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Ultracom2 35 Store Installation & Servicing Manual - Glow-worm

1. Pressure reducer Filter on cold water inlet Domestic hot water pump Non return valve Heating circuit drain tap Water pressure sensor Heating pump Heating return thermistor Air vent Heating flow thermistor Condensate trap Particle filter Ignition and control electrode Burner Main heat exchanger Heating expansion vessel Thermal fuse Flue outlet Silencer Fan Hot water safety valve Discharge tube not supplied Storage tank Storage tank DHW expansion vessel 0020112185 PROTO 13 01 11 Glow worm r0 TMA WS AW 29 lI A 30 G _ __ fs c Hii aaa ante JAI 0 He Storage tank temperature sensor Hot water temperature sensor Gas control valve Ignition module By pass Three way valve Domestic plate to plate heat exchanger Hot water heat exchanger output temperature sensor Tundish Gas isolating valve Domestic hot water isolating valve Heating safety valve Heating flow isolating valve Domestic cold water isolating valve Heating return isolating valve Heating return Cold water inlet Heating flow Domestic hot water outlet Gas Condensate drain Cold water supply Heating safety valve drain Hot water safety valve drain 3 Safety instructions and regulations 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 Incorrect installation can cause electric
2. Key 1 Overheating safety connector for heating floor 2 Outdoor sensor connector 3 Ebus room thermostat connector or Ebus radio receiver 4 24V room thermostat connector Key N e Fit external controls in accordance with the rules in force 3 Double pole connector 4 230V permanent supply p Aa ele 11 5 Testing the electrical connections Mains earth N Mains neutral L Mains live Carry out preliminary electrical system checks as below Resistance to earth lt 1 Ohm Connect mains supply as described Shortcirouit teat inj Resistance to earth L E e Polarity check 0020112185_PROTO_13 01 11 Glow worm eae 11 6 Wiring diagram 6 5 4 3 2 1 NL 230 VAC X21 NG Be 1 oo 23 14 13 Key 12 Domestic
3. Consult the Fault codes chapter Consult the Fault codes chapter Consult the Fault codes chapter e The screen will display the first fault 01 record and F XX fault code To display the other faults registered by the appliance press e To erase the fault memory registered by the appliance consult the or button of the domestic hot water temperature the Installation adjustments chapter and use code d 94 controls ga e Press the button for more than 3 seconds to exit this 15 3 Fault codes menu The faults described in this chapter should be carried out by a qualified engineer and if needed by the After Sales Service FO1 Return heating temperature sensor fault Reuim heating temperature sensor disconnected Hot water temperature sensor fault Sensor disconnected Storage tank temperature sensor fault Sensor disconnected 3 a e Check the sensor s connections Flow heating temperature sensor fault Sensor short circuit e Check the wiring harness j e Check the sensor F11 Return heating temperature sensor fault Return heating temperature sensor shorted Hot water temperature sensor fault Hana temperature sengar shart Storage tank temperature sensor fault AASA tank temperature sensor short circuit Overheating safety device activated e Check the operation of the pump 97 C e Check the wiring harness Overheating fault j bleedi e Check that the flow and return heating isolation WPAP a
4. Incorrect air pressure Incorrect fan speed Check the entire fine system P PERS e Check the fan s electrical connections EBUS voltage fault Fault in EBUS line e Check that the eBus controls are fitted and wired s Short circuit in EBUS connector correctly F61 o Gas valve command fault Gas valve closure fault Fault in the main board memory e Check the main boards connections A a e Check the main board PANTE MANA HAN e Check the appliance DSN number is correct heating sensor e Reset the appliance e Check the return gas circuit gas valve open e Check the observe the flame picture and check the CO setting e Check the igniter unit connections e Check the state of the electrode corrosion No return gas Insufficient gas flow Gas valve incorrectly adjusted Defective firing electrode and flame control Defective igniter unit Fluctuation of flame signal e Check that the appliance DSN code on the screen matches the product code of the nameplate in the Incorrect product code event of a fault and the appliance DSN does not appear consult menu d 93 reserved for the code e Check the boards reference User interface incompatible with the main board Flow heating temperature sensor Flow heating temperature sensor fault unclipped or defective no temperature variation e Check the sensor connections e Make sure that the sensor is clipped to the tube Mismatch between the flow and return heating temperat
5. e Remove the glass 3 50 19 3 1 Central heating expansion vessel Key 1 Connector 2 Expansion vessel 3 Upper support bracket 4 Retaining screw Drain the boiler heating circuit as described in the appropriate chapter Draining Remove the two screws 4 Undo the connector 1 at the base of the vessel Remove upper support bracket 3 Remove the expansion vessel 2 Fit a new gasket between the expansion vessel and connector Refill vent and pressurise the boiler 0020112185_PROTO_13 01 11 Glow worm 19 3 2 DHW expansion vessel Drain the boiler domestic hot water circuit as described in the appropriate chapter Draining Key 1 2 3 4 Expansion vessel Expansion vessel pipe nut bracket Drain the boiler domestic hot water circuit as described in the appropriate chapter Draining e Undo the expansion vessel pipe 2 Remove nut 3 e Remove the expansion vessel 1 0020112185_PROTO_13 01 11 Glow worm 19 3 3 Particle filter 2 MW Key 1 Particle filter 2 Clips Remove the particle filter to check its condition Drain the boiler heating circuit as described in the appropriate chapter Draining e Remove the 2 clips 2 e Remove the particle filter 1 After installing a new particle filter refill and bleed the appliance and the installation if necessary 51 19 4 Hydraulic block 11 Glow worm
6. 60 100 mm Key 1 Gasket fitted 22 80 125 mm Key 1 Gasket fitted pte den 60 100 80 125 Each time an additional 90 bend is necessary or 2 at 45 the length L must be reduced by 1 m 0020112185_PROTO_13 01 11 Glow worm 9 2 2 Vertical concentric flue 60 100 mm 9 2 3 Multiple boiler chimney flue or 80 125 mm C33 type installation 6 60 100 mm C43 type installation The flue connecting from the appliance to the flue system must be supplied from the manufacturer of the boiler gt C43 flue systems must not be a pressurised system but act under natural draught principles C43 type flue systems must have their own condensate drain fitted and not allow condensate to mix into other appliances gt gt no 6 60 100 6 80 125 2 Each time an additional 90 bend is necessary or 2 at 45 the length L must be reduced by 1 m 4 re m lt Pressure balancing system Air inlet pipe Collector pipe Boiler Inspection hatch Final storey Ground floor Type Max length L 60 100 Each time an additional 90 bend is necessary or 2 at 45 the length L must be reduced by 1 m WrunFWNRA 0020112185_PROTO_13 01 11 Glow worm 23 10 Remove the front panel Key 1 Front panel retaining screw 2 Front panel Undo the two screws 1 on the undersi
7. During change of part of the combustion circuit we recommend that the following is the following must be checked The integrity of the flue system and the flue seals The integrity of the boiler combustion circuit and the relevant seals The operational working gas inlet pressure at maximum rate The gas rate The combustion performance 19 1 General The replacement of parts described in sections Combustion block will require the removal of the burner module assembly and the replacement of seal and self locking nuts Replacement parts that have associated components that need replacing on removal i e O ring seals gasket etc will be supplied and should be fitted e Before replacing any parts of the boiler isolate from the mains electric supply and turn off the gas at the gas service isolation valve on the boiler Unless stated otherwise parts are replaced in the reverse order to removal After replacing any parts always test for gas soundness and if necessary carry out functional test of the controls 49 19 2 Boiler Access For replacement of parts the front casing panel of the boiler will need to be removed To remove undo the two screws on the underside of the front casing and lift off 19 3 Viewing window Fibre washer K 1 2 Steel washer 3 Glass 4 Steel washer 5 Circlip e Remove the circlip 5 Remove the steel washer 4 Remove fibre washer 1
8. Electrical Max capacity of the installation at 75 C Electrical supply Heating safety valve preset pressure PMS V Hz 230 50 Standby mode electrical power MPa Operational mode electrical power Max 620 ag Internal fuse rating on main PCB ik Index of electrical protection KA en Lo Electrical classification 1 Gas connection 0 0 mm oen Level of sanitary confort dane Heating flow and return connection O D mm 22 copper Ba af Ca eee pero ee eee High capacity tank O 4 Water flow limitor 1 4 a 6 5 NG Ww 178 0 75 gt Umi Safety valve maximum working pressure bar mila 4 Maximum inlet water pressure psi 1s 0020112185_PROTO_13 01 11 Glow worm Dimensions CT CT Propane Gas G 31 15 C 1013 25 mbar Hg o Saka CO at Qmax DHW tolerance case ON Co Number of CE certificate 1312 15531 lt a CO at Qmax DHW tolerance case OFF KI i tolerance case ON Natural Gas G 20 15 C 1013 25 mbar AI ak maa gas a CO at Qmax DHW tolerance case OFF 910 296 CO at Qmin 2 9 9 tolerance case ON a kak CO at Qmin 4 2 9 9 tolerance case OFF 8 7 20 2 Inlet pressure 0020112185 PROTO 13 01 11 Glow worm INSTALLATION All the drawings dimensions are shown in mm 6 Appliance location 6 1 Location 6 1 1 Instructions Before choosing a site for the appliance carefully read the safety
9. not twist reposition feet instead Keep boiler as close as possible to body throughout lift to minimise strain on back Always use assistance if required Recommend wear suitable cut resistant gloves with good grip to protect against sharp edges and ensure good grip when handling appliance Positioning of Appliance for Final Installation in roof space re stricting installation Recommend 2 persons lift appliance to position into place space permit ting Fit bracket securely onto wall before lifting appliance into position Obtain firm grip on front and sides of appliance lift upwards ensure sta ble balance achieved and lift upwards to drop into place onto bracket If 2 persons positioning onto bracket obtain firm grip at front and sides base of boiler Ensure co ordinated movements during 2 person lifts to ensure equal spread of weight of load If 1 person positioning onto bracket rec ommend obtain firm grip supporting base of boiler Ensure safe lifting techniques are used keep back straight bend using legs when lifting load from floor level Do not twist reposition feet instead Keep boiler as close as possible to body throughout lift to minimise strain on back Al ways use assistance if required Recommend wear suitable cut resistant gloves with good grip to protect against sharp edges and ensure good grip when handling appliance It is recommended a risk assessment of the roof space area be carried out before moving the ap
10. 0020112185 PROTO 13 01 52 Key Safety Discharge Valve Safety Discharge Valve discharge pipe Domestic hot water pump head connector Domestic hot water pump head Domestic hot water pump head nut Domestic hot water pump housing Foaming filter retaining clip Foaming filter Heating pump head connector 10 Heating pump head 11 Heating pump head retaining srcews 12 Heating pump head earth lead 13 Automatic air vent retaining clip 14 Flexible 3WV tank 15 Heating pump housing 16 Automatic air vent 17 Heating return pipe retaining clip 18 Heating return pipe 19 Heating expansion vessel pipe 20 Hot water temperature sensor 21 Flexible 3WV tank 22 Low water pressure sensor connector 23 Low water pressure sensor 24 Low water pressure sensor retaining clip 25 Hot water heat exchanger output temperature sensor 26 Domestic hot water pump housing retaining clip 27 Flexible 3WV tank 28 Pipe 29 Plate to plate heat exchanger 30 Heating flow pipe 31 Bypass screw 32 Plate to plate heat exchanger retaining screws 33 Bypass retaining clip 34 Flexible 3WV tank retaining clip 35 Three way valve 36 Three way valve electrical plug 37 Three way valve retaining screws 38 Flexible 3WV tank retaining clip 39 Safety Discharge Valve discharge retaining clip WOANAUPWNR 19 4 1 Heating pump head only Drain the boiler heating circuit as described in the appropriate chapter Draining Disconnect the e
11. 6 e Remove the 2 spark electrode retaining screws 8 e Carefully remove the electrode 10 from the combustion chamber e Remove the gasket 9 e Check that the distance between the 2 electrodes is between 3 5 and 4 5 mm Install the electrode and a new gasket 19 5 2 Igniter unit e Remove the ignition lead 2 Remove electrical connections 4 Loosen the screws 3 located on the igniter unit 2 e Remove the igniter unit 2 2 56 19 5 3 Removing the combustion burner door assembly A Warning The gasket 13 must be replaced each time the combustion burner door assembly is removed Disconnect the spark electrode cap 7 from the igniter unit e Disconnect the gas supply pipe 36 at the gas valve e Remove the electrical connectors from the gas valve 37 and the fan 34 e Remove the retaining screw of the silencer e Loosen the 4 nuts 12 e Remove the combustion burner door assembly from the heat exchanger 11 The studs 19 must not be damaged If damaged you will need to replace the heat exchanger e The combustion burner door assembly insulation should be inspected and replaced if damaged 19 5 4 Burner e Remove the 3 burner retaining screws 16 e Remove the burner 15 and the gasket 14 Fit the new burner and the new gasket 19 5 5 Heat exchanger A There will be water in the heat exchanger Carefully ease heat exchanger out Drain the boiler heating and
12. Short Listot Pabasa GN NABA NAGINA KAR GANPANAA NANANA 60 INTRODUCTION 1 Instructions guidance 11 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 e 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 These instructions consist of Installation Servicing Fault Finding Replacement of Parts and Spares 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 1 2 Associated documents 1 Instructions for use 1 magnetic lighting instruction label 1 flue guide 1 extended guarantee leaflet 1 guarantee envelope pack 1 wall template 1 gas conversion label 1 3 Explanation of symbols DANGER Risk of injuries DANGER Risk of electric shock ATTENTION Risk of damage to the appliance or to its surroundings E e IB D IMPORTANT Important information 1 4 Guarantee registration Thank you for installing a new Glow worm appliance in your home Glow worm appliances are manufactured to the very highest standard so we are pleased to offer our customers
13. 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 falt before continuing Combustion check and setting the air gas ratio e Remove the front casing panel see diagram above and hinge down the control box Taking care not to touch any internal components proceed as follows e Connect the CO combustion analyser to the relevant test point see diagram opposite 0020112185 PROTO 13 01 11 Glow worm 1 Throttle 2 Combustion analyser sample point 2A Flue elbow 2B Vertical flue adaptor 3 Cap 18 3 3 Maximum rate check and adjustment To verify the maximum gas rate CO setting the appliance must be checked at the maximum rate e Activate the test mode P 01 and set the value to 100 in order to force the burner at P max See chapter Specific adjustment gt Appliance technical settings and parameter list gt Test modes e Wait approximately 5 minutes to read a stabilised CO value e Check that the value is within the range specified in table in the check column G20 Burner CO Model Check case on Setting case off CO CO ratio 9 2 0 3 9 0 2 0 004 G31 Burner CO and Gasket 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
