Glow-worm Compact 24c-AS/1, Installation And Maintenance Instructions Manual

Page 1: ...en Installation and maintenance instructions Compact 24c AS 1 28c AS 1 0020313973_01 05 02 2021 ...

Page 2: ...Start up 28 9 1 Carrying out the initial start up 28 9 2 Checking and treating the heating water filling and supplementary water 28 9 3 Filling the heating installation 29 9 4 Purging the heating installation 29 9 5 Filling and purging the domestic hot water system 29 9 6 Check and gas setting 29 9 7 Checking the heating mode 32 9 8 Checking the domestic hot water generation 32 9 9 Checking leak t...

Page 3: ...commercial processes Any use other than those described in these instructions and any use that goes beyond what is described here 1 2 Qualification The person carrying out the work described here must have completed professional train ing The competent person must demon strably have all of the knowledge skills and capabilities that are required in order to carry out the work mentioned below The fo...

Page 4: ... to aid installa tion 1 3 3 Air supply Unsuitable or insufficient combustion and room air may lead to material damage but also to life threatening situations To ensure that the combustion air supply is sufficient during open flued operation Ensure that the air supply to the product s installation room is permanently unobstruc ted and sufficient in accordance with the relevant ventilation requireme...

Page 5: ...t Check the quality of the heating water Page 28 If you use non diffusion tight plastic pipes in the heating installation ensure that no air gets into the heat generator circuit 1 3 9 Neutralisation device To prevent contamination of the waste water Check whether a neutralising unit must be installed in accordance with national regulations Observe local regulations on neutralising condensate 1 3 1...

Page 6: ...ant group com Spares Enquiries Telephone 01773 881383 To register your Glow worm appliance visit Glow worm is a licensed member of the Benchmark Scheme Benchmark places responsibilities on both manufacturers and installers The purpose is to ensure that customers are provided with the correct equipment for their needs that it is installed commissioned and serviced in accordance with the manufacture...

Page 7: ...e installation types C13 C33 C43 C53 C13 C33 C43 C53 Nominal efficiency in partial load mode 30 107 8 108 2 NOx class 6 6 Nitrogen oxide emissions NOx weighted Hs G20 27 11 mg kW h 32 40 mg kW h CO emissions 137 2 ppm 121 7 ppm Net weight 25 6 kg 26 5 kg 24c AS 1 P GB 28c AS 1 P GB Designated country designation in accordance with ISO 3166 GB IE GB IE Permissible gas categories ll2H3P ll2H3P CE nu...

Page 8: ...w rate in heating mode at P max 8 9 g s 11 6 g s Nominal heat input range for heating 6 2 to 18 8 kW 7 2 to 24 5 kW Technical data Power load G31 24c AS 1 H GB 28c AS 1 H GB Nominal heat output range P at 50 30 C 9 0 to 20 0 kW 7 7 to 25 9 kW Nominal heat output range P at 75 55 C 8 1 to 18 3 kW 6 9 to 23 9 kW Max heat input for domestic hot water Qmax 24 0 kW 28 0 kW Flue gas mass flow rate in he...

Page 9: ...MPa 0 30 to 10 bar Recommended supply pressure 0 3 MPa 3 0 bar 0 3 MPa 3 0 bar Hot water comfort in accordance with the standard EN 13203 Flow rate limiter for cold water 8 0 l min 10 0 l min Domestic hot water output temperature range 35 to 55 35 to 55 24c AS 1 P GB 28c AS 1 P GB Minimum water flow 1 7 l min 1 7 l min Specific flow rate D ΔT 30 K 11 5 l min 13 4 l min Specific flow rate D ΔT 35 K...

Page 10: ...nstallation and maintenance instructions Compact 0020313973_01 24c AS 1 P GB 28c AS 1 P GB Maximum electrical power consumption 90 W 90 W Standby electrical power consumption 1 7 W 1 7 W IP rating IPX5 IPX5 ...

Page 11: ...he data plate is mounted on the rear of the electronics box and on the upper side of the product at the factory Any in formation that is not listed here can be found in separate sections Information Meaning Read the instructions 24c AS 1 28c AS 1 Marketing name ES IT etc Target market Cat Approved gas category Type Products of the category 2H 2HS 2ELw G20 G31 XX mbar X X kPa Gas group and gas conn...

