Glow-worm 30sxi Instructions For Use Installation And Servicing Download

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2000225013B.03.02

This is a Cat I

Appliance

Reference in these instructions to British Standards and Statutory

Regulations/Requirements apply only to the United Kingdom.

For Ireland the rules in force must be used.

T o b e l e f t w i t h t h e u s e r

10081

Instructions for Use

Installation and Servicing

30sxi

High Efficiency

Condensing System Boiler

G.C. No. 41-047-62

Hepworth Heating Ltd.,

Nottingham Road, Belper, Derbyshire. DE56 1JT

General/Sales enquiries:

Tel: (01773) 824141 Fax: (01773) 820569

One Contact Local Service

Customer Services:

Tel: (01773) 828100

Fax: (01773) 828070

Guarantee Registration

The instructions consist of three parts, User, Installation and Servicing Instructions, which includes 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) Regulations, be handed to the user on completion of the installation.

CALL 0208 247 9857

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. In addition this product is guaranteed for 12 months from the date of intallation or

18 months from the date of manufacture, whichever is the shorter, for labour.

The second year of the parts guarantee, from the beginning of the 13th month onwards after installation or

manufacture, is conditional upon the boiler having been serviced by a CORGI registered gas installer, in accordance

with the manufacturer's recommendations. We strongly recommend regular servicing of your gas appliance, but where

the condition is not met, any chargeable spare parts or components issued within the applicable guarantee period still

benefit from a 12 month warranty from the date of issue by the manufacturer.

We recommend you complete and return as soon as possible your guarantee registration return literature, supplied in

the document envelope.

If your guarantee registration return literature is missing you can obtain a copy or record your registration by

telephoning the Heatcall Customer Service number 01773 828100.

Summary of Contents for 30sxi

Page 1: ...nces 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 In addition this product is guaranteed for 12 months from the date of intallation or 18 months from the date of manufacture whichever ...

Page 2: ...ration not approved by Hepworth Heating Ltd could invalidatethecertification boilerwarrantyandmayalsoinfringe the current issue of the statutory requirements CE Mark This boiler meets the requirements of Statutory Instrument No 3083 The Boiler Efficiency Regulations and therefore is deemed to meet the requirements of Directive 92 42 EEC on the efficiency requirements for new hot water boilers fire...

Page 3: ...registered by calling CORGI direct on 01256 372300 Boilers Installed in a Compartment or Cupboard If the boiler is fitted into a compartment or cupboard it does not require any ventilation openings Do not use the compartment or cupboard for storage Protection Against Freezing The boiler has a built in frost protection programme as long as the electricity and gas are left switched on This device op...

Page 4: ... operating User Controls Turn the mains reset switch to the ON position The control light will illuminate green indicating the boiler is lit see diagram 1 Thetemperatureofthecentralheatingwatercanbeadjustedby turning the water temperature control knob to desired setting see diagram 1 A fault is indicated by the control light flashing RED and a flashing fault code on the digital display To reset Tu...

Page 5: ...levant requirements of the current issue of Manufacturer s instructions supplied TheGasSafety InstallationandUse Regulations TheBuilding Regulations The Building Standards Scotland Regulations applicable in Scotland local Water Company Bylaws The HealthandSafetyatWorkAct ControlofSubstancesHazardous toHealth TheElectricityatWorkRegulationsandanyapplicable local regulations Detailed recommendations...

Page 6: ... millimetres except as noted See diagram 1 1 and Tables 1 and 2 The data label is positioned on the inner door refer to diagram 1 2 The Seasonal Efficiency Domestic Boilers UK SEDBUK is 30 sxi Class A ThevalueisusedintheUKGovernment s StandardAssessment Procedure SAP for energy rating of dwellings The test data from which it has been calculated has been certified by B S I 1 5 Electrical Supply The...

Page 7: ...k away see section 9 2 for more details 1 7 Heating System Controls All heating system controls must be low voltage or potential free It is recommended that a programmer and room thermostat control the boiler Thermostatic radiator valves may be installed however they must not be fitted in a room where the room thermostat is located Note For further information see the current issue of the Building...

