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Ultracom hxi Installation & Servicing Manual Boilers - Glow-worm

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1. J gt a es lt 4 SJ G3 f DI T T WW gt X Quum DRAIN RETURN POINT PIPE Diagram 13 10 41 13 16 Access User Interface and Main PCB For access refer to section 13 1 Remove control box retaining screw see diagram 13 11 Hinge down the control box Release the control box cover by carefully pressing the four retaining latches see diagram 13 11 13 17 Main PCB IMPORTANT When replacing the board refer to instructions supplied with the replacement For access refer to section 13 16 Remove the electrical connections to the PCB Ease back the four PCB retaining clips and withdraw the PCB from the retaining lugs see diagram 13 12 When refitting the rear panel ensure the leads are not trapped When replacing the board refer to instructions supplied with the replacement 13 18 User Interface IMPORTANT When replacing the board refer to instructions supplied with the replacement Refer to section 13 16 for access Remove main PCB refer to section 13 17 Remove electrical connection Gently ease back the retaining clips see diagram 13 13 Withdraw the board 13 19 Fuse Main PCB Control Box For access refer to section 13 16 The fuse is located at top left hand side of the PCB see diagram 13 12 13 20 Control Box For access refer to section 13 16 Remove relevant plugs and connectors r
2. 13 Water Pressure Loss metres head of water Water Pressure Loss metres head of water Water Pressure Loss metres head of water 12 hxi Pressure Loss Graph P 24 hxi Pressure Loss Graph 15 5 25 g 4 N J 4 5 _ 2 1 a 1 e 1 P 1 1 1 1 5 i 1 D 1 1 T 1 4 1 0 5 J I 1 5 1 4 0 5 1 S 1 os 7 1 0 gt 0 i 0 100 200 300 400 500 600 0 200 400 600 800 10001 Flow Rate litres hour Flow Rate litres hour 520 20 diff 12kW 1076 l hr 20 diff 24kW 15 hxi Pressure Loss Graph 30hxi Pressure Loss Graph e en o Water Pressure Loss metres head of water oe LL 0 00 V 9 4 94 0 100 200 300 400 500 600 700 800 200 400 600 800 1000 1200 1400 Flow Rate litres hour Flow Rate litres hour 646 l hr 20 diff 12kW 1220 Whr 20 diff 30kW 18 hxi Pressure Loss Graph 38hxi Pressure Loss Graph 2 5 4 50 A e 1 1 1 1 1 1 d a e o m a N a 0 54 0 0 10
3. As a safety feature the boiler will stop working if the condensate drain becomes blocked During freezing conditions this may be due to the forming of ice in the condense drain external to the house Release an ice blockage by the use of warm cloths on the pipe The boiler should then restart Servicing Maintenance and Spare Parts Servicing and Maintenance 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 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 using the telephone number on the inside front cover of this literature After servicing complete the relevant Service Interval Record section of the Benchmark Checklist located on the inside back pages of these instructions Spare Parts Remember when replacing a part on this appliance use only spare parts that you can be assured conform to the safety and perform
4. Do not adjust the Gas Air ratio valve No measurement of the combustion is necessary having checked e the appliance has been installed in accordance with the instructions e the integrity of the flue system and flue seals e the integrity of the appliance combustion circuit and relevant seals e that all internal external controls are calling for heat e the gas service isolation valve diagram 10 1 is open As an option a chargeable boiler performance and function service can be provided by Glow worm Service by calling telephone No 01773 828100 LPG Conversion See section 10 10 NOTE If you have fitted a Glow worm Options Board Kit please refer to the instructions supplied with the kit for completion of commissioning Do not operate the boiler without water Refer to diagram 10 2 1 With no demand from any external controls switch on the electrical supply to the boiler Open the gas service isolation valve see diagram 10 1 2 Select your required function by pressing Mode scroll through your options and select one of the following Central heating Boiler functions ALL switched off OFF 3 Turn ON your external controls and select the room temperature required The boiler will operate automatically NOTE The display will indicate the Heating system water temperature or a fault code if in a fault condition 22d 10 5 Check the Gas Inlet Pressure and Gas Rate The supply from the governed meter must
5. 31 99 5 CONTROL VALVE IGNITION IGNITER HEATING RETURN ELECTRODE UNIT THERMISTOR HEATING FLOW THERMISTOR CHASSIS EARTH LIU LIBELLI O INSTALLER INTERFACE jooooo000 79 A UT 4 7222284 MAIN CONTROL BOARD KEY BROWN BLUE GREEN YELLOW GREY BLACK YELLOW RED INTERFACE WHITE BOARD Diagram 12 4 0020107233 00 06 11 Glow worm 32 START CENTRAL HEATING ZLOEL Is there anything displayed on the LCD Is the power switched on Switch the power on Yes Check wires between main PCB and display PCB Yes Is the display flashing F Consult the Fault Codes Initiate a CH demand Does the boiler light Adjust CH setpoint to 82 C and make sure external control is calling for a demand Does the boiler Does the display flash F during or after a CH demand Successful ignition light Consult the State List Normal operation Diagram 12 5 0020107233_00 06 11 Glow worm 33 Fault Codes DESCRIPTION POSSIBLE CAUSE 80SEL Boiler has attempted to light 5 times and failed on all occasions G
6. BS6700 BS7074 Part 1 and 2 BS7593 BS7671 IE 1 5 813 BS5546 BS 5449 BS 7074 BS 7593 NOTE For further information see the current issue of the Building Regulations approved document L1 in the UK and the following current issues of 1 Central heating system specification CheSS and 2 Controls for domestic central heating system and hot water BRECSU 0020107233_00 06 11 Glow worm 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 1 5 813 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 GB Guidance G17 to G24 and recommendation R17 to R24 of the Water Regulations Guide IE The current edition of S 813 Domestic Gas Installations 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 Regulatio