Page 12: ...er software is designed to recognise the potential for an overheat lockout and will shutdown before this happens To restart the boiler press the button more than 3s If the boiler fails to resume normal operation and all external controls are calling for heat then call your Installation Servi cing company or Glow worm service 5 5 3 Frost protection The appliance has a built in frost protection devi...

Page 13: ...taking or the manufacturer 6 4 Minimum clearances C C A B D Minimum clearance A 60 100 mm diameter air flue pipe 150 mm 80 125 mm diameter air flue pipe 276 mm B 180 mm C 5 mm D 500 mm This clearance can be reduced to 5 mm if the product is installed behind a removable plate or a door The boiler and flue are suitable for installation onto and through combustible materials provided that 1 Minimum 5...

Page 14: ...ng to its type for example C13 Whatever the kind of flue system chosen observe the minimum distances to position the flue terminals To install the flue refer to the separate flue instruction supplied with your appliance Explain these requirements to the user of the appliance In GB the minimum acceptable siting dimensions for the terminal from obstructions other terminals and ventilation openings a...

Page 15: ...ing material Vertical flue clearance to combustible building material 500 mm 1 500 mm J Above below and either side of an opening door air vent or opening window 300 mm K Diagonally to an opening door air vent or opening window 600 mm L 2 To an internal or external corner 200 mm M Below a Velux window Above or to either side of the Velux window 2 000 mm 600 mm N From a pitched roof In regions with...

Page 16: ... from pluming depending on site conditions Terminals must be positioned so to avoid combustion products entering the building Support the flue at approximately one metre intervals and at a change of direction use suitable brackets and fixings Installations in car ports are not recommended The flue cannot be lower than 1 metre from the top of a lightwell due to the build up of combustion products D...

Page 17: ... 3 m including 1 elbow Max length L 16 m including 1 elbow 20 m including 1 elbow Max height H 2 10 m 2 10 m Equivalence to 1 elbow 90 2 5 m 2 5 m Equivalence to 1 elbow 45 1 m 1 m 6 5 3 2 Terminal protection A terminal guard is required if persons could come into con tact with the terminal or the terminal could be subject to dam age If a terminal guard is required it must be positioned to provide...

Page 18: ...principles C43 type flue systems must have their own con densate drain fitted and not allow condensate to mix into other appliances The flue length must be calculated and installed according to the relevant standards EN 13384 1 and 2 C43 flue sys tems only with reference to the table below and the manu facturer s instructions supplied The appliance maximum flue length must be included when calcula...

Page 19: ...aterial that is permitted for the wall Screws with a minimum diameter of 6 mm 4 If required ensure that mounting apparatus on site has sufficient load bearing capacity 5 Wall mount the product as described 6 8 Removing installing the front casing 6 8 1 Removing the front casing 2x1 D B A C 6 8 2 Installing the front casing 2x1 A C B ...

Page 20: ...ly before installing the product Warning Risk of adverse health effects caused by impurities in the potable water Sealing residues dirt or other residues in the pipelines may adversely affect the quality of the potable water Flush all of the hot and cold water pipes thoroughly before you install the product Caution Risk of material damage caused by changes to the pipes that have already been conne...

Page 21: ...leading to escaping gas Using oakum Teflon or any other products of this sort for the gas connection thread can cause leaks Only use the flat seals that are supplied with the product or those supplied by the manufacturer 1 Install the gas pipe on the gas connection such that it is free from mechanical stress 2 Purge the gas pipe before start up 3 Check the entire gas pipe properly for leak tightne...

Page 22: ...ternal termination 7 5 5 External termination into soakaway 500 mm 100 mm 300 mm 50 25 25 25 25 Ø12 Ø32mm 3 m 1 2 3 4 5 6 1 Ground either or 2 Seal 3 Plastic tube 100 mm diameter 4 Bottom of sealed tube 5 Limestone chippings 6 Hole depth 400 mm minimum Least preferred option must not terminate in rain water drain 7 5 6 Internal termination downstream of sink waste 100mm Ø32mm Ø22mm 3 m Open end of...

Page 23: ...isible 2 Connect the expansion relief valve 1 to a suitable discharge siphon The components must be set up in such a way that you can see the water flowing out 3 Ensure that you can view the end of the pipe and that discharged water or steam cannot cause injury to per sons or damage to electronic components 7 7 Filling the condensate siphon Fill the condensate siphon with water 250 ml 7 8 Air flue...