Page 8: ...esareprovided seediagram 2 1 Additional clearances may be beneficial around the boiler for installation and servicing For flue installations where external access is not practicable consideration should be given for the space required to insert the flue internally which may necessitate clearance larger than those specified in diagram 2 1 2 4 Timber Frame Buildings Iftheboileristobeinstalledinatimb...

Page 9: ...izontal flue is fitted onto the top of the boiler See diagram 3 1 and 3 2 to determine whether a standard flue can be used An elevated flue system can be installed with the addition of extension kits see section below Flue Options When extension pipes are used the flue system must be designed to have a continuous fall to the boiler of at least 2 5o to allow condensate to run out via the drain 3 2 ...

Page 10: ...essel volume depends on the total water systemvolumeandtheinitialsystemdesignpressure Tocheck if an additional expansion vessel is required an accurate calculation of vessel size is given in the current issue of BS5449 and BS7074 Part 1 4 3 Flow Rate The flow rate through the boiler must not be allowed to fall below that given in table 4 The system can be fitted with a lockable balancing valve if ...

Page 11: ...VERFLOW CISTERN COMBINED CHECK VALVE AND VACUUM BREAKER PRESSURE REDUCING VALVE 4 Heating System Diagram 4 1 9168 Diagram 4 2 4 6 Water Treatment For optimum performance after installation the boiler and its associated central heating system should be flushed in accordance with BS7593 1992 using a cleanser such as Sentinel X300 or X400 or Fernox Superfloc For long term corrosion protection after f...

Page 12: ...ononaflatwall givingdueconsideration to boiler clearances see section 2 2 6 3 Flue Hole Cutting The standard horizontal flue is designed with an internal fall of 35mm metre towards the boiler for disposal of condensate If the standard flue length alone is being used then the flue hole ofdiameter105mmcanbecutinthepositionmarkedonthewall template For standard side flues the horizontal flue centre li...

Page 13: ...nsert suitable wall plugs Ifgasand orwaterpipesaretobeplumbedthroughtherearwall directly into the fixing jig holes the holes must be drilled as marked on the wall template prior to fixing of the fixing jig Fix the wall products to the wall using suitable screws Locate the jig plate between the wall brackets and secure with the screws supplied 6 5 Pre Plumbing The fixing jig can now be pre plumbed ...

Page 14: ...from the end of the air duct where the flue duct contains the o ring seal When cutting the flue duct should be cut flush with the air duct at the opposite end to where the flue duct contains the o ring seal The system is made up from a standard horizontal flue kit and accessories The accessories include flue extensions bends 450 and 900 and fixing brackets The maximum permitted straight flue lengt...

Page 15: ...e flue installation Refer to diagram 7 5 Secure the flue adapter in position on top of the boiler with four torque headed screws supplied making sure the nib fits into the locating slot in the boiler casing to ensure correct orientation Fit the flue elbow with the securing collar length 40mm on to the flue adaptor Secure the flue elbow by tightening up the two screws on the securing collar Draw fl...

Page 16: ... to the heating system by fitting the sealing washers into the securing nuts and make good the final connection to the isolating valves on the wall mounting jig see diagram 8 1 Do not subject the isolation valves to heat Make sure the drain points are accessible IMPORTANT WithregardstotheManualHandlingOperations 1992 Regulations the following lift operation exceeds the recommended weight for a one...

Page 17: ...ndensate drain connection is behind the pump at the rear of the boiler see diagram 9 1 21 5mm plastic overflow pipe shouldbeusedtofitintothedrainconnectiononthecondensate siphon and discharge condensate to a drain The drain pipe should have a fall of at least 2 5o away from the boiler Condensateshould ifpossiblebedischargedintothehousehold internal drainage system If this is not practicable discha...

Page 18: ...LTAGE FREE HEATING CONTROLS CONNECTION PLUG WARNING This appliance must be wired in accordance with theseinstructions Anyfaultarisingfromincorrectwiringcannot be put right under the terms of the Glow worm guarantee Important If a replacement supply cable is required it must be purchased Part No S1008600 10 1 Mains Cable Route fitted mains cable through the cable clip as shown in diagram 10 1 10 2 ...