7. 2 Z6VEL 610 GOCEL 214 166 FLOW 120 D e 127 k 52 0 etg cp o 1 ic 9 53 130 130 q BOILER CONDENSATE CONNECTION 375 Diagram 2 1 LI FLOW THERMISTOR gt THERMISTOR A GAS CONTROL VALVE FAN DRAIN TAP D D C H C H RETURN GAS FLOW Diagram 2 2 2 Boiler Dimensions amp Hydraulic Schematic All dimensions are given in millimetres except as noted The general arrangement of the boiler is shown in diagram 2 1 and the hydraulic and gas schematic diagram 2 2 The data label is positioned on the front of the inner casing panel 0020107233 00 06 11 Glow worm 3 Boiler Location Clearances and Ventilation 3 1 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 3c In GB this is the current I E E WIRING REGULATIONS BUILDING REGULATIONS In IE ref
8. 7 Burner For access refer to section 13 1 Refer to section 11 3 for removal of the fan gas valve and burner assembly Remove the four screws that secure the burner see diagram 11 6 NOTE The burner will require a new gasket when refitted 13 8 Front Insulation For access refer to section 13 1 Refer to section 11 3 for removal of the fan gas valve and burner assembly Remove spark electrode see section 11 2 Remove burner as described in section 13 7 refer to diagram 11 6 NOTE The burner will require a new gasket when refitted 13 9 Rear Insulation For access refer to section 13 1 Refer to section 11 3 for removal of the fan gas valve and burner assembly Remove securing screw and washer in the centre of the insulation and withdraw insulation see diagram 13 4 13 10 Viewing Window For access refer to section 13 1 Refer to diagram 13 5 Remove circlip Remove steel washer Remove glass Remove fibre washer Replace in reverse order 0020107233_00 06 11 Glow worm GAS MANIFOLD N o0 A 0 UN eN 5 5 99 27o SECURING 2 SCREW 2 Diagram 13 3 REAR WASHER INSULATION 5 HEAT EXCHANGER SECURING SCREW Diagram 13 4 GLASS FIBRE WASHER 8 Meer TERI E CIRCLIP STEEL WASHER Diagram 13 5 39 13 11 Condensate Trap and Siphonic Drain For access refer to section 13 1 Refer to diagram 13 6 Remove
9. 9 4 Electrical Cartridge Securing Close the cartridge and secure with the previously removed Screw Push the electrical cartridge into the interface housing on completion of the wiring see diagram 9 3 Secure with the two cartridge retaining screws provided in the cartridge body 9 5 Electrical Connections Testing Carry out preliminary electrical system checks as below 1 Test insulation resistance to earth of mains cables 2 Test the earth continuity and short circuit of cables 3 Test the polarity of the mains NOTE If you require to test the appliance refer to section 12 Commissioning IMPORTANT At the time of commissioning complete all relevant sections of the Benchmark Checklist located in the inside back pages of this document 10 1 Preliminaries All Systems 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 56798 DO operate 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 Isolate the boiler from the mains electrical supply Test for gas tightness and purge air from the gas supply IMPORTANT Before starting the boiler check that all flue connections are secure and sealed correctly 10 2 Filling the Heating Circuit With the gas isolation valve closed and with no demand from any
10. Connection WARNING This appliance must be earthed e This appliance must be wired in accordance with these instructions Any fault arising from incorrect wiring cannot be put right under the terms of the Glow worm guarantee e All system components must be of an approved type Electrical components have been tested to meet the equivalent requirements of the BEAB e Do not interrupt the mains supply with a time switch or programmer e Connection of the whole electrical system and any heating System controls to the electrical supply must be through a common isolator e 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 e 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 e The boiler is suitable for installation in bathroom zones 2 and 3 9 1 Electrical Wiring Remove the electrical cartridge from the fittings pack Remove the securing screw to open the cartridge see diagram 9 1 NOTE There are two screws supplied loose in the electrical cartridge these will be required to secure the cartridge into the electrical interface housing Slacken the cable strain relief screws in the electrical cartridge see diagram 9
11. Keep load as close to body as possible If 2 persons performing lift ensure co ordinated movements during lift 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 sideways 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 It is recommended a risk assessment of the roof space area be carried out before moving the appliance into the area to take int
12. 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 Electrical Supply The boiler MUST be earthed All system components shall be of an approved type and all wiring to current I E E wiring regulations External 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 85 insulated cable not less than 0 75 2 24 0 20mm Testing and Certification This boiler is tested and certificated for safety and performanc
13. be of adequate size to provide a steady inlet working pressure of 20mbar 8in at the boiler On completion test the gas installation for tightness using the pressure drop method and suitable leak detection fluid purge as necessary Note 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 Press the reset button on the controls fascia release and immediately press and hold in the button After approximately 5 seconds Hi will be displayed Pressing the mode button when is selected will force the boiler to maximum rate the display will flash between Hi and the default display this will indicate the boiler has been forced to maximum Operational Gas Inlet Pressure With ALL other gas appliances operating check the operational supply pressure at the gas service isolation valve test point see diagram 10 1 The nominal supply pressure for Natural Gas G20 is 20mbar The nominal supply pressure for LPG G31 is 37mbar 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 Note The BURNER PRESSURE cannot be measured and is not used to measure the gas rate Gas Rate Make sure that ALL other gas burning appliances and pilot lights are off Ch