Page 24: ...A B B 7 9 2 Cable route 230V 24V eBUS 1 2 1 24 V eBUS cable route 2 230 V cable route 7 9 3 General information about connecting cables Caution Risk of material damage caused by incor rect installation Mains voltage at incorrect terminals and plug terminals may destroy the electronics Do not connect any mains voltage to the eBUS and RT 24 V terminals Only connect the connection cable to the termin...

Page 25: ...ilable and is not covered or blocked 7 9 5 Connecting the control Note When connecting to an eBUS room thermostat after starting up establish the connection in or der to set the heating flow and domestic hot water temperature on the product to the relevant max imum value BUS 24V 24V RT BUS Burner off X106 X41 1 2 3 4 5 1 Limit thermostat for underfloor heating 2 Control 24 V ON OFF 3 eBUS control ...

Page 26: ...973_01 3 Alternatives 4 Connecting the 230 V low voltage room temperature control 30 mm N L X1 230V RT Connect the control to the L main plug and to the RT plug BUS RT B off Burner off RT 24V BUS Remove the bridge from the 24V RT plug 4 Close the electronics box ...

Page 27: ...up the installer level Page 27 2 Use or to select the check programmes P menu 3 Confirm by pressing 4 Use or to select the required check programme Check programmes Page 51 5 Press to confirm The check programme starts is executed and stops after the intended time has elapsed The P check programmes menu is shown 6 If you want to cancel the check programme before the intended time has elapsed press...

Page 28: ...plementary water Provided the national regulations and technical rules do not stipulate more stringent requirements the following applies You must treat the heating water in the following cases If the entire filling and supplementary water quantity dur ing the operating life of the system exceeds three times the nominal volume of the heating installation or If the guideline values listed in the fo...

Page 29: ...4 Purging the heating installation 1 Start the check programme P 00 Page 27 Check programmes Page 51 on is shown in the display 2 Make sure that the filling pressure of the heating install ation does not fall below the minimum filling pressure 0 05 MPa 0 50 bar 3 Check whether the filling pressure of the heating in stallation is at least 0 02 MPa 0 2 bar above the dia phragm expansion vessel s cou...

Page 30: ...e been corrected Condition Gas flow rate in the permissible range End check programme P 01 Allow the boiler to cool down by allowing pump overrun to operate for a minimum of two minutes Record the boiler maximum gas flow rate onto the Benchmark gas boiler commissioning checklist 9 6 4 Checking the gas connection pressure gas flow pressure 1 Temporarily decommission the product Page 42 2 Hinge the ...

Page 31: ...as P 10 6 0 5 Result 1 If the value is outside of the permitted range Measure the CO content at the flue gas analysis point again and log the measured value If the value is still outside of the permissible range do not start up the product and instead report this to customer service Result 2 If the value is inside the permitted range Continue with the process of starting up the product 6 Remove th...

Page 32: ... should ideally be 0 05 MPa 0 5 bar plus an additional pressure corresponding to the highest point of the system above the base of the boiler 10 m head equals an additional 1 bar reading on the pressure gauge The minimum pressure should not be less than 0 1 MPa 1 bar in any install ation If the system is to be treated with an inhibitor it should be applied at this stage in accordance with the manu...

Page 33: ...factory setting for the bypass valve 4 Qmax ΔT 20 C A Installation volume flow in l h B Remaining pump head in hPa mbar Validity Compact 28c AS 1 H GB OR Compact 28c AS 1 P GB 300 400 500 600 700 200 100 0 5 600 400 200 1000 1200 800 A B 1 2 3 4 1 Max pump speed bypass valve closed 2 Max pump speed bypass valve opened by 3 4 rotation factory setting for the bypass valve 3 Min pump speed by pass va...

Page 34: ...s given in the current edition of I S 813 When you have finished the installation affix the en closed sticker which requests that the user reads the instructions to the front of the product in the end user s language Draw attention to the current issue of the Gas Safety Installation and Use Regulations Section 35 which imposes a duty of care on all persons who let out any property containing a gas...

Page 35: ...e ad justment in small increments of a 1 8 turn and wait approx one minute after each ad justment until the value stabilises For liquefied petroleum gas only Only per form the adjustment in extremely small in crements approx 1 16 turn and wait ap prox one minute after each adjustment until the value stabilises 5 Compare the measured value with the corresponding value in the table Setting the CO co...

Page 36: ...casing Page 19 6 Hinge the electronics box downwards 7 Protect the electrical components e g the electronics box from spraying water 8 Use only new seals 12 5 2 Removing the compact thermal module Danger Risk of death and risk of material damage caused by hot flue gas The seal insulating mat and self locking nuts on the burner flange must not be damaged Otherwise hot flue gases may escape and caus...

