Glowworm Lighting 40 manual Servicing, Heat Exchanger Cleaning

Notes

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.

Note. For obtaining a products of combustion reading use the connection on top of the boiler, see diagram 6.1.

Should the gas pressure need adjusting refer to Section 10.4.

Isolate the boiler from the electrical supply.

Before starting a service, remove the casing, refer to diagram 5.1.

Turn the gas supply off at the gas service cock, see diagram 8.1.

Unless stated otherwise, parts removed for servicing should be replaced in the reverse order to removal.

After completing any servicing of gas carrying components, ALWAYS test for gas soundness and carry out functional check of controls.

Also check for condensate leaks at fan outlet/flue elbow and fan inlet/flue hood joints.

It should be noted that the burner is water cooled and a system drain down is necessary if the burner is removed.

12.1 Heat Exchanger Cleaning

Remove the inner case cover, see diagram 5.3.

Remove the bypass heat shield, see diagram 12.1.

Note. The flue hood top will “spring” up.

Disconnect the fan air pressure tubes, combustion sampling tube, electrical connections and remove the three fan securing screws, fan and the flue hood.

Note. On reassembly it is suggested that the two top securing screws for the bypass heat shield and the flue hood be partially engaged before fitting of the bypass heat shield, see diagram 12.3.

Carefully remove the combustion chamber front panel, see diagram 12.4.

Remove the loose baffle from the condensing section, see diagram 12.5.

When replacing note that it is marked “Front”.

Place a container under condense drain trap, see diagram 12.8, and remove red cap.

Flush loose debris from secondary heat exchanger with water poured from above, and allow the water to drain through the flexible condensate tube at the right hand side of the heat exchanger into the container.

Check that this tube is not partially blocked and the water runs freely.

If there is any build up of debris in the condensate trap, the trap should be removed and flushed out.

Important: With use a white oxide coating will form on the aluminium parts - this should only be removed if the coating is blocking the gaps between the fins.

When cleaning take care that the water does not overflow the condensate catchment tray.

Place a sheet of paper over the burner, see diagram 12.6.

Clean the primary heat exchanger, with a suitable soft brush, see diagram 12.6.