Glowworm SwiftFlow 120 Benutzerhandbuch

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

221045A.05.97

Servicing Instructions

120

G.C. No. 47 313 13

One Contact Total Service

Hepworth Heating Ltd.,

Nottingham Road, Belper, Derbyshire. DE56 1JT

General/Sales enquiries:

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

Fanned Flue Combination Boiler

This is a Cat I 2H appliance

Customer Services:

Tel: (01773) 828100

Fax: (01773) 828070

Tobeleftwiththeuser

4559

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

2221045A

An Aid to Servicing

To obtain a products of combustion reading, make sure

that the main burner is alight. Remove the plastic cap,

see diagram 1.4 and connect the analyser probe to the

tube, replace cap after use.

1.2 Data Label

The data label is positioned on the front of the inner case

cover, see diagram 1.3.

1 G e n e r a l

Diagram 1.1

Diagram 1.2

The instructions consist of three parts, Installation,

Servicing and Instructions for Use 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.

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 fired with liquid

or gaseous fuels.

Type test for purposes of Regulation 5 certified by:-

Notified body 0087.

Product/production certified:- Notified body 0087.

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 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.

1.1 Servicing or Replacing Parts

To ensure the continued efficient and safe operation of

the boiler it is recommended that it is checked and

serviced as necessary at regular intervals. The frequency

of servicing will depend upon the particular installation

conditions and usage, but in general once a year should

be enough.

The servicing of this boiler must be carried out by a

competent person in accordance with the rules in force in

the countries of destination.

Unless stated otherwise, parts removed or renewed

during servicing should be fitted in the reverse order

to removal.

After completing any servicing, or renewing of gas

carrying components, ALWAYS test for gas soundness

and carry out functional checks of controls.

Discard all used sealing washers, gaskets and “O” rings

when renewing components.

Use the new ones supplied with the replacement.

SLOT (CLOSED) DRAIN

POINT

HEATING

FLOW

SAFETY

VALVE

DISCHARGE SLOT (CLOSED)

COLD WATER

SUPPLY IN GAS SERVICE

COCK HOT WATER

OUT

HEATING

RETURN

2793

DOOR

PLASTIC PLUGS (2)

COVER PLATE

OUTER CASE

OUTER CASE SECURING

SCREW (2)

SELECTOR SWITCH

4578

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

3221045A

1 G e n e r a l

Diagram 1.3

Diagram 1.4

PLASTIC

CAP

DATA

LABEL

PILOT WINDOW

SCREW (2)

INNER

CASE

COVER

SECURING

SCREW (4)

4579

4580

1.3 Isolation of Boiler

Before commencing any servicing or the replacement of

parts, isolate the boiler from the electrical supply at the

external isolator and close the gas service cock, see

diagram 1.1.

BEFORE DRAINING THE BOILER, REFER TO

SECTION 1.6.

1.4 Outer Case Removal

The door opens to the left or right hand side. The door

catch is spring loaded, to open, push the side opposite to

the hinge then pull.

Remove the two screws securing the outer case then

unhook the case at the top and pull it forward and off,

see diagram 1.2.

1.5 Cover - Inner Case

Remove the cover of the inner case, secured by four

screws, see diagram 1.3.

1.6 System Pressures and Draining

WARNING. All parts containing water of the central

heating circuit within the boiler, are under the system

pressure. Before any parts of this circuit are

disconnected, reduce the system pressure at the external

draining tap. Turn the central heating isolating valves

off and drain at the drain points on the appropriate

valves, see diagram 1.1.

All water containing parts of the domestic hot water

circuit of the boiler will be under the supply water

pressure. Before any parts of this circuit are

disconnected, turn the domestic cold water isolating

valve off, open the hot water taps to reduce the water

pressure in the boiler, close the hot water isolating valve

and drain the boiler at the valves, see diagram 1.1.

After replacing any water containing part of the central

heating circuit, make up the water loss, vent all air and

pressurise the system. Refer to “Commissioning” in the

Installation Instructions.