14. before the appliance can be converted This conversion should only be carried out by a competent person approved at the time by the Health and Safety Executive During the conversion to Propane use of a suitable flue gas analyser is necessary e 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 e The flue gas analyser used should be one meeting the re quirements of BS7927 or BS EN50379 3 and be calibrated in accordance with the analyser manufacturers requirements e 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 As an option a chargeable boiler only commissioning service can be provided by Glow worm Service by calling telephone No 01773 828100 Tools required to make the conversion are a 2mm Allen key and an electricians screwdriver Ensure that the appliance supply pressure 37 mbar 1 Access the gas valve 2 Refer to diagram 10 5 and turn the gas valve throttle fully clockwise 3 Turn the throttle anti clockwise by the number of turns shown in the table 4 Ensure that the gas analyser is set to the correct fuel setting Propane 5 Attach combustion analyser to the combustion test point refer diagram 11 1 IMPORTANT Remember to replace the cap on c
15. core drill NOTE The flue is designed with an internal fall of 44mm metre 2 5 therefore the hole can be drilled horizontally 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 18 90 49 Hanging Electrical Bracket Cartridge Cover Plate Documentation Pack not illustrated Wall Template User Instructions Installation and Servicing Instructions Flue installation instructions and Guarantee Pack Diagram 6 1 2 5 Inclined 44mm metre Extended flue length LOSEL Standard flue length DIA 125 Horizontal Diagram 6 2 0020107233_00 06 11 Glow worm 7 Boiler Fixing 7 1 Hanging Bracket Fixing Reposition the wall template over the flue hole and mark the position of the fixing holes for the hanging bracket see diagram 7 1 Mark and drill the fixing holes and secure the hanging bracket which is supplied in the polystyrene base pack NOTE Due to the varied site conditions we do not supply fixings and advise that the installer should supply those which are suitable 7 2 Boiler Hanging IMPORTANT With regards to the Manual Handling Operations 1992 Regulations the following lift operation exceeds the recommended weight fo
16. systems may require a higher duty pump Water Systems Domestic Hot Water 5 6 Unvented DHW System General All domestic hot water circuits connections fittings must be in accordance with the relevant standards and water supply regulations For GB Guidance G17 to G24 and recommendation R17 to R24 of the Water Regulations Guide for Scotland the Water Byelaws 2000 Scotland Document G Sanitation hot water safety and water efficiency section 3 of the building regulations requires that the installation of an unvented system should be notified to the local authority Building Controls Department and that the work must be carried out by a competent person approved at the time by the Health and Safety Executive as defined in the approved document G3 For IE The current edition of 1 813 Domestic Gas Installations 0020107233 00 06 11 Glow worm 5 3 Flow Rate If itis necessary to alter the flow rate the system can be fitted with a lockable balancing valve in the main flow or return pipes shown as valve A in diagram 5 3 The flow rate through the boiler must not be allowed to fall below that given in diagram 5 1 5 4 Bypass A system bypass B will be required fitted at least 1 5 metres away from the boiler refer to the current issue of the central heating system specifications CHeSS 5 5 Water Treatment Existing system It is ESSENTIAL that prior to installing the new boiler the system is thoroughly flu
17. terminal guard is required if persons could come into contact with the terminal or the terminal could be subject to damage If a terminal guard is required it must be positioned to provide minimum of 50mm clearance from any part of the terminal and be central over the terminal The guard should be similar to that shown in diagram 4 1 A suitable guard is manufactured by Tower Flue Components Morley Rd Tonbridge Kent TN9 1RA Size 280mm x 165mm Part No 899 Diagram 4 1 0020107233_00 06 11 Glow worm UNDER CAR PORT etc Diagram 4 2 Position Position of the flue terminal mm Horizontal flues mn directly below an opening air brick opening windows iB above an opening air brick opening windows horizontally to an opening air brick opening windows Do below gutter drain soil pipe above adjacent ground or balcony level 300 Ja from surface or a boundary facing the terminal 600 0020107233_00 06 11 Glow worm Position Position of the flue terminal mm from opening door window in car port 1200 into dwelling vertical from a terminal 1500 horizontally from a terminal Vertical flues o ___ from another termina eoo IQ jaboverofleve 3o R from adjacent opening window 1000 1 There s
18. thermistor Check harness wires are not trapped between any internal components waiting time no water in system temperature Check flow amp return thermistor connections to pipes gradient error rise flow return sensor too high Check harness connection to thermistor Check harness wires are not trapped between any internal components Waiting period pressure sensor Check system pressure default display Return Sensor check is running demand Check return thermistor connection to pipe DHW or heating is blocked Check harness connection to thermistor Flow Return Sensor check is running Check flow amp return thermistor connections to pipes demand dhw or heating is blocked Check harness connection to thermistor Check harness wires are not trapped between any internal components Diagram 12 8 0020107233 00 06 11 Glow worm Nd 13 Replacement of Parts 13 1 General IMPORTANT The replacement parts described in sections 13 5 to 13 9 and section 13 12 will require the removal of the burner module assembly and the replacement of the burner door 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 Replacement of parts must be carried out by a competent person approved at the time by the Health and Safety Executive Before replacing any parts of the boiler it should be isolated from
