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Glow-worm 23c, Инструкция по использованию, установке и обслуживанию

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20

2000225000B

12 Commissioning

Please ensure the “Benchmark” logbook is completed and left
with the user.

The commissioning and first firing of the boiler must only be
done by a qualified registered person.

Gas installation

It is recommended that any air is purged from the supply at the
gas inlet test point on the gas valve, see 

diagram 12.1.

Filling the system 1 to 8

9973

9972

GAS INLET
TEST POINT

Diagram 12.1

1.

Make sure that:

• The boiler is connected to the electrical supply.
• The gas service cock is open.

Turn the switch 

OFF ( 0 )

3.

• Undo cap on automatic air vent on top of pump
and leave undone.

9974

4.

• Turn the switch 

ON ( I )

• Open the tap on the
filling device and fill the
system until the pressure
indicated on the display is
2 bar. Close filling device.

➜

➜

9838

2.

• Open the three boiler isolating valves. The slot
of the screw corresponds to flow direction.
(To unscrew turn anti-clockwise).

➜

➜

HEATING
RETURN

COLD
WATER IN

HEATING
FLOW

Fully open valves by
turning anti-clockwise.

Содержание 23c

Страница 1: ...ased 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...

Страница 2: ...roduct production certified by Notified body 0063 The CE mark on this appliance shows compliance with 1 Directive 90 396 EEC on the approximation of the laws of the Member States relating to appliances burning gaseous fuels 2 Directive 73 23 EEC on the harmonization of the Laws of the Member States relating to the electrical equipment designed for use within certain voltage limits 3 Directive 89 3...

Страница 3: ...5 11 Boiler Location flue and ventilation 6 12 Fixing jig pack 7 13 Piping System Installation 8 14 Boiler installation 8 15 Flue Installation telescopic and standard 10 16 Electrical Connection 11 19 Commissioning 12 20 Settings 14 22 Routine Cleaning and Inspection 15 22 Fault Finding 16 27 Wiring Diagram 17 34 Replacement of Parts 18 35 Spare Parts 19 44 CONTENTS DESCRIPTION SECTION PAGE No SER...

Страница 4: ...ug both to the current issue of BS1363 may be used provided that they are not used in a room containing a bath or shower Wiring to the boiler must be PVC 85o C insulated cable not less than 0 75mm2 24 0 20mm Gas safety Installation and use Regulations In your interests and that of gas safety it is the law that ALL gas appliances are installed and serviced by a qualified registered person in accord...

Страница 5: ...temperature adjustment Winter Set the control knob between 1 and 5 Summer Set the control knob to 5 If a fault occurs indicated by red flashing light Reset boiler Turn the On Off switch to 0 wait for five seconds Turn the On Off switch to I the boiler is reset If the fault continues call your Installation Servicing company or Heatcall Glow worm s own service organisation using the telephone number...

Страница 6: ...tem pump are activated When the temperature inside the appliance reaches 10 C the burner will shut down and after a short period the pump will stop This device primarily protects the boiler Any other exposed areas of the system should be protected by a seperate frost thermostat If the boiler is to be out of use for any long periods during severe weather conditions it is recommended that the whole ...

Страница 7: ...er or Heatcall Glow worm sownserviceorganisation usingthetelephonenumber behind the controls cover door Please be advised that the Benchmark logbook should be completed by the installation engineer on completion of commissioning and servicing All CORGI Registered Installers carry a CORGI ID card and have a registration number Both should be recorded in your boilerLogbook Youcancheckyourinstalleris...

Страница 8: ...ner pressure 2 mbar Gas rate maximum 2 64 m3 h Heating Heat input max NET Q 25 kW 85 300 BTU H Heat input min NET Q 10 4 kW 35 490 BTU H Heat output max NET P 23 kW 78 480 BTU H Heat output min NET P 8 7 kW 29 670 BTU H Maximum hot water temperature 63 C Minimum hot water temperature 35 C Specific flow rate for 30 C temp rise 11L min Threshold flow rate 1 7 L min Maximum supply pressure 10 bar Min...

Страница 9: ...ailable pressure kPa between heating supply and return lines Diagram 1 1 2 Dimensions 1 2 3 4 5 50 40 30 20 10 0 500 1000 The 23c is delivered in three separate packages The boiler The fixing jig and hanging bracket The flue system 9699 Diagram 2 1 Net lift weight boiler only 36 kg Gross lift weight boiler and packaging 37 kg Optional electro mechanical clock timer shown fitted ...