14. a Comprehensive Guarantee This product is guaranteed for 24 months from the date of installation or 30 months from the date of manufacture whichever is the shorter for parts and labour 0020112185_PROTO_13 01 11 Glow worm The second year of guarantee from the beginning of the 13th month onwards after installation or manufacture is conditional upon the boiler having been serviced by a competent person approved at the time by the Health and Safety Executive in accordance with the manufacturer s recommendations We strongly recommend regular servicing of your gas appliance but where the condition is not met any chargeable spare parts or components issued within the applicable guarantee period still benefit from a 12 month warranty from the date of issue by the manufacturer We recommend you complete and return as soon as possible your guarantee registration card If your guarantee registration card is missing you can obtain a copy or record your registration by telephoning the Glow worm Customer Service number 01773 828100 2 Appliance description 2 1 Safety devices 2 1 1 Overheating safety The appliance is designed to recognise the potential for an overheat lockout and will shutdown before this happens 2 1 2 Safety discharge valve Heating and domestic discharge safety valves and a domestic hot water pressure relief valve are fitted to the boiler This valve must not be touched The heating safety valve opens
15. heating mode i i Display the number of operating hours in domestic hot d 81 Operating hours in domestic hot water mode water mode Multiply the displayed value by 100 Display the number of burner starts in heating mode Multiply the displayed value by 100 Display the number of burner starts in DHW mode Multiply the displayed value by 100 Select the product code of the appliance 31 d 82 Number of burner starts in heating mode d 83 Number of burner starts in DHW mode d 93 Device Specific Number All parameters stored in EEPROM main board appliance interface are reset to factory settings if this function is activated 0 deactivated 1 activated Factory reset CO BATT ES Se Se Digitalizedionisationvoltage _ MET paanan BT S p 0020112185_PROTO_13 01 11 Glow worm 34 13 2 3 Status of the appliance Press button of the Heating temperature controls IM for more than 3 seconds to learn the current state of functioning of the appliance The screen displays the state of the appliance S XX e Press the button for more than 3 seconds to exit this menu 530 Default status no request for heating or domestic water If an 5 EBUS controller is connected to the boiler check that a wiring link is present on terminals 3 and 4 of the boiler s main board 30 31 Hot water only mode 54 5 32 Control cycle the speed of the fan in the functioning phase is outsid
16. hot water circuits as described in the appropriate chapter Draining e Remove the flue connection Undo the two screws located on the top of each side panel e Remove the thermal fuse connector 20 e Remove the 2 heating pipe retaining clips 25 and 29 e Release the heating pipes 24 and 27 from the heat exchanger e Release the condensate trap pipe from the heat exchanger e Remove the combustion burner door assembly 11 refering to chapter Removing the combustion burner door assembly Unscrew the 4 retaining screws 17 and 23 and remove the 2 retaining plates 18 and 22 from the heat exchanger e Pull the heat exchanger towards you to extract it from its 2 side rails 0020112185_PROTO_13 01 11 Glow worm 19 5 6 Re assembling the burner group e Place the burner assembly on the heat exchanger 21 e Progressively tighten the 4 nuts 12 in an alternate order e Reassemble the silencer e Connect the gas pipe 36 with a new gasket to the burner group e Connect the spark electrode connector 5 to the igniter unit Connect the connector to the gas valve 37 and the fan 34 Open the appliance s gas input e Check the tightness of the gas connection 19 5 7 Heating Flow Thermistor Remove the electrical connections from the thermistor 28 e Remove the retaining clip from the flow pipe 27 When reconnecting the polarity of the wiring to thermistors is not important 19
17. lead to the invalidation of this Declaration of Conformity Nantes January 2011 place date Program Manager Richard HUVELIN erufication Manager Yannick GAUDIN GAS BOILER SYSTEM COMMISSIONING CHECKLIST This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference Failure to install and commission according to the manufacturer s instructions and complete this Benchmark Commissioning Checklist will invalidate the warranty This does not affect the customer s statutory rights Customer Name Telephone Number Address Boiler Make and Model Boiler Serial Number tT tT 7 Ett EPP ETP t ete te ete ete et yt yt Commissioned by print name Gas Safe Register Number Company Name Telephone Number Company Address Commissioning Date To be completed by the customer on receipt of a Building Regulations Compliance Certificate Building Regulations Notification Number if applicable CONTROLS Tick the appropriate boxes Time and Temperature Control to Heating Room Thermostat and Programmable Load Weather Optimum Start Programmer Timer Room Thermostat Compens
18. menu 31 Maximum heating power Pump over run time heating Blocking time for burner in heating mode anti cycle time Plate exchanger inlet temperature Temperature of water in the tank Speed of the pump yes Maximum temperature setting for yes domestic hot water Display of the plate exchanger inlet temperature on the short circuit m Factory Modifiable Description o setting parameter Choose a value 8 to 30 kW Choose a value between 2 and 60 To prevent the burner frequently switching on and off the reactivation of the burner is electronically blocked for a period that is determined each time the burner stops The burner blocking time can be adapted to the usage conditions for the heating installation and depends on the temperature that is set for heating at 80 C the period is fixed 2 minutes at 10 C the period is adjustable choose a value between 2 and 60 minutes Ca E EJEA Display tank water temperature Mode 0 With the burner 1 Continuous with ambient temperature 2 Continuous Functioning mode 0 Automatic maximum speed when the burner is switched on 1 Minimum speed 2 Automatic automatic speed when the burner is switched on 3 Maximum speed The recommended maximum temperature setting for domestic hot water is 60 C Choose a value suitable for your needs The following 2 menus are displayed if an option card not supplied is installed on the applianc
19. normally come out of the pump Rotate the pump shaft through several turns then replace the screw 12 3 Filling DHW Circuit Open the various hot water taps to fill the DHW circuit 12 4 Filling the Condensate Trap Key Filling trap Condensate trap Fill the trap 3 4 full with water 1 0020112185 PROTO 13 01 11 Glow worm e Activate the Heating and Domestic Hot Water functions e 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 e Vent air from each radiator again until the water flows normally then close the vents Verify that condensates drain correctly via the flexible pipe If not prime the siphon by pouring a 74 litre of water down the combustion products flue outlet Ifyou have difficulties in removing the air launch the air removal programs in the heating circuit see the chapter Technical settings for the appliance and list of parameters e Make sure that the pressure indicator shows a value of 0 8 bars otherwise fill the appliance again 12 5 Initial lighting 12 5 1 Control The combustion for this appliance has been checked adjusted and preset at the factory for operation on natural gas G20 as defined on the appliance data label No measurement of the combustion is necessary Should the appliance require to be converted to LPG gas ensure you follow the ga
20. outlet to outside 16 Connect the safety valves The drain equipment must allow the water flow to be seen 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 To ease future servicing it is advisable to use a compression type fitting to extend the safety discharge valve tube The pipe must have a continuous fall and be routed to a position so that any discharge of water possibly boiling or steam cannot create any danger to persons damage to property or external electrical components and wiring 8 2 3 Discharge AQ mm D1 600 mm max Ea D2 300 mm min Key 1 Tundish 2 Pressure relief valve 3 Trapped gully 4 Fixed grating Combined Temperature and Pressure relief and Expansion Valve Discharge arrangement The outlet connections of the temperature and pressure relief valve must be connected to the tundish privided The tundish must be installed with no greater than 600mm of 15mm pipe D1 with the tundish fitted in the vertical position It is permissable to connect the expansion valve to this pipe if practicable to do so by means of a tee piece If not the expansion valve must be fitted with a tundish and discharged using the same methods The Tundish must be left in a visible position for the user and in the same space as the boiler and away from any electrica
21. screw 13 Burner 5 Spark electrode gasket 14 Gas valve 6 Spark electrode 15 Fan 7 Burner retaining nut 16 Fan connection 8 Burner retaining screw 17 Gas pipe 9 Thermal fuse connection 0020112185 PROTO 13 01 11 Glow worm 48 18 10 1 Spark electrode e Disconnect the electrode inlet 3 and the grounding cable 2 e Remove the 2 spark electrode retaining screws 4 e Carefully remove the electrode from the combustion chamber e Check that the extremes of the electrode 6 are not damaged e Clean away any accumulation of dirt and check that the distance between the two electrodes is between 3 5 and 4 5 mm e Check that the gasket 5 is not damaged Replace if necessary 18 10 2 Dismantling the burner A Warning The gasket 12 must be replaced each time the burner is dismantled e Disconnect the spark electrode connector 6 from the igniter unit e Remove the gas pipe 17 e Remove the connectors from the gas valve 1 and the fan 15 e 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 Should it be damaged replace the heat exchanger The burner gate insulation should not be damaged Replace if damaged 18 10 3 Cleaning the heat exchanger Clean the coil 19 in the heat exchanger 11 with water 18 10 4 Burner control The burner 13 does not requ
22. shock or A appliance damage e Never disable security devices and do not try to adjust them With regards to the Manual Handling Operations 1992 Regulations the appliance exceeds the recommended weight for a one person lift The handling of the boiler may involve lifting pushing and pulling the use of a sack truck may be required Be sure to consider the following handling techniques and precautions Grip the appliance at its base Use safety clothing where appropriate e g gloves safety footwear Ensure safe lifting techniques are used Keep back straight Avoid twisting at the waist Avoid upper body top heavy bending Always grip using the palm of the hand Use designated hand holds Keep load as close to body as possible Always use assistance if required e Under no circumstances must the user interfere with or adjust sealed parts e When assembling the connections correctly position the seals to avoid any leakage of gas or water e This appliance contains metal parts components and care should be taken when handling and cleaning with particular regard to edges The basic safety instructions must be followed before attempting to maintain or replace spare parts Stop the appliance e Electrically isolate the appliance from the power supply e Turn off the appliance gas isolation valve e Hydraulically isolate the appliance using the isolation valves if provided e All
23. the inlet gas pressure and gas rate have been verified then it will necessary to adjust the combustion rate of the appliance 0020112185_PROTO_13 01 11 Glow worm Adjustment is made by turning the throttle an 73 of a turn waiting 1 minute to allow the appliance to stabilise before checking or making further adjustments e Remove the sticker covering the throttle adjustment screw if fitted e Rotate the throttle 1 anti clockwise to increase to the required CO refer to previous diagram and the Setting column in the table e When you have finished press the On Off button to exit the test modes e Remove the analyser probe and replace the cap on the sampling point replace the controls fascia and the front casing panel Remember to replace the sample point cap on completion of the test 18 3 4 Gas rate check e Check the gas rates as described in the commissioning section 18 3 5 Completion If it is not possible to achieve the required results for either the combustion or gas rates it will be necessary to complete a full service of the appliance and then repeat the combustion check procedure If after servicing and adjustment of the appliance the combustion values are still unacceptable and after further remedial work has been carried out the appliance must be disconnected until the CO CO ratio is acceptable e Advice can be sought from the Glow worm Technical Helpline 18 4 Se
24. the silencer 18 6 Central heating expansion vessel e Following the installation of a new expansion vessel fill and purge the appliance or installation if necessary 1 Expansion vessel 2 Expansion vessel pressure inlet 0020112185 PROTO 13 01 11 Glow worm 46 18 8 Particle filter Key 1 Particle filter 2 Clips Remove the particle filter to check its condition e Check the condition of the particle filter To remove the particle filter 1 remove the 2 clips 2 e The particle filter must be removed and cleaned after the first year s of use e Clean the grill inside e After installing a new particle filter refill and bleed the appliance and the installation if necessary 0020112185 PROTO 13 01 11 Glow worm 18 9 Condensate trap A Warning condensate is mildly acidic Use protective gloves Key 1 The condensate trap 2 Discharge of condensate 3 Siphon Place a container under the condensate trap 1 Remove the siphon 3 from the recoverer and clean Disconnect the condensation discharge 2 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 47 18 10 Combustion block 16 17 Key 1 Gas valve connection 10 Coil 2 Grounding cable 11 Heat exchanger 3 Spark electrode inlet 12 Burner gasket 4 Spark electrode retaining
25. timber frame building it should be fitted in accordance with the Institute of Gas Engineers document IGE UP 7 1998 If in doubt seek advice from local gas undertaking or Glow worm 6 2 Clearances To allow periodic maintenance ensure the distances indicated on the diagram Additional clearances may be beneficial around the boiler for installation and servicing For flue installations where external access is not practicable 10 consideration should be given for the space required to insert the flue from inside the property which may necessitate clearance larger than those specified in diagram below The appliance can be placed with zero clearance on the left hand side if practical to do so Key A removable compartment door can be placed a minimum 5 mm in front of appliance A clearance of 600 mm is required from a fixed surface The boiler and flue are suitable for installation onto and through combustible materials provided that Minimum 5mm clearance is maintained around the circumference of the flue air intake The combustible surface and fixings are suitable for supporting the load The minimum clearances from the boiler case are maintained 6 3 Ventilation 6 3 1 Room Ventilation The boiler is room sealed so a permanent air vent is not required 6 3 2 Cupboard or Compartment Ventilation Due to the high efficiency and low casing temperature of this boiler cupboard or compartmen
26. water isolation valve on the wall mounting jig Open one or more hot water taps to drain the hot water circuit 18 Servicing 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 If this appliance is installed in a rented property there is a duty of care imposed on the owner of the property by the current issue of the Gas Safety Installation and Use Regulations Section 35 0020112185_PROTO_13 01 11 Glow worm e Servicing maintenance should be carried out by a competent person approved at the time by the Health and Safety Executive in accordance with the rules in force in the countries of destination To obtain service please call your installer or Glow worm s own service organisation PLEASE NOTE During routine servicing and after any maintenance we recommend that the following must be checked The integrity of the flue system and the flue seals The integrity of the boiler combustion circuit and the relevant seals The operational working gas inlet pressure at maximum rate The gas rate The combustion performance e See the Safety instructions chapter for a list of operations to be performed prior to the maintenance of the application e Once the maintenance operations have been completed cons
