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Supplied By www.heating spares.co Tel. 0161 620 6677

221473B

4 Replacement of Parts

Diagram 4.14

5027

ELECTRICAL
CONNECTORS

SELECTOR SWITCH

CONTROL RESET
BUTTON

5043

GAS
VALVE

Diagram 4.15

ELECTRICAL
CONNECTOR (2)

TORX
SCREW (2)

GASKET

MODULATOR

SPACER

4.18 Thermistor - Heating

Release the water pressure and drain the heating circuit of the
boiler, refer to Sections 1.3 and 1.6.

Gain access, by removing the user control switch bracket, see
diagram 4.6.

Disconnect the cables from the thermistor, see diagram 4.17.

Remove the thermistor, complete with its “O” ring.

The polarity of the electrical connections is not important.

4.19 Thermistor - Domestic Hot Water

On minimum clearance installations, remove the pump, see
Section 4.24.

Release the water pressure and drain the domestic circuit of the
boiler, refer to Section 1.3 and 1.6.

Disconnect the cables from the thermistor, see diagram 4.17.

Remove the thermistor complete with its “O” ring.

The polarity of the electrical connections is not important.

4.20 Safety Valve

Release the water pressure and drain the central heating circuit
of the boiler, refer to Section 1.3 and 1.6.

Remove the pressure gauge, refer to Section 4.11.

Remove air pressure switch.

Disconnect the union nuts to release the safety valve, see
diagram 4.18.

4.21 Water Inlet Filter

Release the water pressure and drain the domestic circuit of the
boiler, refer to Section 1.3, 1.6 and diagram 4.16.

4.22 Domestic Hot Water Throttle

Release the water pressure and drain the domestic circuit of the
boiler, refer to Section 1.3 and 1.6.

Remove the domestic hot water inlet pipe assembly, refer to
Section 4.17.

Remove the cap nut and carefully remove the throttle adjuster,
by unscrewing and pushing it out, see diagram 4.19.

Clean if necessary, taking care not to damage the throttle body.

Reset the domestic hot water flow rate refer to Section 11.7 in
Installation Instructions.

4.23 Mini Expansion Vessel

Release the water pressure and drain the domestic circuit of the
boiler, refer to Section 1.3 and 1.6.

Remove the domestic hot water inlet pipe complete with the
mini-expansion vessel from the boiler, refer to Section 4.17.

When refitting use the new sealing washer supplied.

Содержание 47 313 18

Страница 1: ...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 In the center pages are to be found your Guarantee Registration Card which we recommend you complete and return as soon as possible If this card is missing you can obtain a copy or record your registration by telephoning the Heatcal...

Страница 2: ...ting to the electrical equipment designed for use within certain voltage limits 3 Directive 89 336 EEC on the approximation of the Laws of the Member States relating to electromagnetic compatibility Substances Hazardous to Health The adhesives and sealants used in this appliance are cured and give no known hazard in this state INSULATION PADS CERAMIC FIBRE GLASSYARN MINERAL WOOL These can cause ir...

Страница 3: ... pole switched fused spur box The fused spur box should be readily accessible and preferably adjacent to the appliance It should be identified as to its use Alternatively a fused 3A 3 pin plug and shuttered unswitched socket may be used Thecoloursofthreecoreflexiblecableare blue neutral brown live green and yellow earth Asthemarkingsonyourplugmaynotcorrespondwiththese colours continue as follows T...

Страница 4: ...s a twenty four hour dial that is 1pm is 13 To set the time turn the whole face clockwise until the pointer is against the time of day To set any Off time push the tappets outwards To set any On time push the tappets inwards Time can be set either On or Off in fifteen minute segments Note Theclocksuppliedcouldbefittedwithanoverridedevice see diagram 1 which switches the clock programme On or Off p...

Страница 5: ...sed the main burner flames will decrease in size but will remain alight until the boiler controls or any heating controls switch it off For domestic hot water only set switch C to Off as shown in diagram 3 The main burner will then light when any domestic hot water tap is opened and go out when the tap is closed Which ever position switch C is in domestic hot water will be available To Turn the Ce...

Страница 6: ...Note Ifthepressuregaugeindicatesalossofsystempressure that is less than 0 7bar YOU MUST CONTACT YOUR INSTALLER Pressure Relief Safety Valve CAUTION A pressure relief safety valve and discharge pipe is fittedtotheboiler Thisvalvemustnotbetouched Shouldthere be any discharge from the pipe turn the boiler off isolate from the electrical supply and contact your installation servicing company Cleaning ...