Check for water soundness.

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

4221045A

2 S e r v i c i n g

Diagram 2.2

SPARK GAP

4.5mm to 5.5mm

Diagram 2.1

FAN OUTLET

SEAL PLUG

STEP 1

Slacken do

not remove

2.1 Pilot Check

Check that the pilot flame is burning correctly and of the

correct size, see diagram 2.1. If the pilot flame is not

correct, the pilot injector will require removing, as

detailed later.

2.2 Isolation and Access

Before starting, refer to Section 1.1.

Isolate the boiler from the electrical supply and close the

gas service cock, refer to Section 1.3.

Remove the outer case and the inner case cover, refer to

Sections 1.4 and 1.5.

Disconnect the electrical plug connector and air pressure

tube from the fan, see diagram 2.2.

Follow steps 1 to 4 on diagram 2.2 to remove the

hooks bolts.

Step 1 - Slacken the two thumb screws securing the

collector but do not remove.

Step 2 - Unhook the hook bolts.

Step 3 - Turn the hook bolts.

Step 4 - Remove the hook bolts.

Remove the fan securing screws.

Pull the fan forwards, at the bottom and rotate to

disengage the fan outlet to flue elbow and rear bracket.

Take care not to damage the seal.

Tilt the fan and withdraw.

Remove the flue collector, note, this may be a tight fit.

Remove the combustion chamber front panel, secured

with four screws, see diagram 2.3.

Slacken, but do not remove the gland seal

securing screw.

Should the pilot burner assembly require servicing, it

will be necessary to disconnect the pilot and

thermocouple nut as this stage, see diagram 2.4.

Remove the pilot burner assembly securing screws

and washers.

When removing the pilot burner assembly, note the pilot

injector is loose and that the electrode and lead are

connected and must not be used to hang the assembly by,

see diagram 2.4.

Remove the main burner from the main injector at the

rear. Raise the burner up and forward, easing the pilot

assembly forward and clear, taking care not to damage

the combustion chamber insulation or pilot burner

assembly, see diagram 2.5.

FLAME

LENGTH

25mm

THUMB

SCREW (2)

FAN

SECURING

SCREWS

AIR

PRESSURE

TUBE

STEP 3

STEP 2

STEP 4

FLUE

COLLECTOR

4574

4581

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

5221045A

2 S e r v i c i n g

Diagram 2.4

Diagram 2.3

SECURING

SCREW (4)

COMBUSTION

CHAMBER FRONT PANEL

SPARK

ELECTRODE

SEALING GLAND

SECURING SCREW

IGNITION

LEAD

PILOT INJECTOR

SPARK

ELECTRODE

RETAINING CLIP

THERMO-

COUPLE

NUT

PILOT TUBE

NUT

WING NUT

SECURING

SCREW AND

WASHER (2)

2.3 Heat Exchanger

Place a sheet of paper or similar in the combustion

chamber, to act as a collector for deposits removed.

Brush the heat exchanger with a suitable brush, remove

paper together with any debris.

2.4 Main Injector

Inspect the injector and clean as necessary.

Do not use wire or a sharp instrument on the hole.

2.5 Main Burner

Use a vacuum cleaner or suitable brush to clean the

burner thoroughly, making sure that all burner ports are

clear and free from obstructions.

Do not use a brush with metallic bristles.

2.6 Service Checks

Before replacing any parts removed during servicing,

inspect the condition of all seals and joints, renewing

them as necessary.

Check the condition of the combustion

chamber insulation.

Check that the spark gap is as shown in diagram 2.1.

2.7 Note. Reassembly

Make sure that the main burner baffle has located in the

side guides and that the burner is located on the

main injector.

Refit the hook bolts.

The combustion chamber front panel should be fitted

loosely, then the flue collector also fitted loosely, make

sure that it is seated onto the heat exchanger and over 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, making sure that the fan

outlet seal is correctly positioned. Secure with the two

screws, see diagram 2.2.

