Glow-worm Betacom 24c Installation And Servicing
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Glow-worm Betacom 24c Installation And Servicing

High efficiency condensing combination boilers
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Installation and Servicing

24c
G.C. No. 47-019-08
30c
G.C. No. 47-019-09
High Efficiency
Condensing Combination
Boilers
Supplied By www.heating spares.co Tel. 0161 620 6677
Betacom
www.glow-worm.co.uk

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  • Page 1: Installation And Servicing

    Betacom Installation and Servicing G.C. No. 47-019-08 G.C. No. 47-019-09 High Efficiency Condensing Combination Boilers www.glow-worm.co.uk Supplied By www.heating spares.co Tel. 0161 620 6677...

  • 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 First Year Guarantee. We recommend you complete and return as soon as possible your guarantee registration card.

  • Page 3: Table Of Contents

    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 the Gas Safety (Installation and Use) Regulations, be handed to the user on completion of the installation.

  • Page 4: Warnings

    This boiler is tested and certificated for safety and perform- ance. It is, therefore, important that no alteration is made to Manual Handling the boiler, without permission, in writing, by Glow-worm. Any alteration not approved by Glow-worm, could invalidate With regards to the “Manual Handling Operations, 1992 the certification, boiler warranty and may also infringe the Regulations”, the appliance exceeds the recommended...

  • Page 5: Statutory Requirements

    Statutory Requirements CE Mark NOTE: For further information, see the current issue of the Building Regulations, approved document L1 ( in the UK) and This boiler meets the requirements of Statutory Instrument, the following current issues of: No. 3083 The Boiler (Efficiency) Regulations, and therefore is 1) Central heating system specification (CheSS) deemed to meet the requirements of Directive 92/42/EEC on the efficiency requirements for new hot water boilers fired with...

  • Page 6: Boiler Design

    (for 15 seconds) and on discharge from the pipe, isolate the boiler electrical supply and again. call your installer or Glow-worm’s own service organisation using the telephone number on the inside front cover of this booklet.

  • Page 7: Servicing, Maintenance And Spare Parts

    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 your installer or Glow-worm’s own service organisation using the telephone number on the inside front cover of this literature.

  • Page 8: Boiler Specification

    Specification Boiler Boiler Design The appliance has a built in frost protection device that These boilers are designed for use as part of a sealed water protects the boiler from freezing. central heating system with fully pumped circulation. The Once the controls are set the boiler operates automatically. pump, expansion vessel and associated safety devices are all fitted within the boiler.

  • Page 9: Boiler Components

    Boiler Components Heating Flow (22mm) D.H.W. Outlet (15mm) Gas Inlet (22mm) Cold Water Inlet (15mm) Heating Return (22mm) 14 - Air Pressure Switch 1 - D.H.W. Sensor 15 - Condensing Unit (Turbo heat exchanger) 2 - Diverter Valve Motor 16 - Overheat Safety thermostat 3 - Diverter Valve 17 - Ignition Electrode 4 - Condensate Trap...

  • Page 10: Boiler Dimensions And Hydraulic Schematic

    2 Boiler Dimensions and Hydraulic Schematic 2.1 Boiler Dimensions and Hydraulic Schematic All dimensions are given in millimetres (except as noted). The general arrangement of the boiler is shown in diagram 2.1 and the hydraulic and gas schematics diagrams, showing the central heating hydraulic circuit and domestic hot water hydraulic circuit in diagram 2.2.

  • Page 11: Boiler Location, Clearances And 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 document IGE/UP/7/1998. If in doubt seek advice from local gas undertaking or Glow-worm. 3.4 Combustible Material The boiler and flue are suitable for installation onto and...

  • Page 12: Flue Options And Terminal Clearances

    4 Flue Options and Terminal Clearances Top horizontal standard flue (Ø60/100) Top horizontal telescopic flue (Ø60/100) Part No. A2043400 - Section 9, page 25 Part No. A2043600 - Section 9, page 21 Plume Management Kit basic set, white, concentric flue (Ø60/100) - Part No.

