Glow-worm 30ci plus Instructions For Use Manual
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Glow-worm 30ci plus Instructions For Use Manual

Fanned flue combination boiler
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4000123944-2 07/03

Instructions for Use

Installation and Servicing

To be left with the user
30ci plus
G.C. No. 47-047-22
Fanned Flue Combination Boiler
Hepworth Heating Ltd., Nottingham Road, Belper, Derbyshire. DE56 1JT

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  • Page 1: Instructions For Use

    4000123944-2 07/03 Instructions for Use Installation and Servicing To be left with the user 30ci plus G.C. No. 47-047-22 Fanned Flue Combination Boiler Hepworth Heating Ltd., Nottingham Road, Belper, Derbyshire. DE56 1JT...

  • 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

    Contents CONTENTS DESCRIPTION SECTION PAGE No. Important Information Draining and Filling INSTRUCTION Appliance Introduction Appliance Safety Devices FOR USE Maintenance and Servicing Controls and Lighting Programmer instructions for use Technical Data General Information Heating System Design Domestic Hot Water System Design Boiler Schematic Boiler Location, Flue and Ventilation Fixing Jig...

  • 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

    Diagram 1 Appliance Introduction The 30ci plus boiler is a wall mounted modulating combination This boiler may be installed in any room, although particular boiler with electronic ignition providing central heating and attention is drawn to the installation of a boiler in a room instantaneous hot water.

  • Page 6: Appliance Safety Devices

    The boiler casing can be cleaned with a damp cloth, followed by a dry cloth to polish. If a part is required contact Glow-worm Service using the telephone number on the inside front cover of this booklet. Do not use abrasive or solvent cleaners.

  • Page 7: Controls And Lighting

    Controls and lighting Central heating adjustment Domestic hot water The temperature of the water in the central heating circuit can The temperature can be adjusted from approx. 38°C up to be set between, approx. 38 C and 87 65°C. It is supplied, factory set to 38 C - 73 Timed central heating and instantaneous domestic hot water...
  • Page 8 • Press - or + to set a temperature between 38°c to 87°c. fault continues call your Installation/Servicing company or Glow-worm Service using the telephone number on the • The display will default to normal after 5 seconds if no inside front cover of this literature.

  • Page 9: Programmer Instructions For Use

    Programmer instructions for use Setting the time. press "+" and and the will be Make sure there is an electrical supply to the boiler and the displayed along with 0 to 24 hour ON / OFF settings and 1 to 7 boiler is switched ON ( I ).

  • Page 10: Technical Data

    12,1 litres/min. Threshold flow rate 1,7 litres/min. Maximum supply pressure 10 bar Minimum supply pressure 0,5 bar The 30ci plus is delivered in two separate Combustion packages: Products outlet diameter 60 mm Fresh air inlet diameter 100 mm • The boiler including fixing jig complete with...

  • Page 11: General Information

    3 Heating System Design • The 30ci plus is for use with sealed central heating systems. • The total volume of water permitted for the heating system depends, amongst other things, on the static head in the cold •...

  • Page 12: Domestic Hot Water System Design

    (if required) TABLE 1. FLOW RATE Model Minimum flow rate 30ci plus 21.26 litres per minute This is equal to 20°C differential at maximum heat input • A bypass is not required on the central heating circuit unless the system controls could allow the boiler to operate when Bypass there is no flow.

  • Page 13: Boiler Schematic

    5 Boiler Schematic 1 - Fan. 14 - Gas valve. 2 - Air pressure switch. 15 - Loss of water sensor. 3 - Heat exchanger. 16 - Domestic heat exchanger 4 - Overheat thermostat. 17 - 3 way valve 5 - Combustion chamber. 18 - Domestic water flow sensor 6 - Expansion vessel.

  • Page 14: Boiler Location, Flue And Ventilation

    6 Boiler Location, Flue and Ventilation 6.1 Boiler Location The recommended clearances are shown in diagram 6.1. 25mm 300mm Note: The boiler must be mounted on a flat wall which is above sufficiently robust to take its weight when full. If in doubt, expert 50mm advice should be obtained.
  • Page 15 6 Boiler Location, Flue and Ventilation 6.2 Terminal guard, see diagram 6.3. 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 to be central over the terminal.

  • Page 16: Fixing Jig

    7 Fixing Jig The fixing jig is supplied within the boiler pack and is made up as follows : A - Heating flow isolating valve. B - Domestic hot water outlet. C - Gas service cock. D - Cold water inlet isolating valve. E - Heating return isolating valve.

  • Page 17: Boiler Preparation And System Connections

    8 Boiler Preparation and System Connections 8.1 Cutting the flue hole • Remove the wall template, follow the instructions given on the REAR TOP FLUE wall template. OUTLET • Position the wall template, taking due regard of the minimum clearances for the selected flue application, see diagram 8.1. •...

