Glow-worm 24ci Instructions For Use Installation And Servicing
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Glow-worm 24ci Instructions For Use Installation And Servicing

Fanned flue combination boiler, fanned flue system boiler
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4000123942-2 07/03

Instructions for Use

Installation and Servicing

T o b e l e f t w i t h t h e u s e r
24ci
G.C. No. 47-047-19
Fanned Flue
Combination Boiler
18si
G.C. No. 41-047-61
Fanned Flue
System Boiler
18si shown
Hepworth Heating Ltd., Nottingham Road, Belper, Derbyshire. DE56 1JT

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  • Page 1: Instructions For Use

    4000123942-2 07/03 Instructions for Use Installation and Servicing T o b e l e f t w i t h t h e u s e r 24ci G.C. No. 47-047-19 Fanned Flue Combination Boiler 18si G.C. No. 41-047-61 Fanned Flue...

  • 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 24ci only Digital Programmer Kit 24ci only Technical Data General Information Heating System Design Domestic Hot Water System Design 24ci only Boiler Schematic 24ci Boiler Schematic 18si Boiler Location, flue and ventilation INSTALLATION Fixing Jig...

  • Page 4: Important Information

    Important Information Gas safety (Installation and use) Regulations Electrical Supply WARNING: This boiler must be earthed. In your interests and that of gas safety, it is the law that ALL gas appliances are installed and serviced by a competent person All system components shall be of an approved type and shall in accordance with the regulations.

  • Page 5: Draining And Filling

    Glow-worm Service using the telephone number on the inside front cover of this literature. Appliance Introduction The 24ci and 18si boilers are wall mounted modulating boilers The central heating and domestic hot water (24ci only) with electronic ignition providing central heating and hot water.

  • 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. 4000123942-2...

  • Page 7: User Controls And Lighting

    It is supplied factory set to 38°C to 73°C PROGRAMMER Pressure gauge (bar) 24 ci Only Domestic hot water temperature selector (24ci 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 24Ci Only

    Programmer Instructions for Use Analogue Programmer (24 ci only) Digital Programmer Kit. 24ci Only Part No. A20087. Not fitted as standard. Part No. A20086. Fitted as standard. KEYPAD DESCRIPTION Setting the time, see diagram 3 See diagram 4 for position of keypads as described below, •...

  • Page 9: Programmer Instructions For Use

    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 24ci 18si Heating Heating Heat input (max) NET Q 26,94 kW Heat input (max) NET Q 20,7 kW 91,200 BTU/H 70,628 BTU/H Heat input (min) NET Q 9,91 kW Heat input (min) NET Q 11 kW 33,820 BTU/H...

  • Page 12: General Information

    1 Technical Data The 24ci and 18si 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) 24ci 34 kg 18si 32 kg...

  • Page 13: Heating System Design

    Regulations must be followed. commissioning stage if the static head differs. An additional expansion vessel can be fitted to the system if required, see • The 24ci and 18si 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 TABLE 1. FLOW RATE at least 1.5 metres away from the appliance, see diagram 3.2. Model Minimum flow rate 3.2 Filling the system 24ci. 24ci 16.94 litres per minute • An integral filling device is fitted to the boiler to initially fill the...

  • Page 15: Domestic Hot Water System Design 24Ci Only

    4 Domestic Hot Water System Design. 24ci 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 24Ci

    5 Boiler Schematic 24ci 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 - 24ci only Domestic hot water outlet. C - Gas service cock. D - 24ci only Cold water inlet isolating valve. E - Heating return isolating valve. Wall template Documentation Pack, inclusive...

  • Page 19: Piping System Installation

    • Mark the securing position holes. • Check that the fixing jig is level. Diagram 8.1 24ci shown • Drill, plug and secure the jig to the wall, using suitable screws (not supplied) for the wall type and capable of supporting the total weight of the appliance.

  • Page 20: Boiler Installation

    NOTE: There will be some spillage of water. WARNING: When installing or servicing this boiler, care • (24ci Only) Fit the cold water inlet restrictor (supplied in the should be taken when handling the edges of sheet metal parts document envelope) into cold water inlet isolating valve, see to avoid the possibility of personal injury.

