condens Installation and Servicing Betacom2 24 G.C. No. 47-019-16 Betacom2 28 G.C. No.
Table of contents INT R O D U C T I O N 1 Instructions guidance.................................................................................................................... 3 1.1 1.2 1.3 2 Appliance description.................................................................................................................... 3 2.1 2.2 2.3 2.4 3 Safety devices . ...................................................................................................3 Data label.........................
Table of contents 11 Commissioning .......................................................................................................................... 21 11.1 11.2 11.3 11.4 11.5 11.6 11.7 11.8 11.9 12 Specified Adjustment.................................................................................................................. 23 12.1 12.2 12.3 12.4 12.5 12.6 12.7 13 Switching on.....................................................................................................
INTRODUCTION INTRODUCTION 1 Instructions guidance 1.1 Product documentation The instructions are an integral part of the appliance and must be handed to the user on completion of the installation in order to comply with the current regulation. • Carefully read the manual, to understand all the information to enable safe installation, use and servicing. No liability can be accepted in the event of damage for not complying with the guidance in this instruction manual.
INTRODUCTION 2.3 2.3.1 Regulation and 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 fired with liquid or gaseous fuels. Type test for purposes of Regulation 5 certified by: Notified body 1312. Product/production certified by: Notified body 0086. 2.
INTRODUCTION 3 Safety instructions and regulations • Use only original spare parts. • Use only new O-rings and gaskets. 3.1 Safety instructions If the gas pressure at the input of the appliance is outside the range specified, the appliance must not be put into operation. e DANGER: Incorrect installation can cause electric shock or appliance damage. • Never disable security devices and do not try to adjust them.
INTRODUCTION Gas Supply The gas installation must be in accordance with the relevant standards. In GB, this is BS6891. In IE, this is the current edition of I.S.813 “Domestic Gas Installations”. The supply from the governed meter must be of adequate size to provide a steady inlet working pressure of 20mbar (8in wg) at the boiler. On completion, test the gas installation for tightness using the pressure drop method and suitable leak detection fluid, purge in accordance with the above standard.
technical data TECHNICAL DATA 5 Betacom2 Boiler, type C13, C33, C43 Description Unit 24 ll2H3P ll2H3P % 89.0% 88.5% kW 18.5 kW Description Unit mm 15 (copper) 15 (copper) mm 22 (copper) 22 (copper) 24 Gas connection Ø O.D. Heating flow and return connection Ø O.D. Domestic Hot Water connection Ø O.D. mm 15 (copper) 15 (copper) 7.7 8 Condensate connection Ø I.D. mm kW 18.0 23.3 Safety valve discharge connection Ø O.D. mm kW 8.5 8.8 Lift weight kW 19.6 25.
INSTALLATION INSTALLATION i 6 ØA IMPORTANT: All the drawings dimensions are shown in mm. ØA 6.1.1 n. Location Instructions Before choosing a site for the appliance, carefully read the safety warnings and installation manual. 0 mi n. • Ensure that wall to which the appliance will be mounted on is structurally safe in order to support the weight of the appliance. • Ensure that the space that the appliance is to be installed within allows the appliance to be installed and the clearances maintained.
INSTALLATION 7 Appliance installation 7.1 7.2 7.2.1 Scope of delivery Domestic hot water circuit design Water pressure The appliance is delivered in a single carton with a document pack and fittings. i Recommendations before installing The minimum working pressure to obtain the maximum domestic flow is 1,0 bar. IMPORTANT: The flues package will be ordered according to the configuration of the installation. The maximum working pressure of the domestic hot water circuit is 10 bar.
INSTALLATION General Drain points This boiler is designed for use as part of a sealed water central heating system with fully pumped circulation. The pump, expansion vessel and associated safety devices are all fitted within the boiler. Drain taps must be provided at all low points of the system, which will allow the entire system to be drained. Drain taps shall be to the current issue of BS2879.
INSTALLATION 7.4 Mounting 7.4.1 • Make sure that the equipment used for implementing the installation is compatible with that of the appliance. 3 • Determine the assembly location. See the "Appliance location" chapter. 2 Fixing to the wall 130 90° 1 4 5 6 Key 1 2 3 4 5 6 Wall template Standard flue length horizontal 2.5° 44mm/metre inclined extended flue length Wall plug Hanging bracket Screw Flue hole cutting • Mark the position of the flue centre.
INSTALLATION 7.4.2 a Boiler hanging DANGER: With regards to the Manual Handling Operations, 1992 Regulations, the following lift operation exceeds the recommended weight for a one person lift, refer to chapter "Manual Handling". a DANGER: Do not perform any 'hot work' directly under the appliance, this may cause damage to the appliance base. Heat may also damage the isolation valves. Always pre-assemble pipes before fitting them to the boiler. • Only use original seals supplied with the appliance.