27. 0112196 Plate to plate heat exchanger Ts 0020097214 3 way vave assembly __ EE High capacity tank 0020125438 Heating Pump head assembly 0020112185_PROTO_13 01 11 Glow worm 59 20 2 Short List of Parts 11 Glow worm 0020112185 PROTO 13 01 60 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 Avoid upper body top heavy bending do not lean forward sideways Recommend wear suitable cut resistant gloves with good grip to protect against sharp edges and ensure good grip Always use assistance if required Removal of carton from delivery van Recommend 2 person lift or 1 person with use of sack truck If 1 person is performing lift straddle the load tilt and place carton into position on truck Recommend secure appliance onto truck with suitable straps Ensure safe lifting techniques are used keep back straight bend using legs Keep load as close to body as possible If 2 persons performing lift ensure c
28. 2009 142 relative to gas appliances European directive n 2004 108 from the European Parliament and Council relative to electromagnetic compatibility European directive n 2006 95 from the European Parliament and Council relative to low voltage European directive n 92 42 relative to the yield of boilers 2 4 2 Local regulations 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 manufacturer s instructions by a competent person approved at the time by the Health and Safety Executive and that it meets the requirements of the appropriate Building Regulations The Benchmark Checklist can be used to demonstrate compliance with Building Regulations and should be provided to the customer for future reference Installers are required to carry out installation commissioning and servicing work in accordance with the Benchmark Code of Practice which is available from the Heating and Hotwater Industry Council who manage and promote the Scheme e Visit www centralheating co uk for more information penchinan THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS 0020112185_PROTO_13 01 11 Glow worm 2 5 Key OANA UA RB WN RA Hydraulic schematic
29. 5 8 Heating Return Thermistor e Remove the electrical connections from the thermistor 26 e Remove the retaining clip from the return pipe 24 When reconnecting the polarity of the wiring to thermistors is not important 19 5 9 Gas valve e Remove the burner door 11 refering to chapter Dismantling the burner door e Remove the two gas valve retaining screws 30 e Remove the gas valve 31 and the gasket 32 e Fit the new gas valve and the new gasket by repeating the operations in reverse After assembly test for gas tightness and purge in accordance with the current issue of BS6891or in IE the current edition of 1 5 813 Domestic Gas Installations e Check the combustion CO 19 5 10 Fan e Remove the burner door 11 refering to chapter Dismantling the burner door e Remove the gas valve 31 see previous paragraph Loosen the 3 screws 38 located on the burner door 11 e Remove the fan 33 and the gasket 35 Fit the new gasket 35 Screw the new fan to the burner door 11 0020112185_PROTO_13 01 11 Glow worm After assembly test for gas tightness and purge in accordance with the current issue of BS6891or in IE the current edition of 1 5 813 Domestic Gas Installations 19 6 Condensate trap A Warning condensate is mildly acidic Wear protective gloves ey Condensate reservoir Condensate outlet pipe Screws Condensate trap Condensate reserv
30. 8 C The thermostatic mixing valve should not be easily altered by users The thermostatic mixing valve conforming to WRAS BS EN 1111 and BS EN 1287 compliant to Part G of the bluiding regulations 7 2 2 Heating circuit design w 12 K 1 Drain point 2 External bypass if required 3 Domestic cold water supply in 4 Domestic hot water out 5 Pressure reducing valve if required 6 Boiler 7 Filling loop in accessory box 8 Additional expansion vessel if required 9 Heating return circuit 10 Heating flow circuit General 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 Safety valve The safety valve is an integral part of the boiler and it cannot be adjusted The pipe from the safety discharge valve must discharge safely in accordance with standards Expansion vessel The boiler has an integral expansion vessel with a capacity of 12 litres 2 64 gallons with a charge pressure of 0 7 5bar The heating system volume should be calculated to ensure that the expansion vessel is suitable itmay be necessary to add an additional vessel In GB Guidance on vessel sizing is also given in the current issue of BS5449 and BS7074 Part 1 In I current edition of S 813 Domestic Gas Installations Bypass The boiler is fitted with an automatic bypass w
31. AL DATA 5 Ultracom 35 Store Boiler type C13 C33 C43 valve SEDBUK 2005 rating NA A SEDBUK 2009 rating N For a supply pressure above 3 bar it is recommended that you install Maximum heating input power a pressure reducer Minimum heating output power at 80 60 C P min 01 a Description 35 Store Maximum heating output power k 0 at 80 60 C P max Combustion W W Minimum heating output power kW 9 at 50 30 C P min W Ve Maximum pressure hot water safety valve Fresh air flow rate 1013 mbar 0 C Flue gas flow rate at Pmin Flue gas flow rate at Pmax Flue gas flow rate in hot water mode 3 5 9 Flue gas temperature at Pmin 80 C 60 C 0 at 50 30 C P max at 80 60 C a at 50 30 C pawa at part load 30 on PCI a at 40 C 30 C ue gas temperature in hot water mode 81 Efficiency level according to the European c a with hot water temperature of 50 C ee eee Value of combustion products measured at nominal calorific rate and with 620 reference gas in heating a kWh Minimum heating temperature 10 o Maximum heating temperature ppm 22 6 Content of heating expansion vessel oe Weighted Nox mg HA 5 3 9 Flue gas temperature at Pmin 50 C 30 C Flue gas temperature at Pmax 80 C 60 C Flue gas temperature at Pmax 50 C 30 C CO mg 3 2 7 0 Cy gt so z N Heating expansion vessel preset pressure Appliance NOx class
32. C www centralheating co uk Service Record It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed Service Provider Before completing the appropriate Service Record below please ensure you have carried out the service as described in the manufacturer s instructions Always use the manufacturer s specified spare part when replacing controls Service 1 Date Engineer Name Service 2 Date Engineer Name Company Name Company Name Telephone No Telephone No Gas Safe Register No Gas Safe Register No Comments Comments Signature Signature Service 3 Date Engineer Name Service 4 Date Engineer Name Company Name Company Name Telephone No Telephone No Gas Safe Register No Gas Safe Register No Comments Comments Signature Signature Service 5 Date Engineer Name Service 6 Date Engineer Name Company Name Company Name Telephone No Telephone No Gas Safe Register No Operative ID No Comments Comments Signature Signature Service 7 Date Engineer Name Service 8 Date Engineer Name Company Name Company Name Telephone No Telephone No Gas Safe Register N
33. FROM APPLIANCE GROUND either or 22mm MIN 500mm MIN NO RESTRICTION ON LENGTH 25mm MIN 100mm PLASTIC TUBE BOTTOM OF OPEN END OF PIPE DIRECT INTO TUBE SEALED GULLEY BELOW GROUND LEVEL LIMESTONE CHIPPINGS BUT ABOVE WATER LEVEL HOLE DEPTH gt 400mm MIN 2 ROWS OF 3 x 12mm HOLES AT 25mm CENTRES 50mm FROM ar BOTTOM OF TUBE HOLES TO Internal Termination Downstream of FACE AWAY FROM HOUSE Sink Waste External Termination into Soakaway NOTE PIPEWORK SHOULD ALWAYS FALL AWAY FROM BOILER BY AT LEAST 2 5 44mm FOR EVERY 1M 0020112185_PROTO_13 01 11 Glow worm 19 9 Evacuation of combustion gas 9 1 Regulation A Only flue accessories supplied by Glow worm must be used Different flue outlet configurations can be carried out e Consult your supplier for more information about the other possibilities and associated accessories 44 mm m yy NI ae Standard flue terminal kits have an in built fall back to the boiler to drain the condensate These can be fitted level between the appliance and the termination position All other extended flues must have a fall of at least 44mm m The maximum length of the flue outlet is defined according to its type for example C13 e Whatever the kind of flue system chosen observe the minimum distances indicated in the chart overleaf to position the fl
34. Gloweworm Installation and Servicing Ultracom 35 Store G C No 47 019 15 TABLE OF CONTENTS INTRODUCTION 1 Instructions guidance 1 1 Product documiental0N ama ING NANANA NGNGN GAT La enin a NANANA 3 1 2 Associated documents si ARABIAN ANNA NA a 3 1 3 Explanation of Symbols wicicicerecssivevesueivertacesescuasacecsvascevevssiedeavecaudeeesevssivvesvesiversyies 3 1 4 Guarantee registration ee eeeccecceceeeceesseeeecececcceneceaseeseeeeeseeeascoaseesereeeeseoenses 3 2 Appliance description 2 1 Safety DEVICES laan ania nA NEANRDENANAN O NINA NANANG E EEN 3 2 2 Data laba ANA KA AG 4 2 3 GAS CALC ROLY AA AA AG AA 4 2 4 Regulation and Statutory requirements cccesesesasasanassssasssssssss sss ss ss 4 2 5 Hydraulie schemabi bi NAKADAGAN 5 3 Safety instructions and regulations 3 1 Safety IMSMHUCHONS maam RNGA ANA NAAN AA AA AN 6 3 2 Regulations naan NAAN BANANA IA NAN ease ATOR 6 4 Recycling 4 1 Appliance e aS a eS E GANA NGA NGARAN 7 4 2 Packaging iba NG edeasausveundenauieduasaneveeadeveuaves 7 TECHNICAL DATA 5 Ultracom 35 Store INSTALLATION 6 Appliance location 6 1 Location Baa KNB GA bA Ae 10 6 2 EN AA 10 6 3 Ventilatlon naik enea NANA NIR ANA NARATING 10 7 Appliance installation 7 1 SCOPE OF delivery viscvsstvesevenrceccecaxecaxesatetsedecedededecevededecesdsesyensdees abedencuseecudeeetennes 11 7 2 Recommendations before installing cee ceeeeeessesseeeeeecce
35. a type of wire cage is fitted to prevent contact 3 Discharged at a high level into a metal hopper and downpipe the end of the pipe must be visible 4 Discharged onto a roof providing that a The roof is constructed of a material designed to withstand the temperatures b The gutter or drain system connected to the roof is at least 3m away from the point of discharge The tundish should be installed so that is is visible to the occupants and is positioned away from electrical devices gt The discharge pipes tundishes drain valves etc shall be positioned away from any electrical components gt Cylinder relief valve connections should not be used for any other purposes No valve should be fitted between the expansion valve and the storage cylinder PG 17 8 5 Connection to the condensate trap Condensate produced by the appliance is mildly acidic pH 3 5 5 0 Use protective gloves Condensate must only be discharged in accordance with these instructions The volume of condensates evacuated can reach about 15 litres per day for a detached house This volume is negligible compared to the volume of waste water discharged by a house because the condensates are diluted in this water o gt e e Refer to BS5546 or BS6798 for advice on disposal of boiler condensate Key 1 Condensate pipe e Make sure there is no protective plug fitted e Connect the condensate pipe 1 The pipe shou
36. anananananananansasasasasesereseseeeeeec0eeeeceeee00ee 28 12 5 Ihitiallightimg 002030 DA BAG KAANAK 29 12 6 lt GaASiWAleS icdccesiszvcessanccevasscceaseSesnecerareecertveacecarsvereeedectcseveverstavencceeveevecaresevecaverete 30 12 7 Testing heating SYStOM siccccsscsessssccdcesstcaacidetssveciets cesaiendeessveciveesneauerscsueseiacccsasnees 30 12 8 Testing domestic hot water SySteM sccssesssesesesnssessccececeseceeeeeceeeseeseseseeeeesess 30 12 9 COMPLELION sccccscvcisseiecsivestersivebeorervebponbuveb cnt ssndenedpnnteinedsacesddeeeteenieeceeeeesdeeceresdvests 30 13 Specific adjustment 13 1 Heating circuit adj stmentainrsineniiniirnrninnnnn n a a a a ii 31 13 2 Appliance technical settings and parameter list seeeseneeseeeseserorereresesrerersreeereeee 31 13 3 CO measurement ssesssessseserssersserssererereeeseenseesseeseernerseeeseeeseeeseeerereeneeenseerseeneeen 36 13 4 Re checkand rasta cides sidadesisbasdee ovvesdicesssyadiekesvssiuadesssbadatee Susahesicsiveniecteousanes 36 14 User information MAINTENANCE 15 Trouble shooting 15 1 FaulbdiagnosIs haa NINANG KGG RAANG 37 15 2 Fault MEMO esses NAN NIA NIAN NU NANU NAAN ANAN 38 15 3 RAUL COdES cs NAA NANANA ANA GANA NAGANA AA 38 15 4 Functional flow diagram enceinte a E KAAU NG 40 16 Gas conversion adjustments 16 1 SENLINES naDL BAI ese vuc sau veavonved NAN LA BANNAN AN HIN BAYAN ADIKS 41 16 2 Restart re check COMMISSIONING sceececccccesseeseeeee
37. appliance from carton Recommend 2 persons unpack appliance from carton Always keep working area clear Cut the carton straps lift carton up and slide over polystyrene end packs Remove top polystyrene pack with fittings Positioning of Appliance for Final Installation no obstructions Recommend 2 persons lift appliance to position into place Fit bracket securely onto wall before lifting appliance into position Obtain firm grip on front and sides of appliance lift upwards ensure stable bal ance achieved and lift upwards to position in place on bracket Ensure safe lifting techniques are used keep back straight bend using legs when lifting load from floor level Do not twist reposition feet instead Keep boiler as close as possible to body throughout lift to minimise strain on back Ensure co ordinated movements to ensure equal spread of weight of load Always use assistance if required Recommend wear suitable cut resistant gloves with good grip to protect against sharp edges and ensure good grip when handling appliance Positioning of Appliance for Final Installation above worktop foreseeable obstructions etc Recommend 2 persons lift appliance to position into place Fit bracket securely onto wall before lifting appliance into position Obtain firm grip on front and sides of appliance lift upwards onto worktop if practicable Ensure stable balance achieved and lift upwards to position in place on bracket If 2 persons
38. art on this appliance use only spare parts that you can be assured conform to the safety and performance specification that we require Do not use reconditioned or copy parts that have not been clearly authorised by Glow worm e If any electrical connections have been disconnected and after their connection checks to the earth continuity polarity short circuit and resistance to earth must be repeated using a suitable multimeter as described in chapter Trouble shooting gt Fault diagnosis gt Check the electrical installation After servicing complete the relevant Service Interval Record section of the Benchmark Checklist located in the centre pages of this document Key 15 Trouble shooting 1 Main aa 2 Neutra 3 Live 4 Multimeter 15 1 Fault diagnosis The following checks should be performed before proceeding lalla Lael onto specific diagnostics e Check the external electrical supply to the boiler is on and a e Make sure that the electricity supply has not been interrupted EE e Enel ee a MARINO Oe in board and that the appliance is connected correctly See chapter eee ee Troubte shooting gt Fault diagnosis Check the electrical Check the electrical installation and appliance carry out tests installation for earth continuity polarity short circuit and resistance to e Ensure that the isolating valves are open i Bare metal points such as screws or rivets will act as suitable e Ensure that the pressu