  • Page 13: Flue Terminal Position

    4 Flue Options and Terminal Clearances 4.1 Flue Options There are various flue options to choose from as illustrated in diagram 4.1. The flue lengths and installation are described in section 9. 4.2 Flue Terminal Position In GB the minimum acceptable siting dimensions for the terminal from obstructions, other terminals and ventilation openings are shown in diagram 4.2.

  • Page 14: Water System - Heating

    5 Water System - Heating 5.1 General The boiler is designed to operate on fully pumped, pressurised sealed systems operating at a maximum of 3bar pressure and maximum design flow temperature of 85°C. 5.2 Safety Valve The safety valve is an integral part of the boiler and it cannot be adjusted.The pipe from the safety discharge valve must not discharge above an entrance, window or any type of public access area.

  • Page 15: Water System - Domestic Hot Water

    5 Water System - Domestic Hot Water 5.10 Water Pressure To obtain the best hot water performance from your boiler it is suggested that the cold water supply to the boiler is the first draw off from the incoming mains supply. NOTE: The boiler will not operate unless there is a minimum ) with a flow rate of 2.5 l/min.

  • Page 16: Installation Preparation

    6 Installation Preparation CHECK IF 230V thermostat plug is COLD WATER required to fit to PCB board. FILTER WALL HANGING BRACKET D.H.W C.H. ISOLATION OUTLET VALVE RETURN COLD WATER ISOLATION VALVE INLET GAS ISOLATION VALVE SAFETY SEALING DISCHARGE WASHERS PIPE CONDENSATE C.H.

  • Page 17: Flue Hole Cutting

    6 Installation Preparation 6.3 Wall Template Take the wall template from the document pack and place in the desired position on the wall, giving due consideration to the required boiler clearances, see section 3, and the flue you are fitting. Mark the position of the flue centre, if fitting a side flue, extend the flue centre line into the corner then 170mm along the adjacent wall, see diagram 6.3.

  • Page 18: Boiler Fixing / Gas / Water / Safety Discharge Connection

    7 Boiler fixing, Gas / Water / Safety Discharge Connections ISOLATION VALVES SHOWN CLOSED Diagram 7.1 7.1 System connection Connect the isolation valves including sealing washers and cold water inlet filter to the boiler ensuring the washers are fitted correctly, see diagram 7.1. Make sure the isolation valves are closed.

  • Page 19: System Pipes And Condensate Connection

    8 System Pipes and Condensate Connections 8.1 Condensate Trap Connection A flexible condensate outlet pipe is supplied and should be used to couple the condensate trap to a 22mm to 25mm O.D. non corrosive plastic pipe (overflow pipe), see diagram 8.1. NOTE: the pipe should have a fall of a least 2.5 44mm/metre away from the boiler.

  • Page 20: Condensate Connections

    8 Condensate Connections Diagram 8.3 Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 21: Telescopic Flue - Length, Preparation And Installation

    The flue restrictor is supplied in the documentation pack, the correct size is supplied for the boiler output:- Betacom 24c - 83mmØ Betacom 30c - 85mmØ The flue restrictor must be fitted in the flue adaptor for, concentric flue installations less than 1 metre and twin flue installations less than 2 metres equivalent length.
  • Page 22 9 Telescopic Flue - Length, Preparation and Installation Diagram 9.2 Diagram 9.3 Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 23 9 Telescopic Flue - Length, Preparation and Installation 9.2 Horizontal Telescopic Flue - A2043600 Refer to diagram 9.2 for kit contents. 9.3 REAR Flue If a wall thickness is between 210mm min. to 420mm max. then the flue can be used without extensions. flue elbow, measure the distance Temporarily secure the...
  • Page 24 9 Telescopic Flue - Length, Preparation and Installation 9.5 Flue Fitting With the air duct seams aligned and the flue set to the required length ‘Y’, mark the securing hole position in the air duct. Drill a 3mm diameter hole at this position, take care not to pierce the inner flue duct.