  • Page 18: Boiler Installation

    9 Boiler Installation 9.1 Sheet metal parts WARNING: When installing or servicing this boiler, care should be taken when handling the edges of sheet metal parts to avoid the possibility of personal injury. 9.2 Installing the boiler IMPORTANT NOTE: The system must be thoroughly flushed using a propriety cleanser from Fernox or Sentinel to eliminate any foreign matter and contamination e.g.
  • Page 19 9 Boiler Installation 9.3 Heating safety valve (3 bar RED) and DOMESTIC SAFETY HEATING SAFETY domestic safety valve (10 bar BLUE) VALVE(10 bar BLUE) VALVE (3 bar RED) discharge, refer to diagrams 9.4. Two short discharge pipes and washers are supplied in the fittings pack, fit these to the heating safety valve 3 bar and the domestic water safety valve 10 bar.

  • Page 20: Horizontal Telescopic Rear Flue Installation

    10 Horizontal Telescopic Rear Flue Installation 10.1 Horizontal Telescopic Rear flue - NOTE: If it is necessary to cut the "flue length", make sure kit No. A2018000, refer to diagram 10.1 that the overlaps are as follows:- air duct = 25mm Suitable for installations that require a flue length "L"...
  • Page 21 10 Horizontal Telescopic Rear Flue Installation FAN RETAINING EARTH TWIST ANTI-CLOCKWISE BOLTS LEAD & LOCK AT 90 POSITION POWER SUPPLY LEADS NOTE: Please check orientation Diagram 10.5 when engaging bayonet spigot Diagram 10.6 10.3 Fan Removal, refer to diagram 10.5 •...

  • Page 22: 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 23 11 Horizontal Telescopic Top Flue Installation 11.3 Installation of telescopic flue assembly STEP 1. • Remove the elbow (D) and the telescopic flue assembly (A) from the flue kit. FLUE LENGTH Outside • Refer to Step 1. diagram 11.3. Fit the telescopic flue assembly wall face (A) into the prepared hole in the wall.

  • Page 24: 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 25 12 Horizontal Top Flue Installation 12a.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 26: Electrical Connection

    13 Electrical Connection WARNING: This appliance must be earthed. This appliance 13.1 Mains Cable 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 terms purchased.
  • Page 27 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 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 MAINS...

  • Page 28: Commissioning

    14 Commissioning Important: The commissioning and first firing of the boiler must Air in pipes only be done by a competant person. Important: A central heating system can not operate correctly unless it is filled with water and air bled from the system. If these Gas installation conditions are not met the system may be noisy.
  • Page 29 14 Commissioning • 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 • Ensure the display indicates a system pressure •...

  • Page 30: Boiler Settings

    14 Commissioning Bypass The boiler has a built-in bypass, see diagram 15.1. The boiler is supplied with the bypass open half a turn. It should not be necessary to adjust the bypass, but if required ensure that under no circumstances does the flow rate fall below the figures specified, refer to Table 1.
  • Page 31 15 Boiler Settings Parameter 3 : Setting the minimum heating temperature This can be set to one of two values : 38°C or 50°C. 38°C Factory setting Parameter 4 : Setting the maximum heating temperature This can be set to one of four values : 50°C, 73°C, 80°C and 87°C.

  • Page 32: Changing Gas Type

    16 Changing Gas Type Press the mode button for about 10 seconds, Use + or - to Should it be necessary to change the gas type, a conversion display code ‘35’, Press the mode button to confirm, The kit with instructions will be required. display idicates line 23 in the data menu, The figure on the left This modification must only be carried out by a suitably is the data, the one on the right is the setting for the data.

  • Page 33: Routine Cleaning And Inspection

    17 Routine Cleaning and Inspection REMEMBER, 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 Hepworth Heating.
  • Page 34 17 Routine Cleaning and Inspection To Drain the Domestic hot water circuit BOILER DRAIN VALVE • Close boiler isolating valve (d). • Turn on one or more hot water taps. To Drain the boiler • Close isolating isolating valves (e) and (a). •...

  • Page 35: Servicing

    17 Routine Cleaning and Inspection 17.7 Combustion chamber cover 17.14 Sealed Chamber Cover - Seal Check • Unscrew and remove the two screws securing combustion Check the condition of the seal, replace as required. chamber cover to combustion chamber, see diagram 17.5. To replace remove the old seal, thoroughly clean the casing •...
  • Page 36 17 Routine Cleaning and Inspection BURNER RETAINING SCREWS BURNER AIR PRESSURE GUIDE SWITCH SENSING TUBE FLUE HOOD Diagram 17.7 HEAT EXCHANGER Diagram 17.9 FAN RETAINING BOLTS CLIP DOMESTIC WATER INLET FILTER EARTH HOUSING LEAD SENSOR PLUG POWER SUPPLY FILTER LEADS Diagram 17.10 Diagram 17.8 RETAINING CLIP...