Page 37: ... 2 on the heat exchanger 4 using water or if required vinegar to a maximum of 5 acid Cleaning agent reaction time 20 min 2 Use a plastic brush or sufficiently strong jet of water to remove the loosened dirt for example by using a spray bottle with ascending pipe In doing so ensure that no spraying water reaches the other components Do not point the jet of water directly at the insulating mat 3 on ...

Page 38: ...the plug 4 to the ignition device 7 Screw the union nut 6 back onto the gas valve as sembly with a new seal 8 Connect the gas pipe using a new seal 9 Open the gas stopcock 10 Check the product for tightness Page 32 11 Check the gas connection pressure gas flow pressure Page 30 12 5 6 Checking the ignition electrode 1 2 3 4 1 Remove the earth cable 1 2 Remove the fixing screws 2 3 Carefully remove ...

Page 39: ...ible range Result 2 0 075 MPa 0 750 bar Fill the expansion vessel in accordance with the static height of the heating installation ideally with nitrogen otherwise with air Ensure that the drain valve is open when topping up 3 If water escapes from the valve of the expansion ves sel replace the expansion vessel 4 Fill the heating installation Page 29 5 Purge the heating installation Page 29 12 5 9 ...

Page 40: ...e last 10 faults in the cylinder Number 01 in the sequence corresponds to the fault that occurred last The sequence position and fault number are dis played alternately 5 Press to exit the fault memory 6 Exit the installer level Page 27 13 2 Eliminating faults Active faults appear in the display s basic display Call up the fault memory to find out which faults occurred most recently on the product...

Page 41: ...e gas valve assembly as shown in the fig ure 2 Install the new gas valve assembly in reverse order 3 Attach the two screws to the gas valve assembly Tightening torque 2 Nm if a torque spanner is available 4 When restarting the product carry out a leak tightness test check the CO content and if required adjust this 13 4 4 Replacing the fan 1 Move the expansion vessel to the maintenance posi tion on...

Page 42: ... the mains power 14 2 Permanently decommissioning 1 Drain the product Page 40 2 Press the on off button The display shows oF and then goes out 3 Disconnect the product from the mains power 4 Close the gas stopcock 5 Close the stopcock on the cold water connection 15 Recycling and disposal Disposing of the packaging Dispose of the packaging correctly Observe all relevant regulations For detailed in...

Page 43: ...he condensate siphon Annually 39 11 Cleaning the heating filter Annually 39 12 Checking the pre charge pressure of the expansion vessel at regular intervals 39 13 Removing the compact thermal module at regular intervals 36 14 Cleaning the heat exchanger at regular intervals 37 15 Checking the burner and burner insulating mat for damage at regular intervals 37 16 Checking the insulating mats in the...

Page 44: ...ating off on Heating on or eBUS control used d 17 Heating control 0 Flow temperature 1 Return temperature adjustment for underfloor heating If you have activated the return temperat ure control the automatic heat output determina tion function is not active 0 d 18 Pump overrun operating mode 1 3 1 Comfort continuously operating pump 3 Eco pump runs intermittently 3 d 20 Maximum target do mestic ho...

Page 45: ...rature cut out limit temperature Current value If the value is greater than 99 the display shows the number alternately Example using the number 1581 The display re peatedly shows the sequence 15 81 __ d 61 Number of unsuccessful ignitions Current value d 62 Day set back function 0 30 K Increment 1 0 d 64 Average burner ignition time Current value s d 65 Maximum burner ignition time Current value ...

Page 46: ...he pump overrun for domestic hot water mode is activated S 20 The domestic hot water demand is activated S 21 The fan start up for domestic hot water mode is activated S 23 The ignition for domestic hot water mode is activated S 24 The burner for domestic hot water mode is activated S 25 The pump and fan overrun for domestic hot water mode is activated S 26 The fan overrun for domestic hot water m...

Page 47: ...nection Interruption in the cable harness Check the cable harness F 10 Flow temperature sensor short circuit Flow temperature sensor de fective Replace the flow temperature sensor Short circuit in the cable har ness Check the cable harness Flow temperature sensor cable defective Check the flow temperature sensor cable F 11 Return temperature sensor short circuit Return temperature sensor de fectiv...

