduced it may be necessary to clean or replace the water inlet filter. Before starting refer to the front of Section 20 Important information.
  • Page 48 20 Replacement of Parts 20.9 Burner injector assembly, refer to diagram 20.6. BURNER INJECTOR 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 49 20 Replacement of Parts 20.13 Heat exchanger, refer to diagram 20.7. information. Before starting refer to the front of Section 20 Important • Remove the front panel, refer to Section 17.3. information. • Unclip control panel user interface and hinge forward . Do •...
  • Page 50 20 Replacement of Parts CONTROL BOARD PCB (CONTROL BOARD) COVER 30ci shown Diagram 20.9 230V CONTROLS CONTROL PANEL PROGRAMMER BOARD USER INTERFACE BOARD MAINS SWITCH Diagram 20.10 30ci shown 4000123923-2...
  • Page 51 • Disconnect pump cable from pump (avoid straining cables). • Connect electrical connection to replacement pump head. • Fit replacement pump head. 20.21 (30ci Only) Filling system tap, refer to diagram 20.12. Before starting refer to the front of Section 20 Important information.
  • Page 52 20.1. Pull out slotted metal clip securing boiler drain valve into housing, remove boiler drain valve. Diagram 20.13 20.24 (30ci Only) Water flow sensor, refer to diagram 20.14. Before starting refer to the front of Section 20 Important information.
  • Page 53 • Remove the igniter unit, refer to Section 20.33. Pull out slotted metal clip, ease out bypass valve from bypass valve housing. 30ci shown Diagram 20.16 20.27 Automatic air vent, refer to diagram 20.16. Before starting refer to the front of Section 20 Important information.
  • Page 54 VALVE • Undo discharge pipe union nut. • Pull out slotted metal clip from valve body and remove valve. 20.31 (30ci Only) Three-way valve head, refer to diagram 20.20. Before starting refer to the front of Section 20 Important information.
  • Page 55 • Pull upwards to release and remove the ignition unit from the retaining slot. Diagram 20.22 20.34 (30ci Only) Domestic hot water plate to plate heat exchanger Before starting refer to the front of Section 20 Important DOMESTIC HOT WATER information.
  • Page 56 • Remove sealed chamber cover, refer to Section 17.4. • Remove the combustion chamber cover, refer to Section 17.5. 30ci shown • Remove the fan, refer to Section 17.10. • Remove air pressure switch sensing tube from the side of the flue hood, see diagram 17.9.
  • Page 57 20 Replacement of Parts • Remove the front panel, refer to Section 17.3. • Remove the sealed chamber cover, refer to Section 17.5. • Remove the old seal, thoroughly clean the casing. Fit the new seal, it is supplied to the correct length. Note: Ensure the seal is fitted correctly giving an air tight seal.

  • Page 58: Spare Parts

    Part No. G.C. No. Central heating thermistor 801935 E91-959 801860 E92-062 Air pressure switch 801862 E92-063 30ci Only Domestic water flow sensor 801910 E84-014 Printed circuit board - Main 801915 E91-904 Pump head (50W) 801857 E92-064 System water pressure sensor...
  • Page 59 4000123923-2...
  • Page 60 Because of our constant endeavour for improvement details may vary slightly from those in the instructions. 4000123923-2...

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30si35ci

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