19. this document Servicing General Inspection 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 e Electrical gas and water connections e System pressure e the combustion performance refer to the following procedure e The operational gas inlet pressure and gas rates refer to the commissioning section paragraph 10 5 Correct any fault before continuing COMPETENCY TO CARRY OUT THE CHECK OF COMBUSTION PERFORMANCE NOTE BS 6798 2009 Specification for installation and maintenance of gas fired boilers of rated input not exceeding 70kW net advises that e 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 e 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 e 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 e Select the i central heating function by pressing the Mode button repeatedly refer to commissioning sectio
20. 0 200 300 400 500 600 700 Flow Rate litres hour 0 00 ded 773 86 Ihr 20 diff 18 kW 200 400 600 800 1000 1200 1400 1600 Flow Rate litres hour i 1633 l hr 20 diff 38kW 800 900 1000 o a Water Pressure Loss metres head of water Diagram 5 1 0020107233 00 06 11 Glow worm 5 Water Systems General 5 1 General This boiler is designed to provide central heating from a fully pumped open vented or sealed water system and domestic hot water using a fully indirect vented or unvented cylinder An options board accessory is available to activate and link the internal programmer with a Honeywell S or Y plan system Domestic Hot Water Cylinder SINGLE FEED INDIRECT CYLINDERS ARE NOT SUITABLE The domestic hot water cylinder must be of the double feed fully indirect coil type Draining Points Draining taps must be provided at all low points of the system which will allow the entire system to be drained Draining taps shall be to the current issue of BS2879 5 2 Pump The pump should be fitted on the flow pipe from the boiler and have isolating valves each side A variable duty pump should be set to give a temperature difference of no greater than 20 between the flow and return with the thermostat set at MAX which is about 809C to give a flow rate as given in the table See chart for pressure loss of the boiler diagram 5 1 High resistance microbore
21. 021 1 2000802662 Burner 24 30 38hxi H36356 2 801655 Igniter E84015 3 0020023825 Main P C B H42783 4 0020037309 Fan H53083 5 0020038061 User Interface H52596 6 2000802664 Gas valve 12 15 18 24 30hxi E84004 6 0020018823 Gas valve 38hxi 7 0020020781 720340 8 2000802462 Electrode H53089 9 801635 Burner Door Seal Kit E85008 144 Diagram 14 1 0020107233 00 06 11 Glow worm 43 15 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 ordinat ed 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 straig
22. 1 Route the mains supply and system cables through the strain relief and connect to the relevant plug see diagram 9 2 9 2 Pump Wiring Ensure that a separate pump supply cable is routed through the strain relief and connected to the relevant plug see diagram 9 2 Slacken the cable strain relief and route the pump electrical supply cable and connect as shown in diagrams 9 1 and 9 2 9 3 System Controls If you are fitting the Glow worm Options Board Kit please refer to the instructions supplied with the kit for the system wiring 22 ELECTRICAL CARTRIDGE 9S9 CABLE STRAIN RELIEF SECURING iE SISSE Diagram 9 1 LZSVEL NOTE This appliance will not operate without a link or system controls fitted 0 00 2 2 2j 22 2 2 2 z KEY DESCRIPTION Zone valve N MAINS NEUTRAL m Programmer Room thermostat L MANSUVE Cylinder thermostat MAINS EARTH R SWITCH LIVE 230v F FROST STAT 230v switchable ov ETE Eus rE BOX NOTE ALL CABLES CONNECTED TO THE 3 AMP FUSE APPLIANCE SHOULD BE PERMANENTLY DOUBLE FIXED TO THE WALL POLE ISOLATOR 230Vac 50Hz PERMANENT N SUPPLY 8 Diagram 9 2 INSTALLER INTERFACE LG snqa a 230Vac FROST STAT 230Vac SYSTEM CONTROLS 0020107233 00 06 11 Glow worm
23. 1 Glow worm INTERNAL SOIL AND VENT STACK EXTERNAL SOIL AND VENT STACK 13000 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 or Rainwater Pipe SINK CONSTITUTES EXTERNAL LENGTH AIR BREAK OF PIPE LH OPEN END OF PIPE DIRECT INTO GULLEY BELOW GROUND BUT ABOVE WATER LEVEL 022mm MIN 22mm MIN NO RESTRICTION ON LENGTH NOTE FOR EXTENDED PIPE RUNS 32mm DIA PIPE SHOULD BE USED Internal Termination into Combined Sink Waste External Termination to a Gulley or Hopper EXTERNAL LENGTH OF PIPE 3M MAX a 22mm MIN TERMINATION FROM APPLIANCE GROUND either or 22mm MIN NO RESTRICTION ON LENGTH 500mm MIN 25mm MIN 534 100mm PLASTIC TUBE BOTTOM OF OPEN END OF PIPE DIRECT INTO GULLEY BELOW GROUND LEVEL BUT ABOVE WATER LEVEL TUBE SEALED LIMESTONE CHIPPINGS gt HOLE DEPTH 3 400mm MIN 2 ROWS OF 3 x 12mm HOLES AT 25mm CENTRES 50mm FROM BOTTOM OF TUBE HOLES TO FACE AWAY FROM HOUSE External Termination into Soakaway Internal Termination Downstream of Sink Waste NOTE PIPEWORK SHOULD ALWAYS FALL AWAY FROM BOILER BY AT LEAST 2 5 44mm FOR EVERY 1M Diagram 8 3 0020107233 00 06 11 Glow worm 21 Electrical
24. 38 37 36 35 34 33 32 31 30 29 28 27 26 25 COVER PLATE Diagram 10 3 e Advise the user that like all condensing boilers this appliance will produce a plume of condensation from the flue terminal in cool weather This is due to the high efficiency and hence low flue gas temperature of the boiler e Advise the user of the precautions necessary to prevent damage to the system boiler and the building in the event of the heating system being out of use during frost or freezing conditions e Advise the user that the permanent mains electrical supply SHOULD NOT be switched off as the built in frost protection and pump saver 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 Note Sealed System Contact your installation servicing company as draining refilling and pressurising MUST be carried out by a competent person approved at the time by the Health and Safety Executive e Leave these instructions and the Benchmark Installation Commissioning and Service Record with the user 25 10 10 LPG CONVERSION all models As an option a chargeable boiler performance and function service can be provided by Glow worm Service by calling telephone No 01773 828100 NOTE Steps 10 1 and 10 3 will need to be completed