Page 48: ...eak tight Check that the gas solenoid valve works correctly F 28 Ignition unsuccessful Gas isolator cock closed Open the gas isolator cock Gas meter defective Replace the gas meter The gas pressure monitor has been triggered Check the gas flow pressure Air in the gas supply e g dur ing initial start up Reset the unit once Gas flow pressure too low Check the gas flow pressure The thermal isolator d...

Page 49: ... d 85 to 10 Presence of a shunt pump in the circuit This product is not compatible with a shunt pump in the install ation remove the shunt pump and change the installation s ba sic diagram accordingly Excessive counter pressure in the air flue pipe If required protect the product wind deflector F 46 Cold water sensor short circuit Cold water sensor defective Replace the cold water sensor Short cir...

Page 50: ...lt Thermal cut out Defective thermal fuse Check the heat exchanger for leakages If the heat exchanger has no leaks bypass the thermal fuse If you can then start the product replace the thermal fuse F 77 Fault Flue non return flap condensate pump No feedback from the flue non return flap or the feedback is incorrect Check that the flue non return flap functions correctly Flue non return flap defect...

Page 51: ...table is used for various products some codes may not be visible for the product in question Check programme Meaning P 00 Purging the domestic hot water and heating circuit The function is activated in the small domestic hot water circuit for 4 minutes and then in the heat ing circuit for 1 minute The pump runs and stops at regular intervals The function is active for five minutes P 01 Start up th...

Page 52: ...30V 24V 230V 2 12 13 14 16 1 8 9 10 11 15 17 18 17 3 4 5 6 X32 eBUS 1 3 2 4 7 1 Main PCB 2 PCB for the control element 3 Limit thermostat with contact for underfloor heating Burner off optional 4 Room thermostat RT 24 V optional 5 Bus connection for control room thermostat optional 6 Outdoor temperature sensor flow temperature sensor external DCF receiver optional 7 External eBUS plug 8 Heating fl...

Page 53: ... and they should be made aware it is ultimately their responsibility to register with the manufacturer within the allotted time period It is essential that the boiler is serviced in line with the manufacturers recommendations at least annually This must be carried out by a competent Gas Safe registered engineer The service details should be recorded on the Benchmark Service and Interim Boiler Work...

Page 54: ...eft at factory settings Yes No If no what is the maximum central heating output selected kW Dynamic gas inlet pressure mbar C Central heating return temperature C System correctly balanced rebalanced Yes COMBINATION BOILERS ONLY Is the installation in a hard water area above 200ppm Yes No Water scale reducer softener pre existing Fitted Not required Brand Product Yes No If yes DHW expansion vessel...

Page 55: ... delete as appropriate Date Engineer name Company name Telephone No Gas Safe registration No Max rate CO ppm CO CO CO Min rate CO ppm CO CO CO undertaken in accordance with manufacturers instructions and readings are correct yes Gas rate m3 h OR ft3 h delete as appropriate Yes No System inhibitor concentration has been checked and appropriate action taken in accordance with BS 7593 and boiler manu...

Page 56: ... delete as appropriate Date Engineer name Company name Telephone No Gas Safe registration No Max rate CO ppm CO CO CO Min rate CO ppm CO CO CO undertaken in accordance with manufacturers instructions and readings are correct yes Gas rate m3 h OR ft3 h delete as appropriate Yes No System inhibitor concentration has been checked and appropriate action taken in accordance with BS 7593 and boiler manu...

Page 57: ...pecify how to set boiler to minimum rate contact Technical Helpline for advice CHECK CO AND COMBUSTION RATIO AT MINIMUM RATE With boiler still set at minimum rate insert analyser probe into flue gas sampling point Allow readings to stabilise before recording NOTE If no flue gas sampling point is present and the correct procedure is not specified in the manual consult boiler manufacturer for guidan...

Page 58: ...g the condensate siphon with water 21 Filling the expansion vessel 39 G Garantie 6 Gas group 20 Gas type 20 H Handing over to the end user 34 Heating filter cleaning 39 Heating flow temperature 34 I If you smell gas 3 Inspection 35 Installing the air flue pipe 23 Installing the compact thermal module 38 Installing the front casing 19 Installing the gas connection 21 Installing the heating flow 21 ...

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Page 60: ...ne 01773 824639 Technical helpline 0330 100 7679 After sales service 0330 100 3142 www glow worm co uk These instructions or parts thereof are protected by copyright and may be reproduced or distributed only with the manufacturer s written consent Subject to technical modifications 0020313973_01 ...