Page 19: ...s cables 2 Test the earth continuity and short circuit of cables 3 Test the polarity of the mains Please ensure the Benchmark logbook is completed and left with the user and the magnetic lighting instructions label is placed on the surface of the boiler casing Diagram 10 4 CONTROL PANEL REAR COVER STRAIN RELIEF EXTERNAL CONTROL CABLE MAINS CABLE SECURING SCREW 2 9808 CABLE EXIT ...

Page 20: ...oiler will have three attempts at ignition Turn the mains reset button OFF then ON and the boiler will restart see diagram 1 in Instructions for Use If the problem persists contact Heatcall Customer Services 01773 828100 Glow worm s own organisation and please quote the name of the appliance this information will be on the front of the appliance After 1st power up the ignition sequence changes Aft...

Page 21: ...user on the use and maintenance of any scale reducer and pass on any relevant instructional documents Advise that to ensure the continued efficient and safe operation of the boiler it is recommended that it is checked and serviced at regular intervals The frequency of servicing will depend upon the installation conditions and usage but in general once a year should be enough Draw attention if appl...

Page 22: ...supply should be turned off at the gas isolation valve see diagram 8 1 All routine servicing requirements can be achieved by the removal of the front panel and inner panel only To remove simply undo the two screws on the underside of the front panel and lift off see diagram 6 3 Undo the two screws on the front of inner panel and lift off see diagram 6 3 Unless stated otherwise any part removed dur...

Page 23: ...iagram 12 3 Remove loose debris from combustion chamber using a soft brush and vacuum cleaner Carefully flush by spraying water any remaining debris through the condensate trap Ensure the water is kept away from electrical components 12 5 Condensate Drain Refer to diagram 12 9 Remove DC fan supply refer to section 14 5 Remove the clips securing the flexible tubes to the siphon adapter by twisting ...

Page 24: ... indicating the maximum fan speed of the appliance 5700 rpm Check the CO2 value which should be 8 8 0 2 Note that with the inner case front panel fitted the combustion readings will increase slightly to 9 0 0 3 If adjustment proves necessary then proceed as follows Refer to diagram 12 6 Adjust the maximum rate CO2 by rotating the throttle to 8 8 in small incrimental adjustments then wait for the a...

Page 25: ...ressurise the heating circuit See section 11 2 Check for leaks 12 8 Draining of Boiler Heating Circuit Drain down the Heating Circuit only by closing the heating flow andreturnisolatingvalvesonthewallmountingjig seediagram 8 1 Attach a length of hose to the drain point and open the drain valve see diagram 12 11 After servicing or replacing parts close the drain valve and remove the hose Open the h...

Page 26: ... RETAINING CLIP HOUSING 12 Servicing Diagram 12 12 10063 SEAL FRONT CASING PANEL FLAT AND HOLE INNER CASING PANEL 12 9 Inner Casing Panel Seal Check Check the condition of the seal replace as required To replace remove the old seal thoroughly clean the casing sufaces Fit the new seal it is supplied to the correct length see diagram 12 12 ...

Page 27: ...27 2000225013B 10154 13 Fault Finding Diagram 13 1 ...

Page 28: ...n supply Gas Valve 24V DC 55 Ω YES YES YES YES YES YES YES YES YES NO NO NO NO NO NO NO Set controls for a demand Adjust system pressure NO Is it flashing indicating zero Is the system pressure displayed Check there is no demand NO YES Replace pressure sensor YES NOTE If the system pressure is too high i e greater than 3 bar the LCD will flash to indicate this Diagram 13 2 Before trying to operate...

Page 29: ...and remove the three screws securing each side panel to the boiler two at the front and one at the top 14 2 Spark Electrode For access refer to section 14 1 Remove the spark plug lead earth lead and two securing screws Withdraw the spark electrode carefully from the combustion chamber see diagram 12 2 14 3 Igniter Unit For access refer to section 14 1 Remove ignition lead and electrical connection...

Page 30: ...e gas supply pipe from the gas control valve When refitting the gas valve take care as it can be fitted more than one way After replacing the gas control valve the combustion CO2 will need to be checked and adjusted if necessary See section 12 6 14 7 Fan For access refer to section 14 1 Refer to section 12 3 for removal of the fan gas valve and burner assembly Remove the gas control valve as descr...