Refit electrical connector making sure that the red spots

are aligned.

Secure the flue collector and combustion chamber front

panel by tightening the thumb screws and securing

screws, see diagram 2.2 and 2.3.

2.8 Operational Checks

Light the boiler, carry out operational checks and any

necessary adjustments as described in “Commissioning”

in the Installation Instructions.

HEAT

EXCHANGER

4582

4583

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

6221045A

2 S e r v i c i n g

Diagram 2.5

STEP 1 STEP 3

STEP 2 STEP 4

SECURING

SCREW

WING NUT

BURNER

BRACKET

WING NUT

BURNER

BRACKET

BURNER

GUIDE

BURNER

SIDE

GUIDES MAIN INJECTOR

BURNER

4586

45844585

4587

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

7221045A

3 F a u l t F i n d i n g

Diagram 3.1

3.1 Initial Checks

If the boiler fails to operate, first check the following:

1. That the electrical supply is available at the boiler and

the fuses are in order.

NOTE: THE BOILER CONTROL BOARDS CAN BE

DAMAGED BY INCORRECT TESTING WITH THE

POWER ON.

2. Make sure that the system pressure gauge registers

0.7bar, minimum and that the automatic air vent works.

Refer to Installation Instructions, Section 11.2.

3. That the gas supply is available at the boiler and

purged of air.

4. Is the pilot burner lit? - If the pilot burner will not

light refer to Section 3.2. If the pilot burner fails to

remain alight, refer to Section 3.3

5. That the boiler is set for the required service.

6. With the boiler central heating selector switched

“Off”, see diagram 3.2 check that the domestic water

supply is available and water flows freely from the hot

taps. Close the taps.

7. With the boiler central heating selector switched

“ON”, see diagram 3.2, check that all heating system

controls, if fitted, are working correctly and calling for

heat. If not isolate the boiler from the electrical supply.

Disconnect the rear multi-pole connector at the base of

the boiler and release the cable from the clamp.

Remove the connector cover and dependent on the type

of control fitted test for continuity, mains or low voltage

at terminals 1 and 2, see diagram 3.1.

If this is satisfactory continue with the detailed

fault finding.

Diagram 3.2

Orange Light

‘MAINS’

Green Light

‘RUNNING’

SWITCH

(OFF)

C.Htg.

SELECTOR

SWITCH

Red Light

LOW C.Htg.

WATER

PRESSURE

SWITCH

(ON)

GAS CONTROL KNOB

PIEZO BUTTON

PRESSURE

GAUGE

CABLE

CLAMP/COVER

SCREW (2)

MAINS

CABLE

LNE2

1CABLE

CLAMP

2883

CABLE TO

REMOTE

HEATING

CONTROLS

CLOCK/TIMER

(IF FITTED)

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

8221045A

3 F a u l t F i n d i n g

Check gas line - open all cocks,

rectify any blockages, purge out

any air. Does pilot light?

Apply match to pilot burner instead

of pressing piezo unit button.

Does pilot light?

Undo tubing nut at pilot burner.

Press multifunctional control knob.

Does gas flow freely?

Does pilot stay alight when

multi-functional control knob

is released?

Does pilot flame

envelope thermocouple?

Check aeration. If necessary -

clean pilot, rectify blockage in pilot

injector, or replace.

Check thermocouple circuit using

thermocouple and boiler overheat

cut-off fault finding.

On pressing piezo unit button is

there a spark across electrode gap?

Undo tubing nut at pilot outlet of

mulitfunctional control.

Press multifunctional control knob.

Does gas flow freely?

Rectify blockage in pilot injector,

or renew pilot injector.

Change blocked pilot tube.

Change multifunctional control.

Check electrode gap. Reposition,

or replace electrode as necessary.

Change

piezo unit.

PILOT SATISFACTORY

PILOT WILL NOT LIGHT

START HERE

YES

NO YES

YES

Diagram 3.3

Remove electrode from pilot bracket.