Страница 10: ...g can be modified at commissioning stage if the static head differs An additional expansion vessel can be fitted to the system if required see diagram 8 2 Provision shall be made for a drain valve at the lowest point of the system Where thermostatic radiator valves are fitted not all radiators must be fitted with this type of valve and in particular where the room thermostat is installed In the ca...

Страница 11: ...10 Pump 11 Heating thermistor Diagram 5 1 9720 9321 A Heating flow B Domestic hot water outlet C Gas D Cold water inlet E Heating return 12 Ignition module 13 By pass 14 Gas valve 15 Loss of water sensor 16 Domestic hot water thermistor 17 Automatic air vent 18 Domestic water flow sensor 19 Filter cold water inlet 20 Filling system 21 Discharge safety valve 3bar 22 Heating filter 23 Drain valve ...

Страница 12: ...ld 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 Terminal guard type K3 supplied by Tower flue components Ltd Morley road Tonbridge Kent TN9 1RA 6 3 Flue options There are various flue systems to choose from as follows Telescopic horizontal flue pack rear only Stand...

Страница 13: ...ting valve q D Domestic hot water outlet E Gas fitting Diagram 7 1 A B C D E COPPER CONNECTIONS AND WASHERS 5 OFF F m v THE FIXING JIG SHOWN ASSEMBLED Other components within the fixing jig pack F Hanging bracket G wall template H copper connections J sealing washers and screws RIGHT HAND SUPPORT BRACKET LEFT HAND SUPPORT BRACKET ISOLATING VALVE PLATE SCREW 9897 q 9717 G J H 1 Heating systems conn...

Страница 14: ...template 8 4 Flue to side of boiler Mark the horizontal centre line for the hole on the rear wall Extend the horizontal centre line to the side wall and mark the vertical centre line of flue hole as shown in diagram 8 1 8 5 Cutting the flue hole Making allowance for the slope of the flue cut hole in external wall preferably using a core drill For installations with internal and external access use...

Страница 15: ...e transit plate from the fan outlet on top of the boiler secured with two screws Remove front panel unscrew and remove the two retaining screws from the bottom of the front panel Remove front panel by lifting up and forward If applicable remove the self adhesive wiring diagram label from the document envelope Fit the self adhesive wiring diagram label to the inside of the front panel put front pan...

Страница 16: ... the flue lengths to be reduced by 1m for 90 and 0 5m for 45 The boiler is only suitable for top outlet flue connection 10 1 Top outlet flue Telescopic kit A2004500 Standard kit 86285 10 2 Flue systems rear Telescopic Flue Extend to suit flue length required 10091 Diagram 10 2 10 Flue Installation Telescopic and Standard 10 3 Flue systems side Telescopic Flue Extend to suit flue length required St...

Страница 17: ...e the fan outlet see diagram 10 6 Ensure transit plate has been removed from the fan outlet on top of the boiler Fit elbow onto boiler and secure with the four screws D Re fit the telescopic flue duct pipe to the flue elbow taking care not to tear the O ring fit the 2 securing screws Re fit the telescopic air duct pipe to the air elbow fit the 2 securing screws 10 6 Installation of standard flue a...

Страница 18: ...dard flue system side only The maximum permissible length L for the standard flue system is 3 0m For flue systems up to 1 5m the flue restrictor a must be fitted inside the fan outlet For longer flue systems the restrictor must be removed For each 90 flue elbow used or two 45 elbows the maximum permissible length L must be reduced by 1metre Diagram 10 7 65 165 L GASKET FLUE RESTRICTOR a 65 GASKET ...

Страница 19: ...upplied provided that the wire link E fitted between the two terminals of the heating controls conection plug is left in place see diagram 11 1 External controls e g room thermostat frost thermostat etc should be fitted in accordance with the rules in force WARNING UNDERNOCICUMSTANCESMUSTANYMAINS VOLTAGE BE APPLIED TO ANY OF THE TERMINALS ON THEVOLTAGEFREEHEATING CONTROLSCONNECTION PLUG If mains v...

Страница 20: ...NLET TEST POINT Diagram 12 1 1 Make sure that The boiler is connected to the electrical supply The gas service cock is open Turn the switch OFF 0 3 Undo cap on automatic air vent on top of pump and leave undone 9974 4 Turn the switch ON I Open the tap on the filling device and fill the system until the pressure indicated on the display is 2 bar Close filling device 9838 2 Open the three boiler iso...