Page 31: ... valve and burner assembly Remove burner as per section 14 8 Remove spark electrode see section 14 2 NOTE THE BURNER WILL REQUIRE A NEW GASKET WHEN REFITTED 14 10 Rear Insulation For access refer to section 14 1 Refer to section 12 3 for removal of the fan gas valve and burner assembly Remove securing screw and washer in the centre of the insulation and withdraw insulation see diagram 14 8 14 11 V...

Page 32: ...of the heat exchanger Undo the two nuts of the flow and return pipes from the heat exchanger Move the pipes away from the heat exchanger Loosen the three heat exchanger securing screws and clamps two at the top and one at the bottom to remove the heat exchanger see diagram 14 11 CAUTION There will be water in the heat exchanger Remove condense pipe connector from bottom of heat exchanger Carefully...

Page 33: ...cess refer to section 14 1 Refer to diagram 14 15 Remove the electrical connections from the thermistor Remove the retaining clip from the return pipe Remove the thermistor from the retaining clip Note that the polarity of the wiring to thermistor is unimportant 14 19 Overheat Thermostat For access refer to section 14 1 Refer to diagram 14 15 Remove the electrical connections from the overheat sta...

Page 34: ... and drain the boiler heating circuit Refer to diagram 14 17 Remove the retaining clips to remove the bypass tube Replace the bypass tube refill vent and pressurise the boiler Check for leaks 14 23 Automatic Bypass Valve For access refer to section 14 1 Refer to section 12 8 and drain the boiler heating circuit Refer to diagram 14 17 Remove the retaining clip to remove the bypass valve Replace the...

Page 35: ... 8 to drain the boiler heating circuit Refer to diagram 14 17 Undo the connector on the bottom of the flow pipe from the hydroblock Undo the nut connecting flow pipe to heat exchanger Lift the flow pipe up out of the way Remove the bypass tube refer to section 14 22 Undothesafetydischargevalveunionandremovethepipework Remove the securing clip and withdraw the safety discharge valve refer to sectio...

Page 36: ... coupling out of the way Remove pump head refer to section 14 15 Note It is not necessary to disconnect the electrical lead but put pumpheadinaconvenientplacewhereitwillnotstrainthelead Remove the bypass tube refer to section 14 22 Remove the electrical connection to the low water pressure sensor refer to section 14 21 Remove the water connection clip 2 below the hydroblock see diagram 14 20 Remov...

Page 37: ...ains reset switch user interface and clock Either remove the connections or support the fascia 14 31 Mains Reset Switch Refer to section 14 30 for access and diagram 14 22 Remove the switch retaining screw Remove switch from housing Remove electrical leads 14 32 Mains Reset Knob Refer to section 14 30 for access Removeactuatorbyspringingbackretainingclips seediagram 14 22 Spring back knob retainin...

Page 38: ...B on setting it up 14 34 Control Box PCB For access refer to section 14 1 Hinge down the control box Remove three TORX screws and unhook the rear panel Remove the electrical connections to the PCB Prise back the two PCB retaining clips and withdraw the PCB When refitting the rear panel ensure the leads are not trapped refer to diagram 14 3 14 35 Control Box For access refer to section 14 34 Remove...

Page 39: ...ols Interface For access refer to section 14 30 Disconnect the electrical connection from the 230V controls board and the electrical connection from the Control box PCB see diagram 14 25 Remove the 230V controls interface retaining screw Remove the 230V controls interface board When ordering spare parts contact Heatcall Glow worm s own service organisation using the telephone number on the front c...

Page 40: ... Filter 8 801722 Heating flow thermistor Heating return thermistor 9 801649 Gas control valve 10 Mains Reset Switch 11 801655 Igniter Unit 12 801909 By pass 13 801923 230V Controls Interface 14 Control Board 15 801380 Pump head only 16 801645 Fan 17 801727 Display Unit PCB 18 Burner 10163 1 3 12 10 5 6 7 8 9 11 4 13 14 17 16 15 18 2 Because of our constant endeavour for improvement details may var...

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