INSTALLATION 8.2 Safety Discharge Valve 2 2 1 3 1 B Key 1 Condensate pipe 2 Condensate outlet pushfit • Make sure there is no protective plug fitted. A Key 1 2 3 A B Discharge pipe 15mm o.d. Pressure relief valve PRV Draining outlet PRV outlet - to outside Appliance drain This must be extended, using not less than 15mm o.d. pipe, to discharge, in a visible position, outside the building, facing downwards, preferably over a drain.
INSTALLATION Washing machine trap / waste INCREASE PIPE SIZE 100 mm min. 75 mm min. 2.
INSTALLATION 9 Evacuation of combustion gas b 9.1 Regulation b ATTENTION: Only flue accessories supplied by Glow-worm must be used. ATTENTION: If the flue terminal is positioned near a light source insects may enter the flue system. Where safe and practical to do so advise the homeowner to check the flue outlet and clear visible insects from the terminal end. Different flue outlet configurations can be carried out.
INSTALLATION 9.2 Flue configuration description 9.2.1 a Each time an additional 90° bend is necessary (or 2 at 45°), the length (L) must be reduced by 1 m. Horizontal concentric flue Ø 60/100 mm or Ø 80/125 mm (C13 type installation) DANGER: If necessary, you must install a terminal protection kit. Ø 60/100 mm When using the Plume Management Kit, the maximum lengths flue pipe A and B (60/100mm) are: A (m) 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 B (m) 5.5 5.0 4.5 4.0 3.5 3.0 2.
INSTALLATION 9.2.3 b Multiple boiler chimney flue Ø 60/100 mm (C43 type installation) Model 24 28 At min thermal load (40°C/30°C) 3.6 3.74 At max thermal load (80°C/60°C) 8.3 10.8 At min thermal load (40°C/30°C) 45 46 At max thermal load (80°C/60°C) 71.6 79 Exhaust mass rate (g/s) ATTENTION: The flue connecting from the appliance to the flue system must be supplied from the manufacturer of the boiler.
INSTALLATION 10.2 Main board 1 2 10.3.1 3 30mm max Key 1 Connector 2 Electrical wires 3 Insulation 230V permanent supply a DANGER: All cables connected to the appliance should be permanently fixed to the wall. i IMPORTANT: This appliance will not operate without a link or system controls fitted. 2 • Keep a distance of a maximum of 30 mm between connector (1) and the start of the insulation (3). 1 • Fix the cables in the cable-clamp on the eBox. 10.
INSTALLATION 10.3.2 230V permanent supply + 230V system controls a DANGER: All cables connected to the appliance should be permanently fixed to the wall. i IMPORTANT: This appliance will not operate without a link or system controls fitted. 3 10.4 External accessories e DANGER: Under no circumstances must any mains voltage be applied to any of the terminals on the 24v connection plug.
INSTALLATION 10.6 Wiring diagram CL 5 INTERFACE X31 4 X51 X40 3 X32 2 6 X90 X30 X15 X2 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 X13 X14 8 X101 1 2 3 4 X20 X21 X1 9 Green/Yellow 10 11 12 13 14 15 16 17 18 X17 NTC M 24 V Ebus Green/Yellow 1 2 3 4 5 6 7 8 9 Green/Yellow X17 1 7 FUS N L 230 VAC 15 X2 X20 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 4 3 2 1 1 2 3 1 2 10 11 12 13 14 15 16 17 18 3 4 1 2 D 18 17 5 4 3 2 1 9 8 ...
INSTALLATION 11 Commissioning i IMPORTANT: At the time of commissioning, complete all relevant sections of the Benchmark Checklist located in the centre pages of this document. The commissioning should be carried out by a competent person approved at the time by the Health and Safety Executive and in accordance with the current issue of BS6798. 11.1 Switching on • Do not operate the boiler without water.
INSTALLATION • Run the appliance for at least 15 minutes, with a heating temperature set to greater than or equal to 50°C (not applicable for an installation with underfloor heating). • Check that hot water is available at all taps, then close. • Vent air from each radiator again until the water flows normally, then close the vents. • Return the appliance to the correct mode by pressing "mode" button unit the desired functions are activated.
INSTALLATION 11.6.2 11.9 Gas Rate Completion • Make sure that all other gas burning appliances and pilot lights are off. • Ensure that the magnetic lighting instruction label is placed on the surface of the boiler casing. • Check the gas rate using the gas meter test dial and stop watch, at least 10 minutes after the burner has lit, see table below for approximate rates. GB: It is a requirement that the “Benchmark” Installation, Commissioning and Service Record is completed and left with the user.