  • Page 25: Standard Flue - Length, Preparation And Installation

    The maximum permissable horizontal flue length is 5.6 metres 44mm/metre to allow condensate to run back into the boiler for Betacom 24c and 4.6 metres for Betacom 30c, this can be and out via the condensate drain. achieved by use of the accessories, see diagram 9.12.
  • Page 26 9 Standard Flue - Length, Preparation and Installation Diagram 9.11 Diagram 9.12 Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 27 9 Standard Flue - Length, Preparation and Installation 9.7 Standard Horizontal Flue - A2043400 Refer to diagram 9.11 for kit contents. 9.8 REAR Flue flue elbow, measure the distance Temporarily secure the from the outside wall to the butt joint, see diagram 9.13. If the measurement ‘Y’...
  • Page 28 9 Standard Flue - Length, Preparation and Installation 9.10 Flue Fitting Remove the flue elbow. Separate the flue duct from the terminal by twisting to release the terminal catch, then pull out of the retaining seal, refer to diagram 9.16. The flue duct cutting length (L + 11mm.) is shown in diagram 9.16.

  • Page 29: Vertical Flue - Length, Preparation And Installation

    Alternatively use 45º bends to avoid horizontal runs, see (b) in diagram 9.18. The maximum permitted straight flue length is 6,8 metres for Betacom 24C, 5,8 metres for Betacom 30C, for each 90°or 45°x2 bends fitted, the maximum length must be reduced by 1 metre.

  • Page 30: Flue Installation

    9 Vertical - Flue Length, Preparation and Installation 9.12 Flue Installation Refer to diagram 9.20 and secure the flue adapter in position on top of the boiler with four screws supplied, NOTE: The rubber ‘O’ rings of each section should be lubricated prior to assembly.
  • Page 31 9 Vertical Flue - Length, Preparation and Installation 9.15 Completion of Installation With the flue terminal positioned in the roof the length of the final pipe can be determined. If a telescopic length cannot be used, then a standard flue length can be cut to make the correct length.

  • Page 32: Twin Flue - Length, Preparation And Installation

    9 Twin Flue - Length, Preparation and Installation Secure long flue lengths (horizontal & vertical) to walls or ceiling at every joint or on straight flue runs at every joint and every metre flue run. Diagram 9.24 Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 33: Terminal Position

    2x45º bends can replace 1x90º bend if necessary. The maximum permitted combined (air inlet + flue outlet) flue length is 14,3 metres for Betacom 24C, 11,9 metres for maximum flue length must be reduced by 1 metre, see diagram 9.24.

  • Page 34: Boiler Connection

    9 Twin Flue - Length, Preparation and Installation 9.19 Boiler Connection Place the twin flue adaptor onto the outlet of the boiler with the air inlet to the left hand side, see diagram 9.26. Secure the adaptor to the top panel with the screws provided. Care should be taken when inserting the screw through the hole in adaptor top.

  • Page 35: Plume Management Kit

    2 x 45 bends the maximum length of the Plume Management Kit must be reduced by 1m. For more information contact Glow-worm, refer to page 2. The Plume Management Kit is supplied with installation instructions. Refer to BS5546 or BS6798 for advice on disposal of boiler condensate.
  • Page 36 10 Electrical Connection 10.2 System Controls 24V WARNING: UNDER NO CIRCUMSTANCES MUST ANY MAINS VOLTAGE BE APPLIED TO ANY OF THE 24V LOW VOLTAGE TERMINALS ON THE 24V CONNECTION. ROOM THERMOSTAT The 24V low voltage room thermostat terminal block is TERMINAL BLOCK located on the left side of the rear cover of the controls box.
  • Page 37 10 Electrical Connection 10.3 System Controls 230V RETAINING CLIPS If a mains voltage thermostat is to be used. Unclip the two front retaining clips on the controls fascia, see diagram 10.3. Unclip and carefully pull down the control circuit board cover, see diagram 10.4.

  • Page 38: Commissioning

    11 Commissioning PUMP VENT PLUG ISOLATION VALVES SHOWN OPEN Diagram 11.1 IMPORTANT NOTE: In order to maintain the appliances IMPORTANT At the time of commissioning, complete all warranty; after initial filling the heating system must be relevant sections of the Benchmark Checklist located in the thoroughly flushed using a propriety cleanser to remove centre pages of this document.