25. B Memory or sensing fault Loose connections on Main PCB or display PCB Central Heating Flow or Return Thermistor wires unconnected faulty trapped Electrode Ignition leads loose unconnected faulty trapped Earthing connection loose disconnected Gas Valve control defective Gas valve connector loose wires unconnected faulty ortrapped Faulty main board Faulty gas valve eBus Voltage failure Short circuit on eBus overload on eBus Diagram 12 6 E 0020107233 00 06 11 Glow worm Low Water pressure Ignition temperature rise too slow Fault Codes continued Lvvel Not enough water in the system Central heating flow or return thermistor wire loose faulty trapped Central heating flow or return thermistor not connected to pipe correctly Air in the system Faulty pump or pump speed too fast Central Heating Flow temperature rise too high during operation Central Heating Return temperature rise or temperature difference too high during operation Central Heating Temperature difference between Flow and Return too high during operation Check thermistors are connected to pipes correctly Air in the system System is too restrictive F43 Generic error Check all electrical connections internal amp external F70 Software incompatible Telephone Group Service F77 Condensate pump error Option Trapped faulty wiring blockage in conden
26. Gloweworm Installation and Servicing Condensing Boilers Ultracom hxi 12 hxi G c No 41 019 01 15 41 019 02 18 hxi 41 019 03 24 hxi G C No 41 019 04 30 hxi G C No 41 019 05 38 Axi G c No 41 019 06 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 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 The second year of the parts 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 Custom
27. HEAT EXCHANGER GLSEL SPARK GAP 3 5 to 4 5mm SPARK ELECTRODE SECURING SCREW 2 OFF EARTH LEAD Diagram 11 4 SPARK ELECTRODE EARTH LEAD PLUG y FAN ELECTRICAL GAS VALVE PLUG amp LEADS ELECTRICAL __ PLUG Diagram 11 5 0020107233 00 06 11 Glow worm 11 2 Spark Electrode Disconnect the spark electrode plug and earth lead see diagram 11 5 Remove the two securing screws and withdraw the spark electrode carefully from the combustion chamber see diagram 11 4 Inspect the tips for damage Clean away any debris and check the spark gap is 3 5 to 4 5 mm Check the electrode gasket for signs of damage and replace if necessary 11 3 Burner IMPORTANT e The following procedure will require that you replace the burner door seal and nyloc nuts Spare kit 801635 e Removal of the burner is not necessary during a normal service but if it is removed it will require a new gasket see diagram 11 6 e When replacing ensure that the sealing grommet situated below the gas valve is correctly re seated Disconnect the gas valve electrical plug at the gas valve see diagram 11 5 Disconnect the electrical plug from the fan Disconnect the spark electrode plug and earth lead refer to diagram 11 6 Remove the gas pipe retaining clip Remove the five combustion chamber burner door securing nuts see diagram 11 7 these should be discarded and replaced with the new nylocs nuts supp
28. L gas appliances are installed by a competent person approved at the time by the Health and Safety Executive and 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 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 If you do suffer irritation to the eyes or severe irritation to the skin seek medical attention Manual Handling With regards to the Manual Handling Operations 1992 Regulations the appliance exceeds the recommended weight for a one man lift refer to section 15 for more information The handling of the boiler may involve lifting pushing and pulling the use of a sack truck may be required The following handling techniques and precautions should be considered Grip the boiler at its base Be physically capable Use safety clothing where appropriate e g gloves safety footwear Ensure safe lifting techniques
29. N PAGE Warnings 4 Important Information 4 Statutory Requirements 5 Boiler Design 6 Safety Devices 6 Servicing Maintenance and Spare Parts 6 INTRODUCTION Boiler Specification 1 T Boiler Dimensions amp Hydraulic Schematic 2 8 Boiler Location Clearances and Ventilation 3 9 Evacuation of Combustion Gas 4 10 Water Systems 5 14 Installation Preparation 6 18 Boiler Fixing 7 19 INSTALLATION Gas Water amp Condensate Connection 8 20 Electrical Connection 9 22 Commissioning 10 23 Servicing 11 27 Fault Finding 12 31 Replacement of Parts 13 38 MAINTENANCE Spare Parts 14 43 Manual Handling 15 44 Declaration of Conformity 45 Commissioning Checklist 46 Service Interval Record 47 WARNINGS Gas Leak or Fault Turn off the gas emergency control valve immediately Eliminate all sources of ignition i e smoking blowlamps hot air guns etc Do not operate electrical lights or switches either on or off Open all doors and windows ventilate the area Metal Parts This boiler contains metal parts components and care should be taken when handling and cleaning with particular regard to edges Sealed Components Under no circumstances must the user interfere with or adjust sealed parts Important Information Gas Category This boiler is for use only on G20 natural gas but may be converted for use on G31 gas Propane L P G Gas Safety Installation and Use Regulations In your own interests and that of safety it is the Law that AL
30. ON 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 CO2 ratio is acceptable Advice can be sought from the Glow worm Technical Helpline INNER CASING D PANEL lt CASING T PANEL lt m od gt gt 2 SN SECURING SCREWS 2 OFF SECURING SCREWS Diagram 11 2 CHASSIS FRONT m A Ts SECURI SCREW 4 OFF rH CONTROL BOX SERVICE POSITION Diagram 11 3 0020107233 00 06 11 Glow worm 11 1 Servicing IMPORTANT If the Combustion CO2 CO CC2 ratio amp Gas rate checks did not require adjustment then it will not be necessary to complete a full service In any case a full service including the replacement of the burner door seal must be carried out at least once every 5 years All routine servicing requirements can be achieved by the removal of the front panel see diagram 11 2 Position the control box into the service position see diagram 11 3 Before commencing with a service or replacement of parts The boiler should be isolated from the electrical and gas supplies