  • Page 21: Horizontal Telescopic Top Flue Installation

    10 Horizontal Telescopic Top Flue Installation The Horizontal Telescopic Top Flue, Kit No. A2004500 Max. Flue length 660mm Min. Flue length 425mm 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.
  • Page 22 10 Horizontal Telescopic Top Flue Installation 10.3 Installation of telescopic flue assembly STEP 1. • For flue lengths up to 0.5m fit the restrictor (supplied in the document envelope) inside the fan outlet, see diagram 10.3. FLUE LENGTH Outside • Remove the elbow (D) and the telescopic flue assembly (A) wall face from the flue kit.

  • Page 23: Horizontal Top Flue Installation

    10a Horizontal Top Flue Installation 10a.1 The Horizontal Top flue - kit 86285H Max. Flue length 660mm Is suitable for installations that require a max. flue length "L" of Min. Flue length 425mm 740mm. If a shorter flue length is required, the flue can be cut to a min. length"L"...
  • Page 24 10a Horizontal Top Flue Installation 10a.4 Installation of horizontal top flue Outside Flue assembly wall face centre line Important: If the flue has been cut, ensure that there are no burrs that could damage the ‘O’ ring. • For flue systems less than 0,5 m long, fit the flue restrictor (a) into the fan outlet, see diagram 10a.4.

  • Page 25: Electrical Connection

    11 Electrical Connection 11.1 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 26 11 Electrical Connection 11.3 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 STRAIN CONNECTION 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 27: Commissioning

    3. • Undo cap on automatic air vent on top of • Turn the switch ON ( I ) • 24ci Only Open the tap on the filling device pump and leave undone. • Fill the system until the pressure indicated on the display is 1 bar.
  • Page 28 12 Commissioning 5. • Bleed each radiator to remove air, ensure all • Leave cap open on automatic air vent. bleed screws are re-tightened. • If necessary repressurise the system, refer to procedure 4 8. • Open various hot water taps to bleed system 7.

  • Page 29: Changing Gas Type

    COLD. conditions. 24ci Only Flush the domestic hot water system by opening the Advise the user that the permanent mains electrical supply hot water taps for several minutes.

  • Page 30: Routine Cleaning And Inspection

    Connect the analyser tube onto sampling point. • Isolate boiler from the gas and electrical supplies. Refer to the combustion product values in Section 1 Technical • (24ci Only) Drain the Domestic hot water circuit, refer to Data. diagram 15.2.
  • Page 31 Section, 18.8. 15.10 Fan, refer to diagram 15.8 • Disconnect power supply leads and earth lead from fan. • Unscrew and remove the two fan retaining bolts. • Ease the fan down and forwards to remove. 24ci shown Diagram 15.4 4000123942-2...
  • Page 32 15 Routine Cleaning and Inspection 15.11 Heat exchanger, refer to diagram 15.9 • Remove air pressure switch sensing tube from the side of the flue hood. • Unscrew and remove the two retaining screws from front of each side panel. •...
  • Page 33 15 Routine Cleaning and Inspection 15.12 (24ci Only) Domestic water inlet filter, CLIP DOMESTIC WATER refer to diagram 15.10 INLET FILTER If the water flow rate through the appliance has reduced it may HOUSING be necessary to clean or replace the domestic water inlet filter.

  • Page 34: Fault Finding

    16 Fault Finding Before trying to operate the boiler make sure that : Overheat thermostat reset button • All gas supply cocks are open and that the gas supply has Refer to Section 18.10 to locate the overheat thermostat been purged of air. reset button.
  • Page 35 No display on control panel • 230V supply • PCB fuse • Connection between PCBs No domestic hot water 24ci Only) • Loose connections on control board (PCB), No central heating • Connections on air pressure switch (electrical or tubes)
  • Page 36 1 and 2 on J10, a lt does boiler fire in central heating? a lt 230V controls board 24ci ONLY FAULT: NO HOT WATER, BUT THE HEATING IS WORKING the old water inlet filter Is the water flow rate greater for dirt.
  • Page 37 16 Fault Finding F1 FAULT DISPLAYED FAULT: THE BURNER LIGHTS BUT THEN GOES OUT. THERE IS NO FLAME DETECTED. he a e s t sprea g acr ss the h e r er a t reach g Check that the gas taps are the se s g e ectr e s the gas Check the gas press re...
  • Page 38 16 Fault Finding F1 FAULT DISPLAYED FAULT: THE BURNER DOES NOT LIGHT AT ALL, BUT THERE IS AN IGNITION SPARK. Are the gas taps on? rn on the gas taps s there at the gas ontro a e? r ng or test ng see o ponent test ng ata the pro e pers sts hange the...
  • Page 39 16 Fault Finding 24ci ONLY FAULT: THE WATER AT THE TAPS IS LUKE-WARM. s the te perature hi her if ou reduce Check the al e is not passin the flow throu h the taps into the radiators. he radiators should...