Страница 7: ...PANSION VESSEL FLOW SWITCH SAFETY VALVE GAS VALVE D H W HOT OUTLET C H RETURN GAS SUPPLY 1 1 Installation Materials and equipment should be fit for their purpose and of suitable quality and workmanship 1 2 Important Notice This boiler is for use only on natural gas G20 1 3 Sheet metal Parts WARNING When installing the appliance care should be taken to avoid any possibility of personal injury when ...

Страница 8: ...00 BURNER mbar 6 2 15 5 1 8 PRESSURE in wg 2 6 6 2 0 7 APPROX m3 h 2 1 3 4 1 2 GAS RATE ft3 h 75 8 121 8 43 4 TABLE 1 C H Max D H W Max MIN TABLE 2 1 General Data 1 5 Data Label The data label is on the inner case cover 1 6 Data See Tables 1 and 2 1 7 Gas Supply Thegasinstallationmustbeinaccordancewiththerulesinforce in the countries of destination The supply from the governed gas meter must be of...

Страница 9: ...ng must be protected If the boiler is to be fitted into a cupboard compartment or unusual location special procedures are necessary Make sure that the cupboard or compartment air vents are positioned to be clear of obstructions at all times refer to Section 3 2 2 Clearances The boiler should be positioned so that at least the minimum operationalandservicingclearancesareprovided seediagram 5 Instru...

Страница 10: ... collar will mean that the flue lengths will need to be altered full instructions are given in the kit Diagram 3 3 REAR FLUE 1 and 2 metre 4738 X Diagram 3 2 SIDE FLUE STANDARD Left or Right DISTANCE Y 80 TO 353mm Diagram 3 1 WALL THICKNESS X 75 TO 408mm 2813 2812 REAR FLUE STANDARD X Y 1m DISTANCE X 75 TO 898mm 2m DISTANCE X 75 TO 1898mm 3 3 Terminal Position The minimum acceptable siting dimensi...

Страница 11: ...minal Guard 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 be central over the terminal The guard should be similar to that shown in diagram 3 5 and can be bought from Tower Flue Components Ltd M...

Страница 12: ...G 2 REMAINING CONVEYING CAPACITY OF PUMP SHOWING RELATIVE SYSTEM DIFFERENTIAL AT VARIOUS SYSTEM HEATING LOADS M 4 Heating System GRUNDFOS WILO AVAILABLE PUMP HEAD SYSTEM DIFFERENTIAL TEMPERATURE SYSTEM HEATING LOAD 0 5 10 15 17 20 11 40 35 30 6 25 19 8 15 10 5 0 F 0 C 0 0 15 30 40 50 60 0 1 2 3 5 10 16 14 4 10 12 5 FEET 4 5 4 0 3 5 3 0 2 5 5 0 GALLONS Min LITRES Min FLOW RATE 18 17 15 13 11 19 20 ...

Страница 13: ...ter should normally be left at maximum 2 but in some cases it is permissible to adjust to a lower setting 1 see diagram 4 1A To use diagram 4 1A start with the required heating system load In the example shown the maximum boiler output has been chosen 17 6kW 60 000Btu h Draw a horizontal line from the required system differential temperature axis to intersect the curve In the example 11 C 19 8 F h...

Страница 14: ...ce must be in accordance with the rules in force in the countries of destination 5 2 Water Pressure For the minimum and maximum working pressures of the domestic hot water circuit of the boiler refer to Section 1 6 Data If the cold water supply pressure exceeds the maximum a pressure reducing valve must be fitted in the supply to the boiler to reduce the pressure to within the limits given Diagram...

Страница 15: ...hat the frame top is horizontal then mark the four wall fixing points through the holes in the two horizontal straps Positionthefluetemplateonthewall thearrowpointsonthe centres of the two upper fixing points previously marked see diagram 6 4 which also shows dimensions For rear flue mark the rear flue position as required centre and or diameter For a side flue mark the horizontal flue centre line...

Страница 16: ... shown in diagram 7 3 then cut to length cutting square and removing any burrs Markaline34mmfromtheendoftheflueduct seediagram7 4 Diagram 6 4 Diagram 6 5 2882 2304 FLUE CENTRE LINE CORNER Left Flue CORNER Right Flue 115Dia 168 168 6 Installation Preparation FLUE TEMPLATE Cut from carton top inner flap TOP OF BOILER MIN CLEARANCE 87 104 115Dia 584 480 300 FLUE CENTRELINE BOILER MOUNTING FRAME FIXIN...