39. ation Control Time and Temperature Control to Hot Water Cylinder Thermostat and Programmer Timer Combination Boiler Heating Zone Valves Fitted Not Required Hot Water Zone Valves Fitted Not Required Thermostatic Radiator Valves Fitted Not Required Automatic Bypass to System Fitted Not Required Boiler Interlock Provided ALL SYSTEMS The system has been flushed and cleaned in accordance with BS7593 and boiler manufacturer s instructions Yes What system cleaner was used What inhibitor was used Quantity litres CENTRAL HEATING MODE Measure and Record Gas Rate m3 hr OR ft hr Burner Operating Pressure if applicable mbar OR Gas Inlet Pressure mbar Central Heating Flow Temperature C Central Heating Return Temperature C COMBINATION BOILERS ONLY Is the installation in a hard water area above 200ppm Yes No If yes and if required by the manufacturer has a water scale reducer been fitted Yes No What type of scale reducer has been fitted DOMESTIC HOT WATER MODE Measure and Record Gas Rate Mm34 hr OR ft hr Burner Operating Pressure at maximum rate L85 Mbar OR Gas Inlet Pressure at maximum rate mbar Cold Water Inlet Temperature C Hot water has been checked at all outlets Yes Temperature C Water Flow Rate l min CONDENSING BOILERS ONLY The conde
40. ce the radiators as required to give the required system differential e Turn off all radiators that can be shut off by the user and check to see if less than the maximum differential allowed of 20 C can be achieved across flow and return Should the appliance require adjustment refer to the Specific adjustment section overleaf e Allow the system to reach maximum temperature then switch off the boiler by isolating from the electrical supply e Drain the entire system rapidly whilst hot using the drain taps at all the low points of the system Fill and vent the system as described previously in chapter Commissioning gt Filling the CH system Central heating Adjust the boiler temperature controls and any system controls to their required settings 12 8 Testing domestic hot water system Open a hot water tap e Check that the temperature obtained is compliant with the setting on the appliance 12 9 Completion Ensure that the magnetic lighting instruction label is placed on the surface of the boiler casing GB It is a requirement that the Benchmark Installation Commissioning and Service Record is completed and left with the user IE it is necessary to complete a Declaration of Conformity to indicate compliance to I S 813 An example of this is given in the current edition of 1 5 813 0020112185_PROTO_13 01 11 Glow worm 13 Specific adjustment 13 1 Heating circuit adjustment It may be
41. ctly 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 e Only use original seals supplied with the appliance e Check that there are no leaks Repair if necessary Key 1 Boiler 2 Hanging bracket e Lifting the boiler into position lean the top of the boiler slightly to the wall and position just above the hanging bracket Lower the boiler slowly and engage onto the hanging bracket Key TEN Gas service isolating valve with pressure test point sealing washer 1f Domestic hot water outlet isolating valve sealing washer 3 Heating flow isolating valve sealing washer 3 4 Cold water inlet isolating valve sealing washer 3 4 Heating return isolating valve sealing washer 3 4 Connection O D 22 mm Gas connection O D 15 mm NOW PWN Use only the original gas cock GER 1 DN15 CE 0085 CL0082 Use only the olive and flat seal washer supplied with the gas cock 0020112185_PROTO_13 01 11 Glow worm 15 8 2 Safety Discharge Valves 8 2 1 Heating safety valve Key 1 Pressure relief valve pipe Heating safety valve Compression fitting Pressure relief valve outlet to outside IYWN 8 2 2 Combined temperature and pressure relief valve Key 1 Pipe for Pressure relief valve 2 DWH safety valve I Pressure relief valve
42. de of the front panel and remove the front panel 2 11 Electrical connections Incorrect installation can cause electric shock or appliance damage The electrical connection of the appliance must be made only by a qualified engineer The appliance must be connected directly to an accessible fixed switched electrical outlet The external wiring must be earthed with correct polarity and in accordance with current standards The manufacturer declines any responsibility for damages to persons or others caused by the incorrect installation of the appliance earthing This includes failure to comply with current standards Electrical components have been tested to meet the equivalent requirements of the BEAB Do not use cable greater than 10 mm in diameter for the electrical connections All system components must be of an approved type e Do not interrupt the mains supply with a time switch or programmer The boiler is suitable for installation in bathroom zones 2 and 3 24 11 1 Access to main board It is necessary to remove the appliance front cover Key 1 User interface 2 Fastening screw e Pivot the user interface to access the electrical panel Key 1 230 V access cover 2 24 V access cover e Tilt the user interface panel to access the 24V and 230V connections 0020112185 PROTO 13 01 11 Glow worm 11 2 Main board 1 dl 2 N 3 TA Ng i 30 mm max Key 1 Co
43. e Function relay 1 Function relay 2 Attributing a function to relay 1 of the option card 1 Domestic hot water circulation pump 2 auxiliary heating pump 3 Reservoir loading pump 4 smoke valve chimney extractor 5 external gas valve 6 external error message Attributing a function to relay 2 of the option card 1 Domestic hot water circulation pump 2 auxiliary heating pump 3 Reservoir loading pump 4 smoke valve chimney extractor 5 external gas valve 6 external error message The following menu displays automatically if an automatic fill kit is installed on the appliance d 31 Refill method d 34 Speed of fan d 35 Position of 3 way valve d 36 Domestic hot water flow m Operating mode 0 Manual 1 Semi automatic 2 Automatic tr Fan speed is displayed between 0 and 99 min Multiply the displayed value by 100 0 Heating 100 Hot water in Display domestic hot water flow The following menu is displayed if a solar system not supplied is connected to the appliance d 39 Solar circuit water temperature i Heating flow temperature d 41 Heating return temperature 32 Displays the water temperature measured by the sensor located upstream of the mixer Display the heating flow temperature Display the heating return temperature 0020112185_PROTO_13 01 11 Glow worm Code Parameter Description Factory Modifiable setting param
44. e air gas ratio valve 18 3 1 Competency to carry out the check of combustion performance BS 6798 2009 Specification for installation and maintenance of gas fired boilers of rated input not exceeding 70kW net advises that The person carrying out a combustion measurement must be assessed as competent in the use of a flue gas analyser and the interpretation of the results The flue gas analyser used should be one meeting the requirements of BS7927 or BS EN50379 3 and be calibrated in accordance with the analyser manufacturers requirements Competence can be demonstrated by satisfactory completion of the CPA1 ACS assessment which covers the use of electronic portable combustion gas analysers in accordance with BS 7967 parts 1 to 4 e Ensure that the gas analyser is set to the correct fuel setting Select the gi Ill constant central heating with DHW function by pressing the menu button repeatedly refer to commissioning section The boiler should fire automatically Safe combustion can only be verified by measuring CO CO ratio This must not exceed the value shown in the table opposite 18 3 2 Preliminaries Prior to during servicing and after any maintenance or changed parts the following must be checked e The integrity of the flue system and flue seals e The integrity of the appliance combustion circuit and relevant seals Electrical gas and water connections e System pressure e
45. e commercial name of the appliance and its serial number The types of flues installations authorised The appliance s gas category The gas type group and pressure set in the factory The DHW specific flow rate D The maximum pressure in the heating circuit PMS The maximum pressure in the domestic water circuit PMW The NOx class of the appliance The type and voltage of electricity supply The maximum power rating The electrical protection class The minimum and maximum heat input Q The minimum and maximum power output P The CEnumber and logo A The appliance shall only be connected to the gas type s indicated on the data label 2 3 Gas category This boiler is for use only on G20 but can be converted for use on G31 To adapt the appliance to another type of gas see the chapter Gas conversion 2 4 Regulation and statutory requirements 2 4 1 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 The CE mark indicates that the appliances described in this manual are in compliance with the following directives European directive n
46. e must be replaced by a qualified and competent electrician e Ease back the two PCB retaining clips 6 and withdraw the PCB from the retaining lugs Ifthe main supply cable is damaged replace it refering to the chapter Electrical connection e Remove the electrical connections to the PCB appliance interface cable 19 7 2 2AFuse Rating e 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 0020112185 PROTO 13 01 11 Glow worm 58 20 Spare parts In order to guarantee the safe and prolonged life of the product manufacturers genuine spare parts must be used This appliance displays a CE Mark of conformity Only use the manufacturer s genuine new spare parts Ensure that spare parts are correctly mounted in the right position and direction After fitting any spare part or servicing the appliance must be tested for its safe operation 20 1 Short List of Parts e When ordering spare parts contact Glow worm s own service organisation e 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 TE oo2oos7a77 fan 2 A000035144 Sparkignter foo 3 2000801935 thermistor row andreu a oo2003e07i asvave Tooo 5 0020038441 Electrode assemby e 0020125457 User interface pce f 7 002
47. e tolerance Frost protection mode Underfloor heating contact open Water pressure too high 5 53 Waiting cycle temperature differential between heating flow and return is too high If AT gt 30 forcing to Pmin s Waiting cycle lack of water in the installation temperature rise between heating flow and return is too high Test temperature sensor for heating return Test temperature sensors for heating flow and return or the S 98 appliance has a fault 0020112185_PROTO_13 01 11 Glow worm 13 2 4 Test modes By activating these various test modes you can enable special functions on the appliance e Press the on off button to switch off the appliance e While keeping the button pressed for more than 5 seconds press the on off button The screen displays the first test mode P01 and Off Press button or of lJ mode to choose the test mode that you wish to launch Test mode P 01 Press the button to display the burner forcing setting The screen displays P 01 and 0 Press button or of Il mode to modify the value of the setting from 0 0 to 100 100 Press the button for 1 second to exit the submenu or for more than 7 seconds to access the configuration menu Test mode P 02 to P 07 Press to launch the test mode The screen displays P OX and On The test mode will be automatically stop after 15 minutes When you have finished press the reset b
48. eceeeeeeseeeeeeeeseeeeaeees 11 7 3 Dimensions ada GAGANA AG BAGA AG 13 Tea MOUMUNS naaa AA ANAN ANNA APAN DA 14 8 Hydraulic connection 8 1 Gas and water CONNECTIONS sssssssssssssssesseesssssseeseeoeeessssseseseeosessssssseeeeeosesssesee 15 8 2 Safety Discharge Valves viccccscssecoscesscececevssesvecetaversrscessevaceccaueeeaccsacessereecseseceendeetce 16 8 3 Connection to the condensate trap ssasawwnwaawaaanaaaaaaaaaaaaaaaasaasasasasssssssana 18 9 Evacuation of combustion gas 91 Regulation aaa ANN NA HANA NANG NINA NANANA NG aveivestenlivte suena 20 9 2 Flueconfiguration description sssssssssssssssssssnssseccccecececeeecececessesseeeeeeseeeeens 22 10 Remove the front panel 11 Electrical connections 11 1 Accessit main DOard iN NANANA RO 24 41 2 MAIN board man AA NAAT ANAN AA 25 11 3 Electrical Wiring 8NG ea ETE A A 25 11 4 External acceSSOnesiassislciiccieteceusstacesesdindieecsevseacesescevcetudaevseudedeacuadenuddevsencedwachs 26 11 5 Testing the electrical connections essssessesssssseessssssssssssceesssssesseeesseessssseseeeessesse 26 11 6 Wiring diagram maga AN KAL NAAN E AANG NANANA 27 TABLE OF CONTENTS 12 Commissioning 1241 SWitChin SON mgA NANANG BARAN NGABA AG 28 12 2 Filling the CH system Central heating ccccccssssssseccesssssssnseceeecesenseceeeessseenes 28 12 3 Filling DHW GIKAN A KANE BIKINI NENGKA 28 12 4 Filling the Condensate Trap c coo0 aaasanan
49. eeeeeeeeeseeeseeeeeeeeeeeeeaeess 42 17 Draining 17 1 Heating CHCUIE oss ARNAN NIDA RR NG KIPIAN BR NAKA EE 42 17 2 Domestic Hot water circuit seessesseesssessssssesseesssssssessesceesssssseeseeoseessssseeeeeessesse 42 18 Servicing 18 1 Annual Maintenance sistance ANAN AG 43 18 2 CaSiNSKEMOVING sic ma ai EER ERN ENE 44 18 3 Combustion check and setting the air gas ratio valve ccssssccccccesstteceeeesesseees 44 T84 ASONVICING nanan KAR mar ANAN causes ersuebsvnes cecouduvasdetevnedvateusevuriestevnadvateuserts 45 18 5 SILENCE IG EAEE TREA EREA 46 18 6 Central heating expansion VeSSEl cssseeseseeeeeeeeeeeeecececeeeeceeeeceeeeeeeeeeeeeeseeeeees 46 18 7 DHW expansionivessal ccciscescsvevevseansvevdcsadenanceacaececeacatvivecsenceccestaceresoavevsesess soovs 46 18 8 Particle MGN au nia KALA AA NANANA NAAN maha 47 18 9 Condensatelapn 3NG ALLAN 47 18 10 Combustion DOCK seisis inie i a AAE A EATE bA 48 18 11 Sevice completiON ssns E E E aE KE RERE 49 19 Replacement of Parts 19 1 General a IKAN E A AEE A 49 19 2 Boiler ACCESS ANA ANA NAA AA a 50 19 3 MIEWINYWINDOW 1 a NA NANG NAA a a aa GLAD 50 19 4 Hydraulicbloeki 3m NG GING R AARIIN Ga inna 52 19 5 Combustion DlOCKiscscscisccieisiecdincstheelesceedevdievsiieelensiewdevdbevsthuslesdaaveneassvacswcenwonneens 55 19 6 CONGENSALG LAD sirpin r 57 19 7 POB anna Aa LAAN ANNA RN NANANA terete 58 20 Spare parts 20 1 ShortListof Panga AA NG NN Na 59 20 2
50. electronic portable combustion gas analysers in accordance with BS 7967 parts 1 to 4 16 1 Settings Steps Switching on to Re pressurising System will need to be completed before the appliance can be converted See chapter Commissioning Tools required to make the conversion are a 2mm Allen key and an electricians screwdriver Having checked the appliance and system have been installed in accordance with the instructions the integrity of the flue system and flue seals the integrity of the appliance combustion circuit and relevant seals that all internal external controls are calling for heat the gas service isolation valve is opened 0020112185 PROTO 13 01 11 Glow worm 1 Throttle 2 Combustion analyser sample point 2A Flue elbow 2B Vertical flue adaptor 3 Cap e Remove the front panel first e Remove the cap 3 and connect a CO analyser to effect the measurement 2 16 1 1 Adjusting the gas valve e Press the on off button to turn the appliance off Turn the screw in the direction and the number of times indicated in the following table Gas adjustment G20 gt G31 G31 gt G20 aa VA d 2 5 turns 16 1 2 Adjusting the maximum power setting Activate the test mode P 01 and set the value to 100 in order to force the burner at P max See chapter Specific adjustment gt Appliance technical settings and parameter list gt Test modes e Wait appr
51. emperature pressure relief valve 6 Filling loop in accessory box 7 Domestic cold water supply in The minimum working pressure to obtain the maximum domestic flow is 1 0 bar The boiler is supplied with a pressure reduction valve pre set to deliver an inlet pressure of 3 5bar Hard water areas The temperatures within the heat exchanger are limited by the boiler control system to minimise scale formation within the hot water pipework However in areas where the water is hard i e more than 200 mg L of calcium carbonate it is recommended that the hot water setting is reduced and that a scale reducer is fitted refer to the manufacturer s instructions or consult the local water company for additional advice Domestic water flow rate The domestic hot water flow has a restrictor factory fitted which reduces the flow to a maximum of 35 Store gt 16 l min 11 Prevention of scalding Thermostatic mixing valve 1 Key 1 Thermostatic mixing valve 2 Standard flue length horizontal A Hot water B Cold water C Mixed water A thermostatic mixing valve is used in the domestic hot water circuit It s function is to maintain the temperature of the mixed water supplied to the user constant at the set value when there are variations in the supply pressure and temperature of the incoming hot and cold water or in the flow rate The hot water supply temperature to a bath should be limited to a maximum of 4