  • Page 40: Wiring Diagram 24Ci

    17 Wiring Diagram 24ci 4000123942-2...

  • Page 41: Wiring Diagram 18Si

    17a Wiring Diagram 18si 4000123942-2...

  • Page 42: 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). To Drain the Domestic hot water circuit (24ci Only) • Close boiler isolating valve (d). BOILER DRAIN VALVE •...
  • Page 43 15.7. 15.13. • Remove burner from boiler, refer to Section 15.9. 18.6 ( 24ci Only) Cold water inlet restrictor 18.8 Burner injectors, refer to diagram 18.5. Before starting refer to the front of Section 18 Important Before starting refer to the front of Section 18 Important information.
  • Page 44 18 Replacement of Parts 18.9 Burner injector assembly, refer to diagram BURNER INJECTOR 18.6. Before starting refer to the front of Section 18 Important information. • Remove the front panel, refer to Section 15.3. • Lower the control panel, refer to Section 15.4. •...
  • Page 45 • Remove the heat exchanger, refer to Section 18.13. • Pull out side insulation panels from combustion chamber. • Tilt rear insulation panel forwards and out. • Fit replacement insulation. Diagram 18.8 PCB (CONTROL BOARD) CONTROL BOARD COVER 24ci shown Diagram 18.9 4000123942-2...
  • Page 46 Section 15.6. • Remove the 230V controls board. • Undo four head fixing screws and remove pump head. 18.19 (24ci Only) Analogue programmer, refer • Gain access to the pump electrical connection box and to diagram 18.10 remove cover.
  • Page 47 18 Replacement of Parts 18.21 (24ci Only) Filling system tap, refer to REDUCED PRESSURE diagram 18.12. ZONE VALVE (RPZ) Before starting refer to the front of Section 18 Important information. • Remove the front panel, refer to Section 15.3. • Lower the control panel, refer to Section 15.4.
  • Page 48 • Remove the front panel, refer to Section 15.3. • Lower the control panel, refer to Section 15.4. Diagram 18.15 24ci shown Drain down the boiler, refer to relevant part of Section 18.1. • Remove the ignition unit, refer to Section 18.33.
  • Page 49 • Drain down the boiler, refer to relevant part of section 18.1 • Undo discharge pipe union nut. • Pull out slotted metal clip from valve body and remove valve. PRESSURE 18.31 (24ci Only) Three-way valve head, refer RELIEF to diagram 18.20. VALVE Before starting refer to the front of Section 18 Important information.
  • Page 50 • Remove ignition unit securing screw. • Pull upwards to release and remove the ignition unit from the retaining slot. 18.34 (24ci Only) Domestic hot water plate to plate heat exchanger Before starting refer to the front of Section 18 Important information.
  • Page 51 • Remove the right hand side panel, refer to Section 15.6. • From the rear of the boiler, unclip wiring harness retaining wire. Diagram 18.24 24ci shown • Undo pipe coupling on expansion vessel. • Unscrew and remove expansion vessel bracket retaining screw.

  • Page 52: Spare Parts

    Part No. G.C. No. Central heating thermistor 801935 E91-959 801920 E92-062 Air pressure switch 801921 E91-953 24ci only Domestic water flow sensor 801910 E84-014 Printed circuit board - Main 801915 E91-904 Pump head 801896 System water pressure sensor 801911 E83-997...

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18si47-047-1941-047-61

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