Страница 17: ...ght or rear flue Fit the air and flue duct assembly to the boiler see diagram 7 5 Note Fully insert the air duct into the air box spigot Make sure the flue terminal is in the correct orientation marked TOP and the flue duct is engaged in the flue terminal Drill a hole diameter as shown in diagram 7 6 in each side of the air duct through the holes in the air box Secure the air duct to the air box u...

Страница 18: ... connected from above within the boiler mounting frame will clear the expansion vessels Flush out the domestic hot water and the heating systems before connecting to the boiler Make the connections to the domestic hot water outlet by straight connector and heating systems by way of the isolating valves see diagram 8 1 Slacken or remove the clips as desired while making the connections Do not subje...

Страница 19: ...earth would be the last to become disconnected CAUTION It is essential that the polarity is correct 9 2 Heating System Controls CAUTION To prevent an induced current from switching the central heating on when not required it is important that the heating system control cables are separated from the other mains supply cables The heating system should have installed a programmer and room thermostat ...

Страница 20: ...P FUSE L N 230V 50Hz PERMANENT MAINS SUPPLY POTENTIAL FREE ROOM STAT NO FROST STAT TO BOILER RED LINK REMOVE WHEN CONNECTING SYSTEM CONTROLS 5 POLE CONNECTOR ON MOUNTING FRAME POTENTIAL FREE ROOM STAT 3 L N 2 1 DOUBLE POLE ISOLATOR JUNCTION BOX 3 AMP FUSE L N 230V 50Hz PERMANENT MAINS SUPPLY 230V 50Hz ROOM STAT NO FROST STAT TO BOILER RED LINK REMOVE WHEN CONNECTING SYSTEM CONTROLS 5 POLE CONNECTO...

Страница 21: ...er securing screws at the top 10 4 Discharge Pipe Remove the two control housing securing screws see diagram 10 1 Remove the control housing and support the control housing on a surface or by screwing it to the front edge of the base using one of its securing screws see diagram 10 1 If required to improve access the air pressure switch can be removed refer to the service instruction section 4 31 F...

Страница 22: ...f red lockout neon is lit press reset switch wait 15 seconds between attempts set switch C to ON see diagram 11 1 any remote heating system controls time switch and room thermostat for duty see diagram 11 1 Note If the clock timer kit is to be fitted refer to the setting instructions in the Instructions for Use Make sure that the automatic air vent is operating correctly see diagram 1 2 Alternate ...

Страница 23: ...nsulate the connector to make sure that it does not contact any metallic part of the boiler Switch on the electrical supply Fully open a hot water draw off tap and the main burner will light at minimum gas rate Check that the burner pressure is 1 8mbar 0 2mbar 0 7in wg 0 1in wg If this is incorrect it may be adjusted by removing the cap and turn the larger adjusting nut of the modulator anticlockw...

Страница 24: ...l housing and refit the housing to the boiler 11 8 Temperature Settings The domestic hot water outlet and central heating flow temperatures are factory preset and sealed The nominal temperature setting for the Domestic Hot Water outlet is 55o C 131o F at a flow rate of 3 6Litre a minute 0 8gal min The nominal flow temperature setting for central heating is 82o C 180o F with the user central heatin...

Страница 25: ...timer Fit the outer case secure with the four screws see diagram 11 5 Note Secure with the two outer screws only if there is no clock timer fitted Set the boiler and any remote heating control to the desired settings then close the door 11 11 Instruct the User Instruct and demonstrate the lighting procedure and advise the user on the safe and efficient operation of the boiler Instruct on and demon...

Страница 26: ...f this boiler must be carried out by a competent person in accordance with the rules in force in the countries of destination NOTE To obtain a products of combustion reading remove the outer case see diagram 1 2 Disconnect the clear upper tube from the air pressure switch see diagram 1 3 and 4 26 insert the analyser probe into the tube Typical values for this boiler at maximum domestic hot water d...

Страница 27: ... the top edge of the front panel To fit the fan locate it into the rear bracket and ease the flue elbow onto the fan outlet and secure with the two screws see diagram 4 1 When fitting the flexible tubes to the air pressure switch make sure the lower red tube from the fan connects to the lower connection of the switch Connect the electrical cables to the fan the polarity of the two connectors is no...