Страница 21: ...ng system and make sure that a pressure of at least 1 bar is indicated when system is COLD Flush the domestic hot water system by opening the hot water taps for several minutes Remove the magnetic lighting instructions label from the document envelope and position it on the surface of the boiler casing 9696 Instruct the User Instruct and demonstrate the lighting procedure and advise the user on th...

Страница 22: ...ce sampling point cap 15 2 Service Check and Preparation Isolate boiler from the gas and electrical supplies Drain the Domestic hot water circuit and the boiler refer to diagram 15 2 On completion check all gas carrying parts for soundness with leak detection fluid Remove boiler casing as follows Diagram 14 1 9975 14 Settings A Bypass The 23c boiler has a built in bypass This must be adjusted acco...

Страница 23: ...ating cocks water and gas are shown in the OFF position To Drain the Domestic hot water circuit Close boiler isolating valve c Turn on one or more hot water taps To Drain the boiler Closeisolatingscrewsontheisolatingvalves b c and d turnfromvertical to horizontal to close Open the boiler drain valve a Turn on one or more hot water taps a BOILER DRAIN VALVE 9839 ...

Страница 24: ... 8 Disconnect power supply leads and earth lead from fan Remove air pressure switch sensing tube from the side of the fan Unscrew and remove the fan retaining screw Ease the fan down and forwards to remove 15 11 Heat exchanger refer to diagram 15 9 Remove the two flue hood retaining screws to remove the flue hood Use a soft brush or vacuum clean the heat exchanger DO NOT USE ANY TOOL LIKELY TO DAM...

Страница 25: ... HEAT EXCHANGER POWER SUPPLY LEADS EARTH LEAD Diagram 15 7 BURNER GUIDE BURNER RETAINING SCREWS 9981 9983 9986 9982 9987 Diagram 15 10 FILTER DOMESTIC WATER INLET FILTER HOUSING CLIP AIR PRESSURE SWITCH SENSING TUBE FAN RETAINING SCREW Diagram 15 11 RETAINING CLIP FILTER FLAT 9835 9834 PULL DOWN ...

Страница 26: ...s required the breaking or remaking of the electrical connections thecontinuity polarity shortcircuitandresistance to earth checks must be repeated using a suitable multimeter TYPE OF FAULT CHECK No domestic hot water or central heating 230V supply No flashing warning light on control panel Is fuse blown Loose connections on control board PCB Faulty control or interface board PCB s No domestic hot...

Страница 27: ...or Dismantle the step motor screw not Check the connections at both sealed in Trigger a demand and check motor and control board PCB that the valve opens during the ignition Change the motor Replace the control board PCB Domestic water flow To test Use a new detector and connect it electrically in place of the faulty one Blow through to simulate a demand for water Diagram 16 1 9913 FAULTY WATER PR...

Страница 28: ...kwise NO Adjust the setting NO Check the thermostat the line the connections both to the room thermostat and the control board PCB YES YES Check by overriding the room thermostat at the connector Does the fault persist YES Check the electrical connections to the control board PCB If the problem persists fit a replacement control board PCB NO Is the system fitted with a external sensor YES YES YES ...

Страница 29: ...ATING IS WORKING Is the cold water inlet tap fully open Is the water pressure greater than 0 5 bar Open it NO NO Insufficient water pressure The appliance will not operate Find out why the pressure is so low YES Is the water flow rate greater than 1 7l min threshold figure NO Check the cold water inlet filter for dirt Is the cold water tap fully open Check the heat exchanger for scaling YES Is flo...

Страница 30: ...d terminal H23 on the control board PCB Check the connector on the end of the wire Check that the spark electrode is pointing towards the flame Check the spark electrode Change it If the problem persists change the control board PCB flame detection module faulty Check the 230V mains supply 16 Fault Finding FAULT THE BURNER DOES NOT LIGHT AT ALL BUT THERE IS AN IGNITION SPARK NO NO YES YES Are the ...

Страница 31: ...If the room temperature is not sufficient adjust YES YES NO NO Is the installation fitted with a external sensor The radiators will only be hot if the thermostat is demanding heat If the room temperature is not sufficient turn the setting of the room thermostat up Is the heating setting high enough YES Turn it up Is the heating power adequate Check the adjustment of the by pass too far open Check ...