52. ernal wiring must be correctly earthed polarised and in accordance with the relevant standards In GB this is BS 7671 In IE this is the current edition of ETCI rules The boiler MUST be connected to a permanent 230V ac 50Hz supply Connection of the whole electrical system of the boiler including any heating controls to the electrical supply MUST be through one common isolator and must be fused 3 Amp maximum Isolation should be by a double pole switched fused spur box with a minimum gap of 3mm for both poles The fused spur box should be readily accessible and preferably adjacent to the appliance It should be identified as to its use Alternatively connection can be made through an unswitched shuttered socket and 3A fused 3 pin plug both to the current issue of BS 1363 provided they are not used in a room containing a bath or shower Wiring to the boiler must be PVC 850C insulated cable not less than 0 75mm2 24 0 20mm 0020112185_PROTO_13 01 11 Glow worm 3 2 2 Other regulations Gas Safety Installation and Use Regulations In your own interests and that of safety it is the Law that ALL gas appliances are installed by a competent person approved at the time by the Health and Safety Executive in accordance with the current issue of these regulations Control of Substances Hazardous to Health Under Section 6 of The Health and Safety at Work Act 1974 we are required to provide information on substances hazardous
53. es valves are open e Fill the installation e Purge the installation e Check the pump connections e Check the flow and return heating sensor connections e Check that there are no leaks Return water valve closed Pump disconnected Leak in the installation Water pressure of the installation 0 3 bar e Check the flow and return heating sensor A Malfunction of the pump excessively e Check that the flow and return heating isolation Water circulation fault 5 rapid temperature increase valves are open e Check the gas valve connections e Check the operation of the gas valve e Check the operation of the condensate pump option Fault in gas valve motor Disconnected or defective cables Abnormal flame detection e Check the flame detection electrode Flame detection fault e Check the main board Gas mechanism defective e Check the igniter unit a ie oe e Check the return gas circuit gas valve open Ignition fault NG reborn gas j Insufficient gas flow e Check the observe the flame picture and check Gas valve incorrectly adjusted 3 Le the CO setting Perec ee a Check the igniter unit connections Loss of flame during operation ive igni i a aR control Defective igniter unit e Check the state of the electrode corrosion 0020112185_PROTO_13 01 11 Glow worm F23 Maximum temperature diference Water circulation fault connection reached between return and flow heating e Check the pump speed 38
54. eter K See the instructions for the external sensor connected to the 12 yes Heating curve base appliance 20 yes The following menus are displayed if an outdoor sensor not supplied is installed on the appliance Exterior temperature Display the temperature measured by the external sensor 62 Choice of lowering the setting between night COMFORT period on the d Night time offset 4 Le 6 C room thermostat and night ECO period on the room thermostat Select a value between 0 and 31 C 67 ume a BOB eeni lad min Display the time remaining before the end of the anti cycle anti cycle in heating mode wf bagay naka tanpe ranyre seting ige gS Select a value between 50 C and 80 C 75 heating outlet i Ea E Choose a value d 85 Minimum heating power 8 to 30 kW aso Detection of eBUS controller G Not detected 1 Detected Reinitialise fault list 13 2 2 After Sales Service settings This function is used to clear the fault list on the appliance 0 No 1 Reset fault list yes yes yes yes yes yes e Press the button for more than 7 seconds to access the configuration menu The screen displays 0 Press or button of the Domestic hot water temperature controls gr and enter the After Sales Service password e Press to validate The screen displays the parameter 00 and its value XX Press or button of the Domestic hot water temperature controls gr to access the parameter t
55. ft Avoid upper body top heavy bending do not lean forward sideways Clear the route before attempting the lift If removing boiler from truck straddle the load and tilt forwards to facilitate secure grip Ensure safe lifting techniques are used keep back straight bend using legs Do not twist reposition feet instead Take care to avoid trip hazards slippery or wet surfaces and when climbing steps and stairs Always use assistance if required Carriage of carton from point of delivery to point of installation roofspace Recommend 2 person lift Ensure co ordinated movements during lift Avoid upper body top heavy bending do not lean forward side ways Clear the route before attempting the lift Take care to avoid trip hazards slippery or wet surfaces and when climbing steps and stairs When transferring appliance into roofspace recommend 1 person to be in roofspace to receive the appliance and other person to be below to pass up and support appliance Ensure safe lifting techniques are used keep back straight bend using legs Keep load as close to body as possible Always use assistance if required It is assumed safe access flooring and adequate lighting are provided in the roof space Itis recommended a risk assessment of the roof space area be carried out before moving the appliance into the area to take into account access stability of flooring lighting and other factors and appropriate measures taken Unpacking of
56. ght No Consult the State List Normal operation 15 4 2 Domestic Hot Water START Is there anything displayed e i 2 ae f on the LCD Is the power switched on Switch the power on Yes Yes Yes Check wires between Is the display flashing F Consult the Fault Codes main PCB and display PCB Yes Initiate a DHW demand Does the boiler light Does the display flash F during or after a DHW demand Adjust DHW setpoint to 60 C and turn on a hot water tap Does the boiler light No Consult the State Table Normal operation 0020112185_PROTO_13 01 11 Glow worm 40 16 Gas conversion adjustments Any seals destroyed must be replaced In order to operate with a gas other than that provided from the factory it is necessary to 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 e During the conversion to Propane use of a suitable flue gas analyser is necessary The person carrying out a combustion measurement should have been assessed as competent in the use of a flue gas analyser and the interpretation of the results The flue gas analyser used should be one meeting the requirements of BS7927 or BS EN50379 3 and be calibrated in accordance with the analyser manufacturers requirements Competence can be demonstrated by satisfactory completion of the CPA1 ACS assessment which covers the use of
57. hat the domestic hot water and heating functions on your appliance are not activated 12 2 Filling the CH system Central heating e Make sure that the installation s cold water inlet isolating valve is open e Open isolating valves located on external filling loop they must be positioned in the direction of the flow Key 1 Airvent 2 Pump 3 Screw for the pump shaft e Open the plug on the air vent located on the pump and the automatic air vents on the installation e If the pressure shown on the pressure gauge is less than 0 4 bar top up the installation by connecting external filling loop to the appliance until you obtain a pressure of between 0 8 and 1 2 bars 296 When turning the 230Vac supply on to the boiler should the water pressure be less than 0 5 bar an automatic air vent function will be activated for a period of 5 minutes During this time the pressure should be increased and air vented from the system Note that the burner will not fire in either CH or DHW mode and the display will blink displaying the current water pressure Vent air from each radiator until the water flows normally then close the vents Leave the pump s air vent open The following two operations will unblock the pump s engine after a prolonged storage period and will purge the air from the pumps circuit Remove the screw from the pump shaft and introduce a flat screwdriver A trickle of water under no pressure should
58. he appliance operates safely e Erase the fault code history from the appliance To do this refer to the section Installation settings and use code d 94 e Check the gas tightness and water tightness of the appliance and eliminate any leaks e Check that the flue joints are tested for tightness and fitted in accordance with the instructions e Check the entire control and safety system its settings and its operation 14 User information At the end of the installation the installer must explain the operation of the appliance and its safety devices to the user if necessary provide a demonstration and answer any questions hand over to the user all the required documentation fillin the documents where necessary advise the user of the precautions necessary to prevent damage to the system appliance and the building remind the user to service the appliance annually 236 Draw attention if applicable 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 appliance in the UK The user shall not interfere with or adjust sealed components It is the Law that any servicing is carried out by a competent person approved at the time by the Health and Safety Executive e Advise the user that like all condensing boilers this appliance will produce a plume of condensation from the fl
59. he reset button Do not use the reset button to purge the installation never press reset more than 3 times Press the Il Central Heating Function Button Indicator button and the factory setting temperature will be displayed Press or buttons to adjust Press the ga Domestic hot water Function Button Indicator button and the factory setting temperature will be displayed Press or buttons to adjust Open a hot water tap the display will indicate the domestic hot water temperature e Check that hot water is available at all taps then close 29 12 6 Gasrates 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 Due to the modulating operation of the boiler and the need to check the gas inlet pressure and measure the gas rate at maximum rate it will be necessary to force it to maximum Activate the test mode P 01 and set the value to 100 in order to force the burner at P max See chapter Specific adjustment gt Appliance technical settings and parameter list gt Test modes 12 6 1 Operational Gas Inlet Pressure 2 1 Key 1 Gas service isolation valve 2 Test point e With all other gas appliances operating check the o
60. hich can be adjusted to suit your system requirements e Ensure that under no circumstances does the flow rate drop below the figure specified refer to chapter Technical data Filling the sealed system The water pressure at the boiler must be at least 1 2bar to operate the filling loop If the pressure is less than 1 2bar an external filling loop must be fitted If this pressure is not available contact the local water authority Suitable external filling systems are shown diagrammatically see diagram overleaf 0020112185_PROTO_13 01 11 Glow worm i ja OL y dym N SS O Il 3 a 2 _ al Ima m m 1 a Heating flow circuit Heating return circuit Boiler Double check valve assembly Domestic cold water supply in Temporary filling loop remove immediately after filling Drain point Back flow prevention device Tundish a m lt gt 5 Oo ONA UA WN RAR KR The system should be pressurised to 0 8bar indicated on the digital display with no heating demand Drain points 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 0020112185_PROTO_13 01 11 Glow worm Water treatment Existing system It is essential that prior to installing the new boiler the system is thoroughly flushed New system For optimum performance after installation the boiler and it
61. hot water pump 1 Overheating safety connector for heating floor 13 Combined spark and flame recognition electrode 2 Control accessories connector 14 Heating outlet temperature sensor 3 Appliance diagnostic connection 15 Heating return temperature sensor 4 Solar connector 16 Gasvalve 5 24V option card 17 Fan 6 User interface 18 Thermal fuse 7 Connector for automatic filling kit 19 Heating pressure sensor 8 Fuse 2A 20 Storage tank temperature sensor 9 Connector for 230 V option 21 Hot water heat exchanger output temperature sensor 10 Main supply 230V 22 Three way valve 11 Heating pump 23 Hot water temperature sensor 0020112185_PROTO_13 01 11 Glow worm 27 12 Commissioning 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 12 1 Switching on Do not operate the boiler without water Make sure that the system has been thoroughly flushed out with cold water and that all cleanser if used has been removed e With the gas service isolation valve closed with no demand from any external controls and the power supply to the boiler switched off Test for gas soundness and purge air from the gas supply e Press the on off button to activate the appliance e Make sure t
62. ipe should the calculation not be permissable in 22mm the pipe must be increased to 28 or even 35mm copper pipe or internal diameter equivilent If in multiple dwellings a common discharge pipe is used it should be at least one pipe size larger than the largest individual discharge pipe to be connected Connection into soil stacks Under normal circumstances it is not permissable to discharge the pipe D2 into a soil stack unless the following conditions are met 1 The soil stack and its seals are clearly designed and marked to withstand the temperatures of the water which could be discharged under fault conditions 2 A mecahnical type seal trap is used water traps are not permitted with a temperature rating defined as above 3 It is a separate branch pipe with no other sanitary appliances connected to it 4 Ifthe branch pipe used is plastic it must be either a Polybutalene PB Class S of BS 7921 2 2006 b Cross linked polyethylene Pe X Class S of BS 7921 3 2006 c A continuous marking applied to the pipe to warn that no sanitary appliance may be fitted to it 0020112185_PROTO_13 01 11 Glow worm The discharge pipe must terminate in a safe place where there is no risk to persons in the vicinity of the discharge Acceptable terminations are 1 Into a trapped gully the end of the pipe may be below the grating but above the water seal 2 Facing downward and up to 100mm above an external surface providing
63. ire maintenance and should not be cleaned e Check that its surface is not damage Replace the burner if necessary Following the verification or replacement of the burner assemble the burner group as described in the following chapter 18 10 5 Re assembling the burner group Place the burner group on the heat exchanger 11 e Progressively tighten the 4 nuts 7 in an alternate order e Reassemble the silencer Connect the gas tube 17 with a new gasket to the burner group e Connect the spark electrode connector 6 to the igniter unit Connect the connector to the gas valve 1 and the fan 15 0020112185 PROTO 13 01 11 Glow worm e Open the appliance gas input e Check the watertightness of the gas connection 18 11 Service completion e Re check the combustion see chapter Combustion check On completion of the service the Benchmark Service Record sould be completed 19 Replacement of Parts Do not use reconditioned or copy parts only use original parts supplied by Glow worm e Ifa partis required contact the Glow worm service organisation e Please quote the name of the appliance this information will be on the name badge on the front of the appliance e If in doubt seek advice from the local gas company or Glow worm s own Service organisation Replacement of parts must be carried out bya competent person approved at the time by the Health and Safety Executive PLEASE NOTE