  • Page 37: Fault Finding

    18 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 20.11 to locate the overheat thermostat been purged of air. reset button.
  • Page 38 18 Fault Finding COMPONENT TESTING DATA COMPONENT NORMAL MEASURE CHECK Gas control valve Under demand during ignition sparks: If 0 Volt: the gas control valve Resistance of coil 116Ω 24V dc for 1 to 2 seconds, then is not faulty. 12Vdc (constant) at the gas control If 24 Volts and then 12 Volts valve electrical connection.
  • Page 39 18 Fault Finding DISPLAY FAULT spark' and 'F' and 'flashing red LED' Ignition fault (lockout) caused by no gas, no detection 'fan' and 'F' and 'flashing red led' Air fault, pressure switch, no power to fan '05' and 'phone' and 'F' and 'flashing red LED' Overheat fault '0 ' and 'phone' and 'F' and 'flashing red LED' entral heating flow...
  • Page 40 18 Fault Finding FAULT: NO HOT WATER, BUT THE HEATING IS WORKING Insu ent water pressure. Is the water pressure greater he app an e w n t perate. than 0.5 bar ? ut wh the pressure s s water n et ter Is the water w rate greater rt.
  • Page 41 18 Fault Finding FAULT: THE BURNER LIGHTS, THEN GOES OUT. The flame is spreading across the With the power turned off, check the whole burner, but not being detected. continuity between the spark electrode CHECK and terminal H24 on the control board CHECK (PCB).
  • Page 42 18 Fault Finding 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 sta cold in u er settin Check that the flow restrictor on the cold water inlet is fitted.

  • Page 43: Wiring Diagram

    19 Wiring Diagram 4000123944-2...

  • Page 44: Replacement Of Parts

    20 Replacement of Parts To Drain the central heating circuit • 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 BOILER DRAIN VALVE •...
  • Page 45 20 Replacement of Parts 20.2 Fan, refer to Section 17.10 Before starting refer to the front of Section 20 Important information. • Remove the front panel, refer to Section 17.3. RETAINING • Remove the sealed chamber cover, refer to Section 17.5. CLIPS AIR PRESSURE •...
  • Page 46 20 Replacement of Parts 20.10 Burner injector assembly, refer to BURNER INJECTOR diagram 20.5 and 20.6. 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 47 20 Replacement of Parts 20.14 Heat exchanger, refer to diagram 20.7. 20.16 Printed circuit board (PCB), refer to diagram 20.9. Before starting refer to the front of Section 20 Important information. Before starting refer to the front of Section 20 Important information.
  • Page 48 20 Replacement of Parts 230V CONTROLS BOARD MAINS CONTROL PANEL SWITCH USER INTERFACE BOARD Diagram 20.10 20.17 User interface board, refer to diagram 20.10. PUMP Before starting refer to the front of Section 20 Important ELECTRICAL information. CONNECTION • Unclip control panel user interface and hinge forward . Do not strain the cables.
  • Page 49 20 Replacement of Parts 20.22 Reduced pressure zone valve (RPZ), REDUCED PRESSURE refer to diagram 20.12. ZONE VALVE (RPZ) 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 50 20 Replacement of Parts 20.26 Bypass valve, refer to diagram 15.1. 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. SYSTEM Drain down the boiler, refer to relevant part of Section 20.1.
  • Page 51 20 Replacement of Parts 20.30 Heating safety valve (3 bar RED), refer to diagram 20.19. Before starting refer to the front of Section 20 Important information. • Remove the front panel, refer to Section 17.3. GAS CONTROL • Lower the control panel, refer to Section 17.4. VALVE •...
  • Page 52 20 Replacement of Parts • Pull upwards to release and remove the ignition unit from the Note: Plate to plate heat exchanger mounting screws are offset retaining slot. to ensure correct fitting. 20.34 Domestic hot water plate to plate heat 20.35 Domestic safety valve (10 bar BLUE), exchanger refer to diagram 20.24.
  • Page 53 20 Replacement of Parts • Undo discharge pipe union nut. • Disconnect the electrical connection plug to the micro accumulator vessel heating element at the control board PCB • Pull out slotted metal clip from valve body and remove valve. connection H4, see diagram 20.9.
  • Page 54 20 Replacement of Parts vessel of the same specification may be connected as close as • Disconnect the boiler pipes at the fixing jig. possible to the boiler, leaving the original in position, refer to the • Disconnect the pressure relief valve discharge pipe. installation instructions.
  • Page 55 20 Replacement of Parts 20.40 Sealed chamber cover seal, refer to diagram 20.29 Before starting refer to the front of Section 20 Important information. SEALED • Remove the front panel, refer to Section 17.3. CHAMBER • Remove the sealed chamber cover, refer to Section 17.5. COVER •...

  • Page 56: Spare Parts

    21 Spare parts When ordering spare parts, quote the part number and description, stating the appliance model number and serial number from the data label. Short parts list Description Part No. G.C. No. 802037 E94-796 Air pressure switch 801862 E92-063 Domestic water flow sensor 801910 E84-014...

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