31. VICE INTERVAL RECORD It is recommended that your heating system is serviced regularly and that you complete the appropriate Service Interval Record Below Service Provider Before completing the appropriate Service Interval Record below please ensure you have carried out the service as described in the boiler manufacturer s instructions Always use the manufacturer s specified spare part when replacing all controls SERVICE 1 Date Energy Efficiency Checklist completed Yes No SERVICE 2 Date Energy Efficiency Checklist completed Yes No Engineer Name Engineer Name Company Name Company Name Telephone Number Telephone Number Engineer ID Number Engineer ID Number Comments Comments Signature SERVICE 3 Date Energy Efficiency Checklist completed Yes No Signature SERVICE 4 Date Energy Efficiency Checklist completed Yes No Engineer Name Engineer Name Company Name Company Name Telephone Number Telephone Number Engineer ID Number Engineer ID Number Comments Comments Signature Signature SERVICE 5 Date Energy Efficiency Checklist completed Yes No SERVICE 6 Date Energy Efficiency Checklist completed Yes No Engineer Name Engineer Name Com
32. ance specification that we require Do not use reconditioned or copy parts that have not been clearly authorised by Glow worm If a part is required contact Glow worm s own service organisation using the telephone number on the inside front cover of this booklet Please quote the name of the appliance this information will be on the name badge on the front of the appliance If in doubt seek advice from the local gas company or Glow worm s own service organisation using the telephone number on the inside front cover of this booklet 0020107233 00 06 11 Glow worm 1 Boiler Specification BOILER SPECIFICATION 12hxi 15hxi 18hxi Lift weight Total weight installed 25kg 5516 30kg 6616 25kg 5516 30kg 6616 25kg 5516 30kg 6610 Gas connection Rc1 2 1 2in BSPT Rc1 2 1 2in BSPT Rc1 2 1 2in BSPT Heating flow and return connection O D 22mm copper 22mm copper 22mm copper Condensate connection 1 0 21 5mm plastic 21 5mm plastic 21 5mm plastic Water circuit bar 43 5lbf in2 bar 43 5Ibf in2 bar 43 5Ibf in2 Electrical supply 230V 50Hz fused 3A 230V 50Hz fused 3A 230V 50Hz fused 3A Electrical rating 60W fused 3A 60W fused 3A 60W fused 3A EN60529 IP clasification IPX4D IPX4D IPX4D Internal fuse rating on main PCB 2A 2A 2A Gas supply governed meter only category G20 n
33. anel alongside the data label Refit the inner door and outer door 18 Continue commissioning from 10 5 OFFSET ADJUSTMENT ELSEL ELECTRICAL PLUG TEST POINT Diagram 10 5 0020107233_00 06 11 Glow worm IMPORTANT NOTES To ensure the continued efficient and safe operation of the boiler it is recommended that it is checked and serviced at regular intervals The frequency of servicing will depend upon the particular installation and usage but in general once a year should be enough It is the Law that any servicing is carried out by a competent person approved at the time by the Health and Safety Executive Before commencing with a service or replacement of parts the boiler should be isolated from the electrical supply and the gas supply should be turned off at the gas isolation valve When replacing a part 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 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 section 12 After servicing complete the relevant Service Interval Record section of the Benchmark Checklist located in the inside back pages of
34. as tap is closed Gas valve connector is loose unconnected faulty or wires are trapped Ignitor connectors are loose unconnected faulty trapped Faulty Ignitor Low gas inlet pressure Incorrect gas valve adjustment Electrode Ignition leads loose unconnected faulty trapped Electrode broken defective or position incorrect Air inlet blocked flue inlet blocked flue duct leaking Earthing connection loose disconnected Condensate blocked Fan fault Fan speed incorrect Fan connector loose unconnected faulty or wires trapped Faulty fan Flame goes out whilst lit during a demand Gas tap is closed Gas valve connector is loose unconnected faulty or wires are trapped Ignitor connectors are loose unconnected faulty trapped Faulty Ignitor Low gas inlet pressure Incorrect gas valve adjustment Electrode Ignition leads loose unconnected faulty trapped Electrode broken defective or position incorrect Air inlet blocked flue inlet blocked flue duct leaking Earthing connection loose disconnected Condensate blocked Overheat Boiler has overheated allow to cool then press reset button Central Heating Flow Thermistor connection fault Thermistor wires unconnected faulty trapped Central Heating Return Thermistor connection fault Thermistor wires unconnected faulty trapped Flow and or return NTC faulty Thermistor wires unconnected faulty trapped PC
35. ate drain fitted and not allow condensate to mix into other appliances gt gt Multiple Boiler Chimney Length The flue length must be calculated and installed according the relevant standards EN 13384 1 and 2 C43 flue systems only with reference to the table below and the manufacturers instructions supplied The appliance maximum flue length must be included when calculating the overall design of the flue system NOTE The horizontal flue terminal must be removed MODEL Ultracom Ultracom 12hxi 15hxi Exhaust mass rate g s At Min Thermal Load 40C 30 C 2 30 lt to oa Pressure balancing system Air inlet pipe Collector pipe Boiler Inspection hatch Final storey Ground floor 60 100 Max length L Each time an additional 90 bend is necessary or 2 at 45 the length L must be reduced by 1 m Ultracom 18hxi Ultracom 24hxi Ultracom 30hxi Ultracom 38hxi At Max Thermal Load 80C 60 C 5 65 Exhaust temperature C At Min Thermal Load 40C 30 C 96 0 At Max Thermal Load 80C 60 C 69 0 0020107233 00 06 11 Glow worm