Страница 28: ...cover and dependent on the type of control fitted test for continuity mains or at terminals 1 and 2 see diagram 3 1 7 Check reset button if red neon is lit press button In certain circumstances the red neon light may not come on due to no system demand Turn on a domestic hot water draw off tap to create a demand the light should come on if reset is required Allow the boiler and system to cool down...

Страница 29: ...onandmakingofelectricalconnectionsthenchecks for earth continuity polarity and resistance to earth must be carried out Before replacing any part please read points below Replacement of parts must only be carried out by a competent person 1 Refer to Section 1 1 2 Always isolate the boiler from the electrical supply and as required the gas supply as Section 1 3 3 Remove outer case described in Secti...

Страница 30: ... User Control Replace With central heating demand on Can the temperature be varied by rotating the control knob Turn off C H and D H W demand Simulate a leak on Central Heating Circuit by draining the appliance As pressure approaches ZERO does the Red Low Pressure light flash User Control board in order To stop Red Low Pressure light flashing Refill C H circuit to 0 7 bar then switch the electrica...

Страница 31: ...t or the boiler fails to detect flame Isolate supply disconnect cables is there continuity across boiler overheat cut off brown and black on APS DHW cut out and yellow and grey on W P S Is there 8kΩ 10KΩ across CH and DHW thermistor Replace faulty device Disconnect red cables to flow switch turn on hot water tap Is there continuity between red cables Replace faulty flow switch Replace faulty flow ...

Страница 32: ... replace Is there 230V ac on pump Faulty main PCB replace Faulty pump replace Turn on CH demand does pump operate As heating system becomes satisfied does burner pressure reduce Normal operation Faulty main PCB replace Does the DC voltage across the modureg reduce Faulty main PCB replace Faulty modureg replace Isolate supply Check dimensions of sense electrode and condition of lead If ok replace C...

Страница 33: ...on fan Faulty CVI ignition unit replace Faulty fan replace Is there 230ac between brown pin 10 and blue pin 11 an CVI ignition connector Is there 24V ac on white and red CNI on main PCB Faulty transformer replace Faulty main PCB replace Is there between 15 30 V DC on the two greys on CN1 main PCB Is there between 15 30 V DC on the Modureg coil Faulty CVl ignition unit Faulty coil Faulty main PCB Y...

Страница 34: ...NO YES YES Faulty clock timer Replace 5666 Diagram 3 6 DIGITAL CLOCK TIMER Does clock keep time Set clock to off period Is there continuity across common and heating on Clock in order if no central heating refer to main fault finding Isolate electrical supply set clock to on period Is there continuity across common and heating on Faulty clock replace No No No If a mains potential room thermostat i...

Страница 35: ...on chamber NOTE Thesensingleadisconnectedtotheburner Disconnect the lead when the burner is being removed Remove the main burner from the main injector at the rear Raise the burner up and forwards Take care not to damage the combustion chamber insulation Remove the sensing electrode and fit to new burner Make sure the sensing lead is reconnected and the main burner is fitted correctly on assembly ...

Страница 36: ...on gas valve Slacken sealing angle and withdraw lead 4 7a Earthing Lead Refer to section 4 6 4 8 Boiler Overheat Cutoff Remove user control switch bracket by slackening securing screws disconnect electrical connectors see diagram 4 6 Disconnect the boiler overheat cutoff electrical connectors see diagram 4 5 Remove the overheat cutoff secured with two screws see diagram 4 5 Use the heat sink compo...

Страница 37: ... the polarity is not important see diagram 4 12 4 11 Pressure Gauge Removethecontrolhousingassembly securedwithtwoscrews Support the control housing on a surface or by screwing it to the front edge of the base using one of the screws previously removed see diagram 4 10 Release the water pressure and drain the central heating circuit of the boiler refer to Section 1 3 and 1 6 Remove the pressure ga...

Страница 38: ...ate the boiler from the electrical supply refer to Section 1 3 Remove the outer case refer to section 1 4 Remove the control housing cover refer to Section 4 11 Support the control housing see diagram 4 10 Remove the transformer cables correctly see diagram 4 12 5229 Diagram 4 12A WIRING AS DIAGRAM 4 12 CLOCK TIMER COMMON HEATING ON L N BR B Y Y BR B Y Y Y1 Y2 N L Diagram 4 11 TRANSFORMER USER CON...