64. l components The pipe connected to the underside of the tundish D2 must be vertical for the first 300mm of length before any bend or elbow then any horizontal pipework must be installed with a fall of at least 1 in 200 to its final discharge location The pipe must be either metal or other approved safe material e g complying with BS 7921 1 2006 The minimum pipe size is 22mm copper or equivilent internal diameter material To calculate the D2 pipe maximum equivilent length see the table and the worked example As an alternative BS 6700 2006 can be used 0020112185 PROTO 13 01 11 Glow worm Sizing of copper discharge pipe D2 for common temperature relief Valve outlet size Minimum size of discharge Minimum size of discharge pipe D1 pipe D2 from tundish Maximum resistance allowed expressed as a length of straight pipe i e no elbows or bends Resistance created by each elbow or bend aan item dT Gam 22mm Termination of the discharge pipe The above table is based on copper tube Plastic pipes may be of different bore and resistance Sizes and maximum lengths of plastic should be calculated using data prepared for the type of pipe being used Worked example The product is supplied with a G1 2 T amp P valve the pipe D2 is measured to be 4m in length from the tundish to the point of discharge with 4 elbows 7m of 22mm pipe 4m 4 22mm elbows 0 8 X 4 3 2m 3 2 4 7 2m and permissable in 22mm p
65. ld have a fall of a least 2 5 44mm metre away from the boiler Condensate should if possible be discharged into the household internal drainage system 18 e If this is not practicable discharge can be allowed into the external household drains or a purpose designed soak away refer to diagram overleaf It is recommended that any external condensate drain pipe is protected and also preferably of 32mm diameter to prevent freezing in adverse weather conditions e Always ensure the pipe is installed with the correct fall e Use push fit plastic pipe to connect to the condensate outlet do not use metal pipes It is permissible to use a condensate neutraliser providing that it is checked for correct operation 0020112185_PROTO_13 01 11 Glow worm INTERNAL SOIL AND VENT STACK EXTERNAL SOIL AND VENT STACK EXTERNAL MAX 3M 22mm MIN NO RESTRICTION ON LENGTH 22mm MIN NO RESTRICTION ON LENGTH Internal Soil and Vent Pipe P External Soil and Vent Pipe SINK CONSTITUTES EXTERNAL LENGTH AIR BREAK OF PIPE 3M MAX 22mm MIN 22mm MIN a NO RESTRICTION JT E ON LENGTH OPEN END OF PIPE NOTE FOR EXTENDED Internal Termination into Combined Sink Waste DIRECT INTO GULLEY PIPE RUNS 32mm DIA BELOW GROUND BUT PIPE SHOULD BE USED ABOVE WATER LEVEL External Termination to a Gulley or Hopper a EXTERNAL LENGTH OF PIPE 3M MAX 22mm MIN TERMINATION
66. lectrical plug 9 from the main board Disconnect the electrical plug 12 from the pump head Remove the four cap head screws 11 e Carefully remove the pump head 10 together with cable Do not strain cable e Reconnect wiring to new pump head and fit cover e Fit the new pump head by repeating the operations in reverse 19 4 2 Safety discharge valve Drain the boiler heating circuit as described in the appropriate chapter Draining e Undo the safety discharge valve union and remove from the pipework 2 e Remove the securing clip 39 and withdraw the safety discharge valve 1 Fit new O ring Refill vent and pressurise the boiler 0020112185_PROTO_13 01 11 Glow worm 19 4 3 Automatic air vent e Drain the boiler heating circuit as described in the appropriate chapter Draining e Remove the retaining clip 13 e Remove the automatic air vent 16 e Fit the new automatic air vent and O ring ensuring the vent cap is left loose Refill vent and pressurise the boiler 19 4 4 Low water pressure sensor Drain the boiler heating circuit as described in the appropriate chapter Draining Disconnect the electrical lead 22 e Remove the retaining clip 24 remove the low water pressure sensor 23 e Fit the new low water pressure sensor e Refill vent and pressurise the boiler 19 4 5 Bypass e Drain the boiler heating circuit as described in the appropriate chap
67. liance s electrical safety 18 1 3 Cleaning of the components e Clean the following components The cold water filter The heating filter The particle filter The condensate trap The fan 18 1 4 Corrosion and anti sludge protection In order to avoid corrosion the addition of a corrosion inhibiter to the heating circuit water is recommended The inhibiter will stop electrolytic reaction and bacterial growth between the different metals used in the installation It will also avoid the formation of gas which could be produced following the chemical reactions It is especially important to treat the water in underfloor heating systems as low temperatures favour bacterial growth This can lead to the formation of sludge which in turn may block some or all of the circuits In order to add the correct dosage of these products you must know the volume of water contained in the installation It is recommended that you note down the volume for future needs The inhibitors must be compatible with the materials employed in the installation 43 18 2 Casing removing 18 2 1 Key 1 Front panel retaining screw Front panel 2 Front panel e Undo the two screws 1 on the underside of the front panel and remove the front panel 2 18 2 2 44 Control box Key 1 Control box e Position the control box 1 into the service position 18 3 Combustion check and setting th
68. lowing current issues of 1 Central heating system specification CheSS and 2 Controls for domestic central heating system and hot water BRECSU 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 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 Domestic Hot Water All domestic hot water circuits connections fittings must be in accordance with the relevant standards and water supply regulations Heating System In GB it is necessary to comply with the Water Supply Water Fittings Regulations 1999 for Scotland the Water Byelaws 2000 Scotland To comply with the Water regulations your attention is drawn to The Water Regulations guide published by the Water Regulations Advisory Service WRAS gives full details of the requirements In IE the requirements given in the current edition of 1 5 813 Domestic Gas Installations and the current Building Regulations must be followed Electrical Supply The boiler MUST be earthed All system components shall be of an approved type and all wiring to current E E wiring regulations Ext
69. mm from the back wall To allow for the flue passing through the wall at this angle a 125mm hole should be drilled irrespective of internal or external installation Hanging bracket fixing Due to the varied site conditions fixings are not supplied and advise that the installer should supply those which are suitable Drill the holes for the fixing screws in accordance with the wall template e Fix the hanging bracket on the wall 0020112185_PROTO_13 01 11 Glow worm 7 4 2 Boiler hanging 8 Hydraulic connection With regards to the Manual Handling Operations 1992 Regulations the following lift operation exceeds 8 1 Gas and water connections the recommended weight for a one person lift refer to chapter Manual Handling The whole of the gas installation including the meter should be inspected tested for tightness and purged in accordance with the current issue of BS6891 and in IE the current edition of 5 813 Domestic Gas Installations The appliance may contain a small amount of water place a water container beneath the boiler connections Take care to clean the pipes before assembly removing any debris or burrs Grease and oils may need to be removed they are not possible to remove by cleansing and flushing Foreign bodies in the system may enter the appliance and interrupt its operation Do not use any solvent products due to the risk of damaging the circuit Do not perform any hot work dire
70. mp disconnected burner is lit Leak in the installation Inverted or disconnected flow and return heating temperature sensors Defective temperature sensors Flow and return heating sensors fault Phew anes retum heating temperature e Check temperature sensors connections sensor connected to same tube e Check the sensor connections e Check that the sensor is connected to the main board and the shunt is removed e Check connection from user interface PCB to User interface fault Defective user interface main PCB e Replace user interface 0020112185 PROTO 13 01 11 Glow worm Permanent temperature difference between flow and return heating sensors e Check temperature sensors connections e Replace faulty sensors Floor heating contact open Sheer east beting Rae NA Sensor disconnected or defective F32 F49 F62 F63 F64 F65 F67 F68 F70 F71 F72 F73 F74 F76 E77 F79 F81 F83 F84 F85 F86 Err 39 15 4 Functional flow diagram 15 4 1 Central Heating START Is there anything displayed f 9 i on the LCD Is the power switched on Switch the power on Yes Yes Yes Check wires between Is the display flashing F Consult the Fault Codes main PCB and display PCB Yes Initiate a CH demand Does the boiler light Does the display flash F Successful ignition during or after a CH Adjust CH setpoint to 75 C demand and make sure external control is calling for a demand Does the boiler li
71. n the wall giving due consideration to the required boiler clearances see chapter Appliance location gt Clearances and the flue you are fitting 7 4 1 Fixing to the wall 14 ey Wall template Standard flue length horizontal 2 5 44mm metre inclined extended flue length Wall plug Hanging bracket Screw not supplied NWO PWNRP AR Flue hole cutting e Mark the position of the flue centre e Remove the wall template then drilling the flue hole The flue is designed with an internal fall of 44mm metre 2 5 therefore the hole can be drilled horizontally Usea 105mm diameter core drill for external access flue installation 60 100 flue 80 125 flue gt 130mm e Usea 125mm diameter core drill for internal access only flue installation 60 100 flue 80 125 flue gt 150mm If flue extension pipes are to be used then a core drill size of 125mm is required This will allow the extension pieces to slope at 44mm metre 2 5 towards the boiler If fitting a side flue extend the flue centre line into the corner then 130mm along the adjacent wall If fitting an extended side flue determine the flue hole centre by extending the dashed inclined line on the template to the side wall This dashed line is drawn at 44mm metre 2 5 rise from the boiler Where this line reaches the side wall a horizontal line should be marked The vertical centre line of the flue should then be marked at 130
72. nd 0020112185 PROTO 13 01 11 Glow worm UNDER CAR PORT etc Position Position of the flue terminal Position of the flue terminal mm Horizontal flues from opening door window in car port 1200 directly below an opening air brick into dwelling opening windows m vertical from atermin isoo above an opening air brick opening windows N horizontally from a terminal cc 500 horizontally to an opening air brick opening Vertical flues OO P from another termina 600 Q above roofteve foo R from adjacent openingwindow 1000 below a balcony or car port from adjacent wall to flue from vertical drain pipes and soil pipes 25 from internal external corners 25 to a boundary alongside the terminal 300 above adjacent ground or balcony level 300 These dimensions comply with the building regulations but they may need to be increased to avoid wall staining and nuisance from pluming depending on site conditions from surface or a boundary facing the terminal 0020112185_PROTO_13 01 11 Glow worm 21 9 2 Flue configuration description Key 1 DWH safety valve A Be careful not to damage the DWH safety valve during installation of the flue 9 2 1 Horizontal concentric flue 60 100 mm or 80 125 mm C13 type installation If necessary you must install a terminal protection kit
73. necessary to adjust the by pass to the design of the system The boiler is delivered pre set open 1 2 turn 1 Key 1 Screw for by pass Depending on the design of the system the by pass may need further adjustment It is adjusted clockwise to close and anti clockwise to open This should be balanced to ensure that it operates if the pump output is adjusted Output pressure curve Ultracom 35 Store 1 2 Key A Available pressure between heating flow and return kPa B Heating circuit flow rate l h 1 Speed min 2 Speed max 0020112185 PROTO 13 01 11 Glow worm 13 2 Appliance technical settings and parameter list The access to the boilers technical data allows you to adjust the boiler to the exact system requirements Note the heating power decrease has no effect on the domestic hot water power 13 2 1 Installation settings Press the menu button for 7 seconds to access the configuration menu The screen displays 0 Press the button 4 times for mode The screen displays 96 This is the installer s password Press to validate The screen displays the parameter 00 and its value XX Press or button of gr mode to access the parameter to modify Press or button of the heating temperature controls Ill to modify the value of the parameter Repeat the past two stages for each parameter that needs to be modified Press the button for more than 3 seconds to exit the installer
74. nnector 2 Electrical wires 3 Insulation When you connect the electrical wires to a connector on the electronic board Keep a distance of a maximum of 30 mm between connector 1 and the start of the insulation 3 Ifusing single core wires are used 2 ensure that the are wrapped together in an insulating sheath e Fix the cables in the cable clamp on the eBox 11 3 Electrical wiring Connection of the whole electrical system and any heating system controls to the electrical supply must be through a common isolator Isolation should preferably be by a double pole switched fused spur box having a minimum contact separation of 3mm on each pole The fused spur box should be readily accessible and preferably adjacent to the boiler It should be identified as to its use A fused three pin plug and shuttered socket outlet may be used instead of a fused spur box provided that it is not used in a room containing a fixed bath or shower 0020112185_PROTO_13 01 11 Glow worm Key 1 Power supply cable Connect the appliance s power cable to the 230 V single phase network earth Connect the appliance in accordance with the live and neutral connections 25 11 3 1 230V permanent supply 11 4 External accessories All cables connected to the appliance should be Under no circumstances must any mains voltage be permanently fixed to the wall applied to any of the terminals on the 24v connection plug
75. nsate drain has been installed in accordance with the manufacturer s instructions and or BS5546 BS6798 Yes If the condensate pipe terminates externally has the pipe diameter been increased and weatherproof insulation fitted Yes ALL INSTALLATIONS If required by the manufacturer record the following CO OR CO ppm OR CO CO Ratio The heating and hot water system complies with the appropriate Building Regulations Yes The boiler and associated products have been installed and commissioned in accordance with the manufacturer s instructions Yes The operation of the boiler and system controls have been demonstrated to and understood by the customer Yes The manufacturer s literature including Benchmark Checklist and Service Record has been explained and left with the customer Yes Commissioning Engineer s Signature Customer s Signature To confirm satisfactory demonstration and receipt of manufacturer s literature AII installations in England and Wales must be notified to Local Authority Building Control LABC either directly or through a Competent Persons Scheme A Building Regulations Compliance Certificate will then be issued to the customer 7 enchmar COLLECTIVE MARK THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS Heating and Hotwater Industry Council HHI
76. o Gas Safe Register No Comments Comments Signature Signature Service 9 Date Engineer Name Service 10 Date Engineer Name Company Name Company Name Telephone No Telephone No Gas Safe Register No Gas Safe Register No Comments Comments Signature Signature GLOW WORM Nottingham Road Belper Derbyshire DE56 1 T www glow worm co uk Because of our constant endeavour for improvement details may vary slightly from those shown in these instructions Subject to engineering changes 113 01 11 0020112185 PROTO 13 Gloweworm