36. ated in diagram 6 1 Remove the carton sleeve and top pack then lift the boiler and its polystyrene base support out of the lower pack 6 2 Site Requirements The boiler mounting wall should be suitable for the weight of the appliance and be true and flat NOTE Due to the varied site conditions we do not supply fixings and advise that the installer should supply those which are suitable 6 3 Wall Template Take the wall template from the document pack and place in the desired position on the wall giving due consideration to the required boiler clearances and the flue you are fitting Mark the position of the flue centre if fitting a side flue extend the flue centre line into the corner then 176mm along the adjacent wall see diagram 6 2 For extended side flues the flue hole centre should be determined 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 176mm 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 Remove the wall template 6 4 Flue Hole Cutting External access flue installation can use a 105mm diameter core drill Internal access only flue installation will need a 125mm diameter
37. atural gas G20 natural gas G20 natural gas Inlet gas working pressure 20mbar 20mbar 20mbar Burner CO case 9 3 nominal 9 3 nominal 9 3 nominal Burner CO case off 9 1 nominal 9 1 nominal 9 1 nominal Approximate max gas rate after 10 mins from cold 1 29 m3 h 45 6 ft3 h 1 61 m3 h 57 ft3 h 2 00 m3 h 70 6 ft3 h Approximate min gas rate after 10 mins from cold 0 53 m3 h 18 7 ft3 h 0 53 m3 h 18 7 ft3 h 0 53 m3 h 18 7 ft3 h Flue type C33 C13 C33 C13 C33 C43 NOx Class 5 Class 5 Class 5 Heat output condensing mode 12 9kW 16 2kW 20 02kW Heat input Q kW 12 20 min 5 max 15 26 5 0 max 18 9 min 5 Heat output P kW max 12 4 95 15 4 95 18 57 4 95 SEDBUK rating 96 2005 90 5 90 5 90 4 SEDBUK rating 96 2009 BOILER SPECIFICATION Lift weight 88 7 28kg 621b 88 7 28kg 621b 88 6 28kg 6216 Total weight installed 33kg 7316 33kg 7316 33kg 7318 Gas connection Rc1 2 1 2in BSPT Rc1 2 1 2in BSPT Rc1 2 1 2in BSPT Heating flow and return connection O D 22mm copper 22mm copper 22mm copper Condensate connection 1 0 21 5mm plastic 21 5mm plastic 21 5mm plastic Wa
38. bilise before checking or making further adjustments 10 Exit the check sequences press the mode and buttons simultaneously this will reset the boiler to the default display 11 Check the burner CO at minimum rate to the value shown in the SETTING column of the table 12 If adjustment is required press the reset button on the controls fascia release and immediately press and hold in the button After approximately 5 seconds Hi will be displayed Pressing the or buttons will cycle between Hi and Lo Pressing the mode button when Lo is selected will force the boiler to minimum rate the display will flash between Lo and the default display this will indicate the boiler has been forced to minimum 13 Adjustment of the is very coarse so carefully adjust the CO to the value shown in the SETTING column of the table with the offset adjustment see diagram 10 5 and CO Table Rotate clockwise to increase 14 To exit the function press the mode and buttons simultaneously this will reset the boiler to the default display 15 Repeat 8 and check CO at maximum rate adjust if necessary Check that the CO CO2 ratio is less than the value in the table below 16 Remove analyser probe from the test point and replace the cap Refit the control panel 17 IMPORTANT Fit the LPG conversion label supplied in the documentation pack to the inner front p
39. dicate compliance to 1 5 813 An example of this is given in the current edition of 1 5 813 10 9 Instruct the User e Demonstrate then instruct the User about the lighting procedure and heating system controls operation e Advise that to ensure the continued efficient and safe operation of the boiler it is recommended that it is checked and serviced at regular intervals The frequency of servicing will depend upon the installation conditions and usage but in general once a year should be enough e 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 e The user shall not interfere with or adjust sealed components e is the Law that any servicing is carried out by a competent person approved at the time by the Health and Safety Executive 0020107233_00 06 11 Glow worm OSvEL lt gt LSVEL Diagnostic value 2D E du number Diagnostic display 1 Diagnostic display 2 a 25 883 36 v 20 35 14 1 19 671 34 120 18 635 ur 16 17 609 32 us 15 15 565 31 os 14 15 530 30 16 18 14 495 25 28 959 M 12 424 25 2s oe 10 1 12 389 4 5 3 A 2 3 1 2 0 19 0 18 1 9 17 1 8 16 1 7 15 1 6 14 1 5 13
40. e It is therefore important that no alteration is made to the boiler without permission in writing by Glow worm Any alteration not approved by Glow worm could invalidate the certification boiler warranty and may also infringe the current issue of the statutory requirements 0020107233 00 06 11 Glow worm This boiler meets the requirements of Statutory Instrument No 3083 The Boiler Efficiency Regulations and therefore is deemed to meet the requirements of Directive 92 42 EEC on the efficiency requirements for new hot water boilers fired with liquid or gaseous fuels Type test for purposes of Regulation 5 certified by Notified body 0087 Product production certified by Notified body 0086 The CE mark on this appliance shows compliance with 1 Directive 2009 142 EC on the approximation of the laws of the Member States relating to appliances burning gaseous fuels 2 Directive 73 23 EEC on the harmonisation of the Laws of the Member States relating to electrical equipment designed for use within certain voltage limits 3 Directive 89 336 EEC on the approximation of the Laws of the Member States relating to electromagnetic compatibility IMPORTANT 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 Ex
41. e up bottle mounted in a position higher than the top point of the system connected through a non return valve to the return side of either the heating circuit or the hot water cylinder Alternatively provision for make up can be made using a filling loop 5 15 Filling a Sealed Water System Provision for filling the system at low level must be made see diagram 5 4 There must be no permanent connection to the mains water supply even through a non return valve 0020107233 00 06 11 Glow worm 66621 3 LITRES 0 66 gals MAKE UP BOTTLE if required AIR RELEASE POINT FLOW CONTROL VALVE A i 3 AUTO t VENT FILLING POINT VALVE AUTOMATIC E X BYPASS reed VALVE B CIRCULATING PUMP SAFETY VALVE FLOW CONTROL VALVE A HEATING CIRCUIT RETURN PRESSURE GAUGE Make up alternatives BOILER EXPANSION VESSEL Diagram 5 3 SUPPLY PIPE BOILER CONTROL VALVE DOUBLE CHECK VALVE FLOW RETURN HOSE FLOW RETURN TYPE CA BACKFLOW UNION PREVENTION DEVICE i CONTROL CONTROL Sia VALVE VALVE SIY HEATING TEMPORARY PIPE CIRCUIT CONTROL HOSE CONNECTION VALVE UNION HEATING CIRCUIT AIR GAP DRAIN E POINT Method 1 TUNDISH Method 2 Diagram 5 4 0020107233 00 06 11 Glow worm 17 6 Installation Preparation 6 1 Appliance Pack The top polystyrene pack contains all the items illustr