INSTALLATION 12.2 Installation settings • Press or button to access the parameter to modify. • Push in and hold the button for more than 7 seconds to access the configuration menu. The screen displays "0". button to modify the value of the parameter and • Press select with the or keys. • Press the button 4 times. The screen displays "96". This is the installer's password. • Press button to confirm and save the changes. • Press and hold the exit. to validate.
INSTALLATION Factory setting Modifiable parameter Display the digitalized ionisation voltage. Multiply the displayed value by 100. - no - Display the number of unsuccessfull ignitions at first attempt. - no Unsuccessfull ignitions at second attempt - Display the number of unsuccessfull ignitions at second attempt. - no d.80 Operating hours in heating mode h Display the number of operating hours in heating mode. Multiply the displayed value by 100. - no d.
INSTALLATION 12.5 Test modes 12.7 Re-check and restart By activating these various test modes, you can enable special functions on the appliance. • Once the appliance is installed, check the operation of the appliance. • Press the on/off button to switch off the appliance. • Start the appliance to ensure that any adjustments operate correctly and check that the appliance operates safely. pressed for more than 5 • While keeping the button seconds, press the on/off button.
MAINTENANCE MAINTENANCE 14.1.1 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 particular installation and usage, but in general once a year should be enough. It is the Law that any servicing is carried out by a competent person approved at the time by the Health and Safety Executive.
MAINTENANCE 14.2 Fault memory • This menu allows you to display the 10 most recent failure codes registered by the appliance. • In order to display the fault code memory, simultaneously for more than 7 seconds. press the buttons and • The screen will display the first fault "1." (record) and after "XX" (fault code). • To display the other faults registered by the appliance, press the button or . • Press button for more than 3 seconds to exit this menu.
MAINTENANCE Fault codes F61 F62 F63 F64 Description Cause Gas valve command fault Gas valve closure fault Fault in the main board F65 F67 Fault in the main board memory Rapid fluctuation of return or flow heating sensor. Excessive main board temperature Flame signal fault in the main board Solution • Check the main boards connections. • Check the main board. • Check the appliance DSN number is correct. • Reset the appliance.
MAINTENANCE 14.4 Functional flow diagram 14.4.1 Central Heating 14.4.
MAINTENANCE 15 Gas conversion adjustments 2 3 In order to operate with a gas other than that provided from the factory, it is necessary to make some adjustments to the gas valve. This conversion should only be carried out by a competent person approved at the time by the Health and Safety Executive. • During the conversion to Propane, use of a suitable flue gas analyser is necessary.
MAINTENANCE • Compare the value measured with the values indicated in the table below. Gas adjustment 16.1 G20 G31 CO2 case ON 9 ± 0.2 % 10.1 ± 0.2 % CO2 case OFF 9.2 ± 0.3 % 10.3 ± 0.3 % i 15.1.3 16 Draining Heating circuit IMPORTANT: Safe combustion can only be verified by measuring CO/ CO2 ratio. This must not exceed the value shown in the table under the section "Maximum Rate and Adjustment". Restarting • Replace the cap • Replace the appliance front panel.
MAINTENANCE • To obtain service, please call your installer or Glow-worm’s own service organisation. 17.1.
MAINTENANCE 17.2.2 Control box • Electrical, gas and water connections. • System pressure. 1 • The combustion performance, refer to the following procedure. • The operational gas inlet pressure and gas rates, refer to the commissioning section paragraph 12.5. Correct any fault before continuing. 24 V 23 Combustion check and setting the air/gas ratio 0 V • Remove the front casing panel and hinge down the control box.
MAINTENANCE G31 Burner % CO2 Model Check (case on) Setting (case off) CO/CO2 ratio 24 10.3 ± 0.3% 10.1 ± 0.2% 0.004 28 10.3 ± 0.3% 10.1 ± 0.2% 0.004 If the combustion reading is not within the acceptable values and the integrity of the complete flue system and combustion circuit seals have been verified and the inlet gas pressure (and gas rate) have been verified, then, it will necessary to adjust the combustion rate of the appliance.
MAINTENANCE 17.6 Expansion vessel The condense trap will contain water, lift taking care not to spill the water. 2 • Remove the condensate trap (5) using the retaining screw (4). • Clean the hose, the trap and the siphon, remove any accumulated dirt. • Reassemble the components, taking care to position the gaskets correctly. • Start the siphon (3) and fill with water.
MAINTENANCE 17.8 Combustion block 9 8 7 6 5 10 4 11 3 12 2 13 1 14 15 16 17 Legend 1 Gas valve connection 2 Grounding cable 3 Spark electrode inlet 4 Spark electrode retaining screw. 5 Spark electrode gasket 6 Spark electrode 7 Burner retaining nut 8 Burner retaining screw 9 Thermal fuse connection 10 Coil 11 Heat exchanger 12 Burner door seal 13 Burner 14 Gas valve 15 Fan 16 Fan connection 17 Gas pipe 0020145065_01 - 09/12 - Glow-worm 17.8.