77. o modify Press Por button of the Heating temperature controls Ill to modify the value of the parameter e Repeat the process for each parameter modified e Press the button for more than 3 seconds to exit the configuration menu 0020112185_PROTO_13 01 11 Glow worm 33 Code Parameter Description Factory Modifiable setting parameter Flow temperature set point from external eBus control FE xternal eBus set value pe oO Mm WO oo 3 d 10 Heating pump status open no heating closed heating mode e O ll d 16 Current state of the 24V room thermostat emperature regulation on flow radiator or return under floor heating temperature sensor o d 17 Flow or Return temperature monitoring R d 22 DHW demand active tapping e O oil o 9 5 0 CH not available summer mode 1 CH available winter mode iiia Fan speed is displayed between 0 and 99 p Multiply the displayed value by 100 V Display the digitalized ionisation voltage Display the number of unsuccessfull ignitions at first attempt Display the number of unsuccessfull ignitions at second attempt Display the number of operating hours in heating mode Multiply the displayed value by 100 Central heating mode Speed setpoint of fan a a a A w N w w 4 Digitalized ionisation voltage Unsuccessfull ignitions at first attempt Unsuccessfull ignitions at second attempt d 80 Operating hours in
78. o ordinated movements during lift Always use assistance if required Carriage of carton from point of delivery to point of installation ground floor Recommend 2 person lift or 1 person with use of sack truck If 1 person is performing lift straddle the load tilt and place carton into position on truck Recommend secure appliance onto truck with suitable straps Ensure safe lifting techniques are used keep back straight bend using legs Keep load as close to body as possible If 2 persons per forming lift ensure co ordinated movements during lift Clear the route before attempting the lift If removing boiler from truck straddle the load and tilt forwards to facilitate secure grip Ensure safe lifting techniques are used keep back straight bend using legs Do not twist repo sition feet instead Take care to avoid trip hazards slippery or wet surfaces and when climbing steps and stairs Always use assistance if required Carriage of carton from point of delivery to point of installation first or higher floor cellar Recommend 2 person lift or 1 person with use of sack truck If 1 person is performing lift straddle the load tilt and place carton into position on truck Recommend secure appliance onto truck with suitable straps Ensure safe lifting techniques are used keep back straight bend us ing legs Keep load as close to body as possible If 2 persons perform ing lift ensure co ordinated movements during li
79. oir retaining clips Hose Heat exchanger NOW PWNRP AR e Place a container under the condensate trap 4 e Remove the condensate 1 from the reservoir Disconnect the condensation discharge 2 Disconnect the hose 6 from heat exchanger 7 Remove the retaining screws 3 of the condensate trap 4 The condense trap will contain water lift taking care not to spill the water e Remove the condensate trap 4 using the clips 5 e IMPORTANT Partially fill the condensate trap with water before replacing Start the siphon 1 and fill with water 57 19 7 PCB 19 7 3 User interface PCB When replacing the board refer to instructions supplied with the spare part 19 7 1 Main PCB Key 1 Control Panel 2 User interface 3 User interface PCB 4 Retaining screw 5 Bracket Switch On Off 6 Retaining clips 7 User interface PCB retaining screws e Open the user interface 2 e Remove the retaining screws 4 7 of the bracket 5 e Ease back the two PCB retaining clips 6 and withdraw the ey ae AA PCB from the retaining lugs Screw Remove the electrical connections to the PCB Main PCB access cover When refitting the user interface ensure the leads are not trapped Main PCB Retaining clips K 1 2 3 4 24Vaccess cover 5 6 7 Control Panel 19 7 4 Mains supply cable Remove the 24V and 230V connections add ppiy Open the covers 1 3 4 A The main supply cabl
80. ow the appliance to cool before performing maintenance work Should you need to replace hydraulic components drain the appliance e Protect all the electrical components from water while working on the appliance e Use only original spare parts e Use only new O rings and gaskets After having completed work on gas or water carrying components check for their tightness e When work on the appliance is completed perform an operational test and check for safety 3 2 Regulations 3 2 1 Statutory requirements IMPORTANT Installation of this appliance falls within the scope of the Building Regulations 2010 Part G This requires that the installation of an unvented system should be notified to the local authority Building Control Department and the work must be carried out by a competent person as defined in the approved document G3 Where no British Standards exists materials and equipment should be fit for their purpose and of suitable quality and workmanship The installation of this boiler must be carried out by a competent person approved at the time by the Health and Safety Executive and in accordance with the rules in force in the countries of destination Manufacturer s instructions must not be taken as overriding statutory requirements Statutory Requirements In GB the installation of the boiler must comply with the requirements of the current issue of BS6798 and be carried out by a competent person app
81. oximately 5 minutes to read a stabilized CO value 41 e Compare the value measured with the values indicated in the table below CO case ON 920 2 Yo 10 1 0 2 CO case OFF 9 240 3 Yo 10 3 20 3 Yo Safe combustion can only be verified by measuring CO CO ratio This must not exceed the value shown in the table under the section Maximum Rate and Adjustment 16 1 3 Restarting e Replace the cap e Replace the appliance front panel Note following the replacement of the front panel the CO value will change you can check that the value case on is correct by the values in the previous table Key 1 Gas change label location 2 Data label location e Firmly attach the gas replacement label to the appliance in the corresponding location 1 on the electrical box Depending on the gas replacement label tick the type of gas used on the sticker 16 2 Restart re check commissioning Before putting the appliance into operation follow the instructions within the chapter Specific adjustment 42 17 Draining 17 1 Heating circuit Key 1 Heating drain tap e Open the heating drain tap 1 located under the boiler e Make an air intake by for example opening a bleed in the installation To just drain the heating circuit water contained within the appliance first close the heating outlet and return valves 17 2 Domestic Hot water circuit e Drain the domestic Hot Water circuit by closing the cold
82. perational supply pressure at the gas service isolation valve test point The nominal supply pressure for Natural Gas G20 is 20mbar The nominal supply pressure for LPG G31 is 37mbar e Turn the taps and appliances off then disconnect the pressure gauge Additionally the safe nominal maximum heat input of the appliance can be achieved at an inlet pressure down to 15mbar The burner pressure cannot be measured and is not used to measure the gas rate 12 6 2 Gas Rate e Make sure that all other gas burning appliances and pilot lights are off e 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 e Gas rates for both central heating and hot water can be verified using the test program P 03 and P 01 respectively 30 Gas rates G20 Gas rates G31 approx after 10 mins from cold wm In communal or LPG installations where the gas rate cannot be measured it is acceptable to measure the combustion rate as described in the servicing section e On completion press the reset button to reset the boiler 12 7 Testing heating system e Ensure that the external controls and programmer are calling for heat e Fully open all radiator valves see chapter Appliance installation gt Recommendations before installing gt Heating circuit design e Activate the C H function on the appliance s control panel Balan
83. pliance into the area to take into account access stability of flooring lighting and other factors and appropriate measures taken Declaration of Conformity CE DECLARATION OF CONFORMITY Glow worm Nottingham Road Belper Derbyshire DE36 1JT CONDENSING WALL HUNG GAS COMBINATION BOILER Name and Address of the Manufacturer Identification of product Appliance type amp models GLOW WORM ULTRACOM 2 35 Store A 1 The appliance types satisfy the essential requirements of the relevant directives and Standards 2009 142 EEC including amendments Directive on the approximation of the law of the member states relating to appliances burning gaseous fuels 92 42 EEC including amendments Directive of efficiency relating to boiler burning gaseous fuels 2006 95 EEC including amendments Directive on the harmonization of the laws of Member States relating to electrical equipment designed for use within certain voltage limits 2004 108 EEC including amendments Directive on the approximation of the law of the member states relating to electromagnetic compatibility Designed and built to CE type examination certificate PIN N 1312CL5531 Designed and built according to European Standards EN 483 EN 297 A4 EN13203 1 EN 677 EN 625 EN 60335 1 amp EN 60335 2 102 EN 60529 EN 50165 EN 55014 EN 61000 3 2 EN 61000 3 3 Any change to the appliance and or any use not according to the instructions will
84. positioning onto bracket obtain firm grip at front and sides base of boiler Ensure co ordinated movements during 2 person lifts to ensure equal spread of weight of load Ensure safe lifting tech niques are used keep back straight bend using legs when lifting load from floor level Do not twist reposition feet instead Keep boiler as close as possible to body throughout lift to minimise strain on back Avoid upper body top heavy bending do not lean forward sideways Al ways use assistance if required Recommend wear suitable cut resistant gloves with good grip to protect against sharp edges and ensure good grip when handling appliance Positioning of Appliance for Final Installation within compartment etc restricting installation Recommend 2 persons lift appliance to position into place space per mitting Fit bracket securely onto wall before lifting appliance into posi tion Obtain firm grip on front and sides of appliance lift upwards onto worktop if practicable Ensure stable balance achieved and lift upwards to drop into place onto bracket If 2 persons positioning onto bracket obtain firm grip at front and sides base of boiler Ensure co ordinated movements during 2 person lifts to ensure equal spread of weight of load If 1 person positioning onto bracket recommend obtain firm grip supporting base of boiler Ensure safe lifting techniques are used keep back straight bend using legs when lifting load from floor level Do
85. re indicator displays a value of 0 8 bar earth check points on the appliance if the pressure falls below 0 4 bar the air vent function will run automatically for a period of 5 minutes until you see 0 5 bar on the pressure indicator If not fill the appliance 15 1 2 Check the gas supply e Check that all external controls are connected correctly e Ifthe symbol Jl and the message rE SEt are displayed on the screen display the fault code memory see chapter Trouble shooting Fault memory Press the reset button to restart the appliance e Check the functional flow diagram 2 1 Key 1 Gas service isolation valve 2 Test point 0020112185 PROTO 13 01 11 Glow worm 37 e Check that there is a gas supply to the boiler and the gas ma service isolation valve is turned on Record Fault code Description e Check pressure at the gas service isolation valve Consult the Fault coudes chapter Consult the Fault codes chapter Consult the Fault codes chapter 15 2 Fault memory Consult the Fault codes chapter This menu allows you to display the 10 most recent failure codes registered by the appliance Consult the Fault codes chapter e In order to display the fault code memory simultaneously Consult the Fault codes chapter press the buttons and of the heating temperature Consult the Fault codes chapter controls If for more than 7 seconds
86. refully remove the pump head 4 together with cable Do not strain cable Fit the new pump head by repeating the operations in reverse 54 0020112185_PROTO_13 01 11 Glow worm 19 5 Combustion block 0020112185_PROTO_13 01 11 Glow worm 55 Key Igniter unit retaining bracket Igniter unit Igniter unit retaining screw Igniter unit electrical connector Electrode igniter unit connection cable Earth cable Spark electrode cap Spark electrode retaining screw Spark electrode gasket 10 Spark electrode 11 Combustion burner door assembly 12 Combustion burner door assembly nut 13 Combustion burner door assembly gasket 14 Burner gasket 15 Burner 16 Burner retaining screw 17 Heat exchanger retaining screw 18 Heat exchanger retaining bracket 19 Burner gate retaining screw 20 Thermal fuse connection 21 Heat exchanger 22 Heat exchanger retaining bracket 23 Heat exchanger retaining screw 24 Heating return pipe 25 Heating return pipe retaining clip 26 Return heating temperature sensor 27 Heating flow pipe 28 Flow heating temperature sensor 29 Heating flow pipe retaining clip 30 Gas valve retaining screw 31 Gasvalve 32 Gas valve gasket 33 Fan 34 Fan electrical connection 35 Fan burner gasket 36 Gas pipe 37 Gas valve electrical connection 38 Fan retaining screw OANKDAUPWNPR 19 5 1 Spark electrode Disconnect the electrode cap 7 and the earthing cable
87. roved at the time by the Health and Safety Executive and as described in the following regulations The manufacturer s instructions supplied The Gas Safety Installation and Use Regulations The appropriate Buildings Regulations either The Building Regulations The Building Regulations Scotland The Building Regulations Northern Ireland The Water Supply water fittings Regulations 1999 and water byelaws 2000 Scotland The Health and Safety at Work Act Control of Substances Hazardous to Health COSHH Any electrical work must conform to BS7671 and part P of the building regulations where applicable Where no specific instructions are given reference should be made to the relevant British Standard Code of Practice In IE the installation must be carried out by a competent person approved at the time by the Health and Safety Executive and installed in accordance with the current edition of S 813 Domestic Gas Installations the current Building Regulations and reference should be made to the current ETCI rules for Electrical Installation GB the following Codes of Practice apply BS4814 BS6798 BS5440 Part 1 and 2 BS5546 Part 1 BS5449 BS6891 BS6700 BS7074 Part 1 and 2 BS7593 BS7671 IE 1 5 813 BS5546 BS 5449 BS 7074 BS 7593 0020112185_PROTO_13 01 11 Glow worm NOTE For further information see the current issue of the Building Regulations approved document L1 in the UK and the fol
88. rvicing If the Combustion CO CO CO ratio amp Gas rate checks did not require adjustment then it will not be necessary to complete a full service All routine servicing requirements can be achieved by the removal of the front panel e Position the control box into the service position e Before commencing with a service or replacement of parts isolate the boiler from the electrical and gas supplies 18 4 1 Service interval record e Refer to benchmark book stapled in the centre pages of this manual 45 MAINTENANCE 18 5 Silencer e Check the expansion vessel s supply pressure see Technical Data chapter by means of the pressure inlet located on the expansion vessel Adjust the pressure if necessary e Following the installation of a new expansion vessel fill and purge the appliance or installation if necessary 18 7 DHW expansion vessel 1 Key 1 Fixed silencer 2 Silencer retaining clip 3 Removable silencer Unclip and remove the silencer 3 e Clean the interior of the silencer with a dry cloth if necessary taking care not to damage the internal foam Key 1 DHW expansion vessel It is not necessary to remove the heating expansion tank to remove the hot water expansion tank e Check the hot water expansion tank supply pressure see section Technical data using the pressure tap located below it and adjust if necessary e Repeat the operation in reverse order to replace