Страница 39: ...CTOR SWITCH DHW FLOW SWITCH THERMISTOR CH C WATER PRESSURE SWITCH RESET NVLO INDICATOR BOILER OVERHEAT CUT OFF AIR PRESSURE SWITCH IGNITION UNIT GAS VALVE FAN DHW HIGH LIMIT CONTROL THERMISTOR DHW PUMP L N E G Y W G Y B B B BR BR BK 230V AC TOP 6V BTM 24V B 230V N 7 8 P P OR P GY GY GY GY Y BR BR NC G Y BR BR B OR P BLOCK 3 BLOCK 2A BLOCK 2B MAINS TXR 230V G Y G Y G Y G Y Y OR R R N L N L N L N L ...

Страница 40: ...Reset Switch Slacken the user control switch bracket securing screws and remove the bracket from the keyhole slots see diagram 4 6 Pull the leads from the switch see diagram 4 14 To remove the switch press in the tabs on each side of it THE POLARITY OF THE ELECTRICAL CONNECTORS IS IMPORTANT see diagram 4 12 4 16 Modulator Isolate the boiler from the electrical supply and closethe gas service cock ...

Страница 41: ...not important 4 20 Safety Valve Release the water pressure and drain the central heating circuit of the boiler refer to Section 1 3 and 1 6 Remove the pressure gauge refer to Section 4 11 Remove air pressure switch Disconnect the union nuts to release the safety valve see diagram 4 18 4 21 Water Inlet Filter Releasethewaterpressureanddrainthedomesticcircuitofthe boiler refer to Section 1 3 1 6 and...

Страница 42: ...NLET PIPE ASSEMBLY THROTTLE FLOW SWITCH LOCKNUT FLOW SWITCH ELECTRICAL CABLES FLOW SWITCH A FILTER UNION NUT WATER FILTER 5267 6628 O RING CONNECTORS CENTRAL HEATING THERMISTOR D H W THERMISTOR O RING Diagram 4 18 Diagram 4 19 Diagram 4 20 4600 DISCHARGE PIPE 2794 SAFETY VALVE UNION NUT THROTTLE ADJUSTER CAP NUT O RING UNION NUT SEALING WASHER MINI EXPANSION VESSEL 5271 ...

Страница 43: ... does not operate remove the end screw or cap see diagram 4 21 then turn the pump spindle to release any temporary seizure DO NOT HIT THE SPINDLE 4 25 Automatic Air Vent Release the water pressure and drain the central heating circuit of the boiler refer to Section 1 3 and 1 6 Remove the automatic air vent see diagram 4 22 SLACKEN THE SMALL CAP ON THE AIR VENT THIS MUST NOT BE RE TIGHTENED When re...

Страница 44: ... 27 Combustion Chamber Insulation Remove the fan refer to Section 4 1 Removethefluecollector securedwithtwoscrews seediagram 4 1 Removethecombustionchamberfrontpanel securedwithfour screws see diagram 4 2 Remove the front insulation piece secured with a clip see diagram 4 23 Slide out both side insulation pieces Pull the lower rear insulation forwards then slide the upper rear insulation down from...

Страница 45: ...oInstallationInstructions Remove the fan from the flue collector refer to Section 4 1 Remove the air box secured to the boiler with four screws and to the air duct with two screws see diagram 4 24 Disconnect the boiler water connection union nuts at the front of the isolating valves see diagram 1 1 Disconnect the gas service cock union Disconnect the safety valve discharge pipe from the boiler see...

Страница 46: ...lean out the old adhesive Glue the new seal into place making sure that there are no breaks in it 4 31 Air Pressure Switch Disconnect the two electrical connectors at the air pressure switch see diagram 4 26 Remove the flexible tubes from the switch Remove the air pressure switch secured with two screws When replacing the tubes to the air pressure switch make sure that the lower red tube from the ...

Страница 47: ...135 12 800136 DHW switch assembly 313 277 13 202240 Fuse 2 type T 630 mA not illustrated 14 202226 Fuse 1 type 2AT not illustrated 278 136 15 800150 Water pressure switch assembly 397 862 16 202218 User PCB 278 141 17 204537 Air pressure switch assy 375 737 18 208214 Water inlet filter 281 359 19 800153 Automatic air vent assembly 313 285 20 800149 Safety valve assembly 397 677 21 800744 Gas valve...

Страница 48: ...res co Tel 0161 620 6677 48 221473B Diagram 5 1 11 2 18 7 8 6 4 9 19 1 5274 16 5 3 10 20 10A 15 17 12 21 22 Because of our constant endeavour for improvement details may vary slightly from those in the instructions 5 Spare Parts ...

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