  • Page 39: Initial Lighting

    11.3 Commissioning Central heating and domestic hot water temperature The Betacom 24c and 30c boilers have been tested and pre- controls: The boiler’s integral control unit monitors and set at the factory and is dispatched with its on board controls adjusts both the boiler’s hydraulic circuit and D.H.W.
  • Page 40 11 Commissioning 11.5 Setting Operational Pressure Minimum setting GAS VALVE AND Remove the sensing tube from the gas valve. MANIFOLD INLET Remove one lead from the modulating gas valve coil, see CONNECTIONS diagram 11.6. Refer to diagram 11.7. Connect a suitable pressure gauge the pressure outlet of the SENSING TUBE gas valve.
  • Page 41 Maximum net heat input in kW Natural gas in (m / h) nominal 25,7 2,72 Betacom 24c Betacom 30c 28,5 3,02 Checking the combustion products While adjusting the burner pressure at maximum and minimum, combustion products can be checked according to the table below:...

  • Page 42: Boiler Adjustments

    OFF POSITION then cause the boiler over-heat thermostat to trip out. Setting the Heating output: The Betacom 24c and 30c boilers are factory set to give maximum CH heating output. The maximum heat output for heating is pre-set on ‘P2’...

  • Page 43: Instruct The User

    11 Commissioning 11.8 Completion GB: It is a requirement that the “Benchmark” Installation, Commissioning and Service Record is completed and left with the user. IE: it is necessary to complete a “Declaration of Conformity” to indicate compliance to I.S.813. An example of this is given in the current edition of I.S.813.
  • Page 44 Fit new injector bar (manifold), new sealing washer and ELECTRODE LEADS tighten, ensuring that the injector size is marked 0.75 mm for LPG (both for Betacom 24c and Betacom 30c) Diagram 11.15 Fit burner and re-assemble. The joint must be checked for Gas Tightness.
  • Page 45 Betacom 30c LPG Dip switch 7 must be in the ON position for LPG and OFF for NG. Dip switch 8 must be in the OFF position for Betacom 24c and ON for Betacom 30c. To set the Minimum Setting:...

  • Page 46: Servicing

    4. 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. 5. 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.
  • Page 47 CO/CO2 ratio is acceptable. Advice can be sought from the Glow-worm Betacom 24c 8,60 ± 5 3,85 ± 5 9,60 ± 5 4,40 ± 5 <...
  • Page 48 12 Servicing RETAINING LUGS SECURING SCREWS (6 OFF) INNER CASING PANEL VIEWING WINDOW VIEWING WINDOW COMBUSTION CHAMBER SECURING COVER SCREWS Diagram 12.2 Diagram 12.4 ELECTRICAL PRESSURE SWITCH CONNECTIONS CONNECTION TUBE EARTH LEAD SECURING SCREW FAN HOOD PRESSURE SWITCH CONNECTION TUBE Diagram 12.5 SIDE PANELS SECURING...

  • Page 49: Burner Removal

    12 Servicing 12.2 Fan removal SPARK GAP 4mm Disconnect the electrical connections and air pressure switch connection tubes from the fan, remove the fan securing screw and withdraw fan from fan hood with its 56º bend, see diagram 12.5. 12.3 Burner removal BURNER Remove the burner assembly from the combustion chamber as follows:...

  • Page 50: Fault Finding

    13 Fault finding HALL EFFECT SENSOR AIR PRESSURE GAS CONTROL SWITCH VALVE PUMP LIMIT IGNITION THERMOSTAT ELECTRODES WATER PRESSURE SWITCH DOMESTIC HOT WATER FLAME SENSOR (IONISATION) ELECTRODE THREE WAY CENTRAL HEATING NTC VALVE SENSOR 230V ROOM OVERHEAT SAFETY CHASSIS THERMOSTAT THERMOST AT EARTH CONNECTION...
  • Page 51 13 Fault finding 13.1 Preliminary fault finding The following checks should be performed before proceeding onto specific diagnostics: Check the external electrical supply to the boiler is on and a 230V supply of 230V is present at the ‘L’ and ‘N’ terminals. TEST Check the electrical installation and boiler, carry out tests for POSITION...
  • Page 52 13 Fault finding 13.2 Fault finding chart 1. Check electrical supply central heating sensor and frost protection. Diagram 13.4 Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 53 13 Fault finding 13.2 Fault finding chart 2. Check domestic hot water operation. Diagram 13.5 13.3 Fault finding chart 3. Check central heating operation. Ensure DHW taps are closed Check and if Is overheat necessary reset or thermostat LED flashing? replace Put CH temperature Is 230 V AC...
  • Page 54 13 Fault finding 13.4 Fault finding chart 4. Check domestic hot water operation. Diagram 13.7 13.5 Fault finding chart 5. Check domestic hot water and central heating modulation Diagram 13.8 Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 55 13 Fault finding 13.6 Fault finding chart 6. Check ignition system. Diagram 13.9 Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 56: Replacement Of Parts