MAINTENANCE 17.8.2 b Dismantling the burner Warning: The burner door seal (12) must be replaced each time the burner is dismantled. • Disconnect the spark electrode connector (6) from the igniter unit. • Remove the gas pipe (17). • Remove the connectors from the gas valve (1) and the fan (15). • Remove the retaining screw of the silencer. • Loosen the 4 nuts (7). • Remove the burner group from the heat exchanger (11). • The studs (8) fixed to the heat exchanger must not be damaged.
MAINTENANCE 18.2 Boiler Access 18.3.1 Expansion vessel For replacement of parts, the front casing panel of the boiler will need to be removed. A • To remove undo the two screws on the underside of the front casing and lift off. 18.3 Viewing window 4 2 D 3 1 E 3 2 2 1 4 C 5 Key 1 2 3 4 5 Fibre washer Steel washer Glass Steel washer Circlip B 24 V 1 23 0 V • Remove the circlip (5). • Remove the steel washer (4). • Remove fibre washer (1). • Remove the glass (3).
MAINTENANCE 18.
MAINTENANCE 18.4.2 Automatic air vent • Drain the boiler heating circuit as described in the appropriate chapter "Draining". • Remove the retaining clip (19). Remove the automatic air vent (18). • Fit the new automatic air vent and ‘O’ ring ensuring the vent cap is left loose. • Refill, vent and pressurise the boiler. 18.4.3 Low water pressure sensor • Drain the boiler heating circuit as described in the appropriate chapter "Draining". • Disconnect the electrical lead (4).
MAINTENANCE 18.
MAINTENANCE 18.5.1 Spark electrode • Disconnect the electrode cap (7) and the earthing cable (6). • Remove the 2 spark electrode retaining screws (8). • Carefully remove the electrode (10) from the combustion chamber. • Remove the gasket (9). • Check that the distance between the 2 electrodes is between 3.5 and 4.5 mm. • Install the electrode and a new gasket. 18.5.2 Igniter unit 18.5.5 b Heat exchanger ATTENTION: There will be water in the heat exchanger.Carefully ease heat exchanger out.
MAINTENANCE 18.5.9 Gas valve • Place a container under the condensate trap (5). • Remove the burner door (11) refering to chapter "Dismantling the burner door". • Remove the two gas valve retaining screws (30). • Disconnect the condensation discharge (2). • Disconnect the heat exchanger hose (6). • Remove the gas valve (31) and the gasket (32). • Fit the new gas valve and the new gasket by repeating the operations in reverse.
MAINTENANCE 18.7.2 19 Spare parts 2A Fuse Rating • For access, refer to chapter "Main PCB". • The fuse is located at top right hand side of the PCB, see chapter "Electrical connection >Wiring diagram". 18.7.3 User interface PCB In order to guarantee the safe and prolonged life of the product, manufacturers genuine spare parts must be used. i IMPORTANT: This appliance displays a CE Mark of conformity. Only use the manufacturer’s genuine, new spare parts.
MAINTENANCE Short List of Parts • When ordering spare parts, contact Glow-worm’s own service organisation. • Please quote the name of the appliance and serial number, to be found on the data label. If ordering from British Gas also quote the G.C. number of the part. Key No. 1 2 3 4 5 6 Part No. Description 0020097277 A000035144 2000801935 0020097279 0020038441 0020118159 Fan Spark igniter Thermistor (flow and return) Gas valve Electrode assembly User interface PCB GC Part No. Key Part No. No.
Manual Handling IMPORTANT. With regards to the Manual Handling Operations, 1992 Regulations, the following lift operation exceeds the recommended weight for a one man lift. General recommendations when handling Clear the route before attempting the lift. Ensure safe lifting techniques are used – keep back straight – bend using legs. Keep load as close to body as possible. Do not twist – reposition feet instead. If 2 persons performing lift, ensure co-ordinated movements during lift.
Declaration of Conformity Installation, Commissioning and Service Record
SERVICE INTERVAL RECORD It is recommended that your heating system is serviced regularly and that you complete the appropriate Service Interval Record Below . Service Provider. Before completing the appropriate Service Interval Record below, please ensure you have carried out the service as described in the boiler manufacturer’s instructions. Always use the manufacturer ‘s specified spare part when replacing all controls.
Subject to engineering changes 0020145065_01 - 09/12 GLOW-WORM Nottingham Road, Belper, Derbyshire. DE56 1JT www.glow-worm.co.uk Because of our constant endeavour for improvement, details may vary slightly from those shown in these instructions.