Страница 32: ...board PCB FAULT THE FAN RUNS BUT THERE ARE NO SPARKS Thermistor Control board PCB Air flow switch take off CONNECTIONS TO THE AIR PRESSURE SWITCH Pr 3 2 1 P2 P1 L H Electrical contacts NO YES Does the warning light flash 45 seconds after the start of the demand Check the pressure drop on the flue pipe Is the plastic tube on the correct pressure connection of the air pressure switch Are the electri...

Страница 33: ...J4 J12 S1 J1 J13 J15 J11 H5 H2 H1 H4 H3 H8 H6 H7 ON OFF SWITCH AIR PRESSURE SWITCH FAN SENSE ELECTRODE IGNITION ELECTRODES g y g y CHASSIS EARTH bk br w g w g w g p p or y gn b b w r br g y g y b br OVERHEAT THERMOSTAT g y g y br b 4 3 2 1 br WATER PRESSURE SENSOR w g or b br PUMP w r br gn w b y r gn b br b b y THERMOSTAT 2 INPUT FROST STAT THERMOSTAT 1 INPUT ROOM STAT VOLTAGE FREE HEATING CONTRO...

Страница 34: ...Section 15 4 Remove the sealed chamber cover refer to Section 15 5 Locate central heating thermistor on the top left hand side of the heat exchanger see diagram 18 2 Diagram 18 2 9988 CENTRAL HEATING THERMISTOR 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 a To Dr...

Страница 35: ...ng filter refer to section 15 13 18 6 Cold water inlet restrictor 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 Drain down domestic hot water circuit of boiler only refer to relevant part of diagram 18 1 Remove the retaining wire Undo union nuts from boiler cold water in isolating va...

Страница 36: ...placementthermostat the polarity is not important 18 11 Domestic hot water thermistor 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 Locate domestic hot water thermistor on domestic hot water pipe to the left of centre of the boiler see part of diagram 18 7 Disconnect electrical conne...

Страница 37: ...3 Lower the control panel refer to Section 15 4 Remove the sealed chamber cover refer to Section 15 5 Remove the combustion chamber cover refer to Section 15 7 Remove the heat exchanger refer to Section 18 14 Carefully bend back side insulation retaining tabs pull out side and front insulation panels from combustion chamber Tilt rear insulation panel forwards slide up and out Fit replacement insul...

Страница 38: ...el refer to Section 15 3 Lower the control panel refer to Section 15 4 Diagram 18 10 PCB CONTROL BOARD CONTROL BOARD COVER Diagram 18 11 USER INTERFACE BOARD CONTROL PANEL 10001 10000 10019 9762 Unclip control panel user interface and hinge forward Do not strain the cables Disconnect the electrical connections from the mains switch Remove and replace the mains switch 18 19 230V Controls board refe...

Страница 39: ...control panel refer to Section 15 4 Drain down the boiler only refer to relevant part of diagram 18 1 Pull out slotted metal clip securing tap into housing remove tap Pull out slotted metal clip and remove pipe from tap 18 22 Reduced pressure zone valve RPZ refer to diagram 18 13 Before starting refer to the front of Section 18 Important information Remove the front panel refer to Section 15 3 Low...

Страница 40: ...remove water flow sensor 18 25 System water pressure sensor refer to diagram 18 16 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 Drain down the boiler refer to relevant part of Section 18 1 Remove electrical connections from water pressure sensor Pull off slotted metal clip and remov...

Страница 41: ...lectrical connections to gas control valve Note The washers must be kept for use on reassembly Withdraw gas control valve assembly After fitting replacement gas control valve test for gas soundness 18 29 Gas control valve stepper motor 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 Di...

Страница 42: ...wal of the expansion vessel requires the boiler to be removed from the wall As an alternative a separate expansion vessel of the same specification may be connected as close as possible to the boiler leaving the original in position refer to the installation instructions Remove the front panel refer to Section 15 3 Lower the control panel refer to Section 15 4 Disconnect the mains cable and any ex...

Страница 43: ...6 3 Air pressure switch 801928 4 Domestic water flow sensor 801910 5 Printed circuit board Main 801915 6 Pump head 801896 8 System water pressure sensor 801911 9 Gas control valve 801911 10 Discharge safety valve 801904 11 Overheat thermostat 801927 12 Ignition electrode 801888 13 Flame sense electrode 801887 14 230V controls board 15 User interface PCB 801914 16 Stepper motor 801892 17 Ignitor un...

Страница 44: ...44 2000225000B Because of our constant endeavour for improvement details may vary slightly from those in the instructions Notes ...

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