    14 Replacement of parts 14.1 General Replacement of parts must be carried out by a competent person. Before replacing any parts the boiler should be isolated from the mains electric supply and the gas should be turned off at the gas service isolation valve on the boiler. The boiler is cold.

  • Page 57: Air Pressure Switch

    14 Replacement of parts 14.6 Air pressure switch 14.8 Printed circuit board For access, refer to section 14.1. For access, refer to section 14.1. The air pressure switch is located above the expansion Turn off and isolate the electrical supply. vessel, see diagram 14.3.
  • Page 58 14 Replacement of parts 14.10 Pump body SECURING For access, refer to section 14.1. SECURING SCREWS Remove the motor as described in section 14.9. SCREW Remove the low water pressure sensor refer to section 14.11. Remove the secondary heat exchanger as described in section 14.12.

  • Page 59: Primary Heat Exchanger

    14 Replacement of parts 14.11 low water pressure sensor 14.13 Primary Heat Exchanger For access, refer to section 14.1. For access, refer to section 14.1. Drain the boiler circuit, refer to section 14.2. Drain the boiler circuit, refer to section 14.2. Locate the low water pressure sensor at the front right Refer to diagram 14.13.

  • Page 60: Gas Valve

    14 Replacement of parts 14.14 Gas valve For access, refer to section 14.0. GAS VALVE AND Ensure that gas supply to boiler is turned off. MANIFOLD INLET Refer to diagrams 14.14 and 14.15. CONNECTIONS Disconnect the electrical connections to the modulating coil. Remove the screw to disconnect the gas valve electrical plug.
  • Page 61 Check that the gas rate is as stated in the table below: Gas rate Appliance Maximum net heat input in kW Natural gas in (m / h) nominal Betacom 24c 25,7 2,72 28,5 3,02 Betacom 30c Checking the combustion products...

  • Page 62: Expansion Vessel

    14 Replacement of parts 14.15 Expansion vessel OVER HEAT SAFETY For access, refer to section 14.1. THERMOSTAT Drain the boiler circuit, refer to section 14.2. Refer to diagram 14.16. Disconnect the flexible pipe coupling on expansion vessel. Release and remove the nut securing the expansion vessel to the boiler.

  • Page 63: Flow Sensor

    14 Replacement of parts 14.18 R.H. and L.H. Hydroblock 14.21 Three way valve motor For access, refer to section 14.1. For access, refer to section 14.1. Drain the boiler circuit, refer to section 14.2. Refer to diagram 14.20. Refer to diagram 14.12. Ensure that the electric supply to the boiler is switched OFF.

  • Page 64: Spare Parts

    15.1 Spare Parts When ordering spare parts, contact Glow-worm’s own service organisation using the telephone number on the inside front cover of this booklet. 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.

  • Page 65: Spare Parts 15

    15 Spare parts 2, 3 15,16 28, 29 18, 19 20, 21 Diagram 15.17 Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 66: Manual Handling

    16 Manual Handling IMPORTANT. of packaging in a responsible manner. Recommend wear suitable With regards to the Manual Handling Opera- cut resistant gloves with good grip to protect against sharp edges and tions, 1992 Regulations, the following lift operation exceeds the ensure good grip when handling appliance outside packaging.

  • Page 67: Declaration Of Conformity

    17 Declaration of conformity Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 68 Because of our constant endeavour for improvement, details may vary slightly from those shown in these instructions. Glow-worm, Nottingham Road, Belper, Derbyshire. DE56 1JT www.high-efficiency.info Supplied By www.heating spares.co Tel. 0161 620 6677...

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Betacom 30c

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