89. s associated central heating system should also be flushed Flushing shall be carried out in accordance with BS 7593 a chemical cleanser can be used either Sentinel X300 X400 or Fernox F3 are suitable It is recommended to flush existing systems first before fitting the new boiler Ensure all cleanser is removed from the whole system before adding an inhibitor For long term corrosion protection after flushing an inhibitor suitable for stainless steel heat exchangers can be used Either Sentinel X100 or Fernox F1 inhibitor can be used Artificially softened water BS7593 notes that soft water has an increased potential for corrosion and this may influence the choice of corrosion inhibitor Where water is artificially softened it is advisable to feed unsoftened water to drinking water taps The boiler primary circuit should only be filled with unsoftened water 7 3 Dimensions 13 7 4 Mounting Make sure that the equipment used for implementing the installation is compatible with that of the appliance Determine the assembly location See the Appliance location chapter kO p 913p 0105 a 8 z La N R t4 0 B se aaa NG st DS b ch Ib Bir T i ey S Bey A ir ii Tit wt 36 102 70 60 100 flue xx 80 125 flue Take the wall template and place in the desired position o
90. s conversion section before lighting the boiler e Check that the appliance has been installed in accordance with the instructions e Check the integrity of the flue system and flue seals e Check the integrity of the appliance combustion circuit and relevant seals e Check that all internal external controls are calling for heat e Check that the gas service isolation is open To adapt the appliance to another type of gas see chapter LPG conversion 0020112185 PROTO 13 01 11 Glow worm 12 5 2 Adjusting the temperature 1 2 3 gf cc ble T i i mo 7 6 5 4 Key 1 Reset button 2 Display 3 On Off button 4 Heating temperature controls 5 Central Heating Function Button Indicator 6 Domestic hot water Function Button Indicator 7 Domestic hot water temperature controls e Light the appliance by following the procedure below Select the Heating domestic hot water function by pressing the Central Heating Function Button Indicator and Domestic hot water Function Button Indicator buttons repeatedly to scroll through your options until II gi are shown The appliance will enter a self checking routine then the fan will start and the ignition sequence commence The boiler if necessary will automatically repeat the ignition sequence a further 4 times If the burner fails to ignite F28 will be displayed initially this may be due to air in the gas supply line Press t
91. t ventilation is not necessary e Existing ventilation should be investigated for its purpose before removing 0020112185_PROTO_13 01 11 Glow worm 7 Appliance installation 71 Scope of delivery The appliance is delivered in a single carton with a document pack and fittings Please check the contents The flues package will be ordered according to the configuration of the installation 1 Boiler 2 Accessories bag 2 1 Wall template 2 2 Fittings pack Heating return valve Cold water inlet valve Heating flow valve Domestic hot water connection Gas isolation valve Compression fitting 2 3 Seals bag 2 4 Filling loop 2 5 Pressure reducing valve 2 6 Pressure relief valve 20 Check valve 2 8 Tundish 2 9 Hanging bracket 2 10 Mixing valve 0020112185_PROTO_13 01 11 Glow worm x1 x1 x1 x1 x1 x1 x1 x1 x1 x1 x1 x1 x1 x1 x1 x1 x1 x1 3 Documents bag x1 3 1 Installation and servicing manual x1 3 2 Flue book x1 3 3 Instructions for use x1 3 4 Extended guarantee leaflet x1 3 5 Guarantee envelope pack x1 3 6 Magnetic lighting instruction label x1 3 7 Gas conversion label x1 7 2 Recommendations before installing 7 21 Domestic hot water circuit design Water pressure Key 1 Domestic hot water out 2 Pressure reducing valve if required 3 Mixing valve 4 Boiler 5 T
92. ter Draining e Remove the retaining clip 33 to remove the bypass screw 31 After replacing the bypass refill vent and pressurise the boiler 19 4 6 Three way valve e Drain the boiler heating circuit as described in the appropriate chapter Draining Disconnect the electrical plug 36 e Remove the two retaining screws 37 e Remove the three way valve 35 e Fit new three way valve assembly Refill vent and pressurise the boiler 19 4 7 Foaming filter Drain the boiler heating and domestic hot water circuits as described in the appropriate chapter Draining e Remove the filter retaining clip 7 located under the pump e Relieve the foaming filter 8 e Refill vent and pressurise the boiler 53 19 4 8 Plate to plate heat exchanger Drain the boiler heating and domestic hot water circuits as described in the appropriate chapter Draining Remove the two securing screws 32 Remove the plate to plate heat exchanger 29 When replacing the plate to plate heat exchanger ensure that the four rubber sealing washers are fitted into the hydroblock NOTE The plate to plate heat exchanger only fits one way Refill vent and pressurise the boiler 19 4 9 Domestic hot water pump head only Drain the boiler heating and domestic hot water circuits as described in the appropriate chapter Draining Disconnect the electrical plug 3 from the main board Unscrew the nut 5 Ca
93. to health The adhesives and sealants used in this appliance are cured and give no known hazard in this state Insulation Pads These can cause irritation to skin eyes and the respiratory tract If you have a history of skin complaint you may be susceptible to irritation High dust levels are usual only if the material is broken Normal handling should not cause discomfort but follow normal good hygiene and wash your hands before eating drinking or going to the lavatory e Ifyou do suffer irritation to the eyes or severe irritation to the skin seek medical attention 4 Recycling The recycling of the packaging must be carried out by the qualified professional who installed the appliance 4 1 Appliance Most of the appliance is made of recyclable materials DI This symbol indicates that this appliance must not aS be disposed of with household waste that it should be selectively collected for energy recovery reuse or recycling e Take the appliance to an appropriate collection point By complying with this directive you will contribute to the preservation of natural resources and the protection of human health 4 Packaging We recommend that you recycle the packaging of the appliance in a responsible fashion Sort the waste in order to separate those elements which can be recycled cardboard plastics and those which cannot be recycled Eliminate the waste in accordance with existing regulations TECHNIC
94. ue terminal in cool weather This is due to the high efficiency and low flue gas temperature of the boiler e Advise the user that the permanent mains electrical supply should not be switched off as the built in frost protection and pump exercise program will not operate e Advise the User if the mains electricity and gas are to be turned off for any long periods during severe weather it is recommended that the whole system including the boiler should be drained to avoid the risk of freezing Sealed system The system must be refilled to the Li correct pressure by a competent person as indicated in these instructions e Leave these instructions and the Benchmark Installation Commissioning and Service Record with the user 0020112185_PROTO_13 01 11 Glow worm MAINTENANCE 15 1 1 Check the electrical installation To ensure the continued efficient and safe operation of the 2 ES 3 boiler it is recommended that it is checked and serviced at o BEN regular intervals The frequency of servicing will depend upon UI X1 0 Wf the particular installation and usage but in general once a year CEA should be enough 1 It is the Law that any servicing is carried out by a competent person approved at the time by the Health and Safety Executive Before commencing with a service or replacement of parts isolate the boiler from the electrical supply and turn off the gas supply at the gas isolation valve e When replacing a p
95. ue terminals To install the flue refer to the separate flue instruction supplied with your appliance e Explain these requirements to the user of the appliance If necessary you must install a terminal protection kit 20 A Caution The connection between the flue elbow and the flue outlet must be sealed In GB the minimum acceptable siting dimensions for the terminal from obstructions other terminals and ventilation openings are shown in diagram overleaf In IE the minimum distances for flue terminal positioning must be those detailed in 1 S 813 Domestic Gas Installations The terminal must be exposed to the external air allowing free passage of air across it at all times Being a condensing boiler some pluming may occur from the flue outlet This should be taken into consideration when selecting the position for the terminal Carports or similar extensions of a roof only or a roof and one wall require special consideration with respect to any openings doors vents or windows under the roof Care is required to protect the roof if made of plastic sheeting If the carport comprises of a roof and two or more walls seek advice from the local gas supply company before installing the boiler If the flue terminal is positioned near a light source IN 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 e
96. ult the Start Up chapter to restart the appliance 18 1 Annual Maintenance 18 1 1 Verification of components e Check that the flow sensor is working properly See chapter Specific adjustment gt Appliance technical settings and parameter list gt Installation settings and use code d 36 e Check that the fan is working properly See chapter Specific adjustment gt Appliance technical settings and parameter list gt Installation settings and use code d 34 e Check that the temperature sensors are working properly See chapter Specific adjustment gt Appliance technical settings and parameter list gt Installation settings and use code d 3 d 4 d 40 d 41 e Check the ionisation quality e Check that the thermal fuse protects the appliance against dry fire Disconnect the thermal fuse and check if F76 fault code is displayed on the screen e Check that the pressure sensor is working properly The pressure must be displayed on the screen e Check the pressure of the expansion vessel the DHW expansion vessel e Check the particle filter 0020112185 PROTO 13 01 11 Glow worm 18 1 2 Other checks e Check the CO rate in the fuel and compare with the values indicated in the chapter CO Measurement e Check that there are no leaks in the joints and the safety valves Check that there are no gas leaks e Verify that the flue system is sound and complete e Check the app
97. ures permanent difference Heating circuit pressure sensor fault The sensor is shorted or disconnected e Check the sensor s connections Heating circuit pressure sensor fault Fault in pressure sensor e Check the sensor Themaat tase tait Thermal fuse disconnected e Check the fuses connections Defective thermal fuse e Replace the heat exchanger e Check the gas valve connections Defective gas valve e Check the operation of the gas valve Permanent temperature difference between flow and return heating sensors e Check temperature sensors connections e Replace faulty sensors Fault i gas valve motor Defective condensate pump option e Check the operation of the condensate pump option e Check the sensor connections Storage tank temperature sensor fault Storage tank temperature sensor fault Check the sensor cables e Check the sensor e Check whether temperature sensor not clipped correctly plate exchanger outlet hot water pump not functioning Overheating of hot water circuit Fault in the hot water circuit non return valve blocked plate exchanger blocked tank outlet pipes blocked air in the primary circuit main pump not functioning e Fill the installation e Purge the installation e Check the pump connections e Check the flow and return heating sensor connections e Check that there are no leaks No water in the installation the Return water valve closed temperature does not increase when the Pu
98. utton or the On Off button to exit the test modes The appliance functions at a power adjustable from 0 0 Pmin to 100 100 Pmax by using buttons or of the Heating temperature controls after successful ignition Forcing the adjustable power burner when heating Forcing the burner to heating ignition power Facing the j The appliance functions at its maximum P 03 burner to Heating PAGE power after successful ignition Pmax The appliance functions at ignition power after successful ignition The 3 way valve is in the central position the pump and the burner stop so that the appliance can be filled Filling the appliance The function is activated for a period of 5 minutes on the heating circuit Make sure that the air vent is open Venting the installation The function is activated for a period of 5 minutes on the short circuit Make sure that the air vent is open Venting the appliance 35 13 3 CO measurement The combustion for this appliance has been pre set at the factory for operation on Natural Gas G20 as defined on the appliance data label No adjustment of the combustion is necessary If you wish to check the combustion then follow the instructions in the Servicing section 13 4 Re check and restart e Once the appliance is installed check the operation of the appliance Start the appliance to ensure that any adjustments operate correctly and check that t
99. warnings and installation manual e 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 This will ensure that the connections to the water gas and flue can be accessed and inspected see chapter Clearances e Explain these requirements to the appliance user Do not install the appliance above another appliance that could damage it for example above a cooker that might emit steam or grease or in a room which has a lot of dust in the atmosphere which is corrosive e The boiler must be fitted inside the property and exposed pipe work may need to be protected from frost by fitting a frost thermostat 6 1 2 Regulations Location This boiler is not suitable for outdoor installation This boiler may be installed in any room although particular attention is drawn to the installation of a boiler in a room containing a bath or shower where reference must be made to the relevant requirements This boiler is suitable for installation in bathroom zones 2 and 3 In GB this is the current I E E WIRING REGULATIONS and BUILDING REGULATIONS In IE reference should be made to the current edition of I S 813 Domestic Gas Installations and the current ETCI rules Timber Frame Buildings If the boiler is to be installed in a
100. when the pressure in the heating circuit exceeds 3 bars The domestic hot water safety valve opens when the pressure in the heating circuit exceeds 10 bars Should there be any discharge from the pipe isolate the boiler electrical supply and call your installer or Glow worm s own service organisation 2 1 3 Frost protection The frost protection system operates the pump to start as soon as the temperature in the heating circuit falls below 12 C The pump stops as soon as the temperature of the water contained in the heating circuit reaches 15 C If the temperature in the heating system falls below 7 C the burner ignites until it reaches 35 C The frost protection system is active when the appliance is switched on The system alone cannot ensure that the installation is protected against frost An separate frost thermostat is necessary to control the temperature of the system A Your domestic water circuit hot or cold is not protected by the boiler 2 1 4 Condensate drain blockage During freezing conditions this may be due to the forming of ice in the condense drain external to the house In this case a safety device shuts down the appliance 2 2 Data label The data label certifies the country where the appliance is intended to be installed Data label location Key 1 Data label The data label contains the following data The name of the manufacturer The country of intended destination Th

Ultracom2 35 Store Installation & Servicing Manual - Glow-worm

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Ultracom2 35 Store Installation &amp; Servicing Manual - Glow-worm

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Ultracom2 35 Store Installation & Servicing Manual - Glow-worm