Hold tip close to pilot burner and

operate piezo unit.

Is there a spark across gap?

Pull ignition lead off piezo unit.

Using blade of an insulated screw-

driver, touch unit chassis and leave

approx. 4mm gap from connection

tag on piezo unit. Operate piezo.

Is there a spark across gap?

Change electrode

assembly.

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

9221045A

3 F a u l t F i n d i n g

Diagram 3.5

CONNECTION

'D'

MULTIFUNCTIONAL

CONTROL

BOILER

OVERHEAT CUTOFF

CONNECTION 'E'

CONNECTION

'C'

CONNECTION

'B'

CONNECTION

'A'

With the boiler cold, check connections of the thermocouple, boiler overheat cut-off and multifunctional

control. Disconnect overheat cutoff connectors at points A and B at the multifunctional control,

see diagram 3.5. Test continuity of the overheat cutoff. Is there continuity?

Re-connect boiler overheat cutoff to points

A and B. Disconnect thermocouple at point

D of the mulitfunctional control. Test continuity

between point C and the body of the multi-

functional control. Is there continuity?

Test continuity of thermocouple between inner

connection point D and point E.

Is there continuity?

Thermocouple and boiler overheat

circuit satisfactory.

Faulty cutoff connectors into

multifunctional control, either at A or

C. Renew where faulty.

Faulty boiler overheat cutoff, renew.

Faulty thermocouple, renew.

YES

Diagram 3.4

3.2 Pilot Burner and Ignition System

Symptom: The pilot burner will not light or stay alight.

Test the pilot burner and ignition system as shown in

diagram 3.3.

3.3 Thermocouple and Overheat Cutoff

Symptom: The pilot burner fails to stay alight.

On completion of initial checks, as Section 3.1.

Test the thermocouple, overheat cutoff and thermocouple

connectors, as described in Fault Finding diagram 3.4

and shown in diagram 3.5.

Check the millivoltage of the thermocouple closed

circuit at points “A” and “E”, this should be within the

range of 6 to 11mV, see diagram 3.5.

4588

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

10221045A

(N)

(L)

PERMANENT

LIVE

240V~50Hz

OPTIONAL

SWITCHED LIVE

FROM ROOM

STAT. 240V~50Hz

PUMP

TRANSFORMER

240V~

LOW

VOLT.

26V~

CONTROL BOARD

FUSE 1

3 3

COMMON

(N)

(L)

CLOCK/TIMER

3 F a u l t F i n d i n g

Diagram 3.6

CONTROL BOARD

TERMINALS, CN 3

CONTROL BOARD

TERMINALS, CN 4

CONTROL BOARD

TERMINALS, CN 2

KEY

br........................BROWN

b.........................BLUE

p.........................PURPLE

3.4 Clock/Timer - if fitted

If the clock has failed it can be bypassed by

disconnecting the plug at the wall frame.

Disconnect the plug at the control box and connect this

plug to the connection at the wall frame.

This is a temporary measure and the clock should be

repaired or replaced as soon as possible.

3.5 Electrical

Preliminary electrical system checks, as outlined in a

Multimeter Instruction book, are the first checks to be

carried out during a fault finding procedure.

Isolate the boiler from the electrical supply, refer to

Section 1.3.

Gain access to the boiler controls by removing the outer

case, refer to Section 1.4. Check that all cables and

connectors are secure.

Gain access to the control board, refer to Section 4.13.

Check all cables at the multi-pin connectors on

the board.

Test the two fuses on the main control board and renew

as necessary, the fuse are, type 2AT and type 3.15AT.

If a fuse fails repeatedly or the initial fault finding

checks described in Section 3.1 indicate a boiler fault,

check the boiler electrical circuits and follow the fault

finding procedures, see diagram 3.5, 3.6, 3.7 and 3.8

and for clock/timer fault diagram 3.9.

On completion of a fault finding task that has required

the disconnection and making of electrical connections

then checks, for earth continuity, polarity and resistance

to earth must be carried out.

0192M

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