42. eck 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 GAS RATES G31 approx after 10 mins from cold GAS RATES G20 approx after 10 mins from cold MIN MAX MIN MAX m h ft h m h ft h kg hr kg hr 98 0 53 18 7 129 456 0 39 0 95 0 53 18 7 1 61 57 0 39 1 19 0 53 18 7 2 00 0 39 1 47 0 56 19 8 2 58 0 41 1 9 0 56 19 8 3 02 0 41 2 22 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 On completion press the mode and buttons simultaneously this will reset the boiler 0020107233 00 06 11 Glow worm 10 6 Range Rating 38kW only These boilers are fully modulating therefore it is not necessary to range rate them however if desired you can adjust the 38hxi boiler in 1KW increments between 10 and maximum output of your appliance as described below Please refer to the table to check the gas rates a Press and hold the MODE button for 5 seconds The display will change to flashing 0 b Use the heating or buttons to scroll to 96 This is the installer level access password c Press MODE to confirm see diagnostic display 1 d Press MODE to change to the heating load value see diagnostic display 2 U
43. ecutive 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 approved 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 The Current I E E Wiring Regulations 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 I 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
44. efer to wiring diagram 12 4 Withdraw grommets and leads so they are hanging loose Unthread the retaining cord and remove the control box by drawing it outwards away from its retaining slots see diagram 13 11 13 21 Inner Casing Panel Seal For access refer to section 13 1 Refer to diagram 11 8 Remove the inner casing panel To replace remove the old seal thoroughly clean the casing surfaces Fit the new seal it is supplied to the correct length Refit the inner casing panel NOTE Ensure the seal is fitted correctly giving an airtight joint 42 RETAINING CHASSIS FRONT scREW RETAINING CORD CONTROL BOX X CONTROL BOX SERVICE RETAINING POSITION LATCHES 4 Diagram 13 11 RETAINING FUSE CLIPS 4 OFF c69 l MAIN PCB RETAINING LUGS Diagram 13 12 APPLIANCE 2 RETAINING INTERFACE CLIPS RER ELECTRICAL PF CONNECTION a Q e gt Diagram 13 13 0020107233_00 06 11 Glow worm 14 Spare Parts When ordering spare parts contact Glow worm s own service organisation using the telephone number on the inside front cover of this booklet Please quote the name of the appliance and serial number to be found on the data label If ordering from British Gas also quote the G C number of the part Key No Part No Description GC Part No 1 2000802463 Burner 12 15 18hxi E84
45. ently by the manufacturer The expansion vessel volume depends on the total water system volume and the initial system design pressure For any system an accurate calculation of vessel size is given in the current issue of BS5449 and BS7074 Part 1 Example For an initial design pressure of 0 7 bar the minimum total vessel volume required is 0 063 x Total System Volume NOTE A higher initial design pressure requires a larger volume expansion vessel In GB guidance on vessel sizing is also given in the current issue of BS5449 and BS7074 Part 1 In IE refer to the current edition of 1 5 813 Domestic Gas Installations The charge pressure must not be less than the static head of the system that is the height of the highest point of the System above the expansion vessel 5 13 Pressure Gauge A pressure gauge with a set pointer and covering at least 0 to 4 bar 0 to 60 Ib in2 shall be fitted permanently to the system in a position where it can be seen when filling the system 16 Open vented system Recommended 5 relationship between 450mm pump cold feed and vent MIN BEREIT 22mm MIN VENT FEED AND LA EXPANSION CISTERN 15mm MIN COLD FEED 15mm MIN AUTOMATIC BY PASS 2 m 1000mm m MIN Y a A 2 gt 9 lt HEATING BOILER 150mm MAX Diagram 5 2 5 14 Water Makeup Provision should be made for replacing water loss from the System using a mak
46. er Service 01773 828100 Technical Helpline 01773 828300 General and Sales enquiries Tel 01773 824639 Fax 01773 820569 To register your Glow worm appliance call 0800 0732142 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 competent persons 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 Visit www central heating co uk for more information THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS TABLE OF CONTENTS 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 CONTENTS DESCRIPTION SECTIO
47. erence should be made to the current edition of 1 5 813 Domestic Gas Installations and the current ETCI rules 3 2 Clearances The boiler should be positioned so that at least the minimum operational and servicing clearances are provided see diagram 3 1 Additional clearances may be beneficial around the boiler for installation and servicing For flue installations where external access is not practicable consideration should be given for the space required to insert the flue internally which may necessitate clearance larger than those specified in diagram 3 1 3 3 Timber Frame Buildings If the boiler is to be installed in a 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 3 4 Combustible Material The boiler and flue are suitable for installation onto and through combustible materials provided that 1 Minimum 5mm clearance is maintained around the circumference of the flue air intake 2 The combustible surface and fixings are suitable for supporting the load 3 The minimum clearances from the boiler case are maintained 3 5 Room Ventilation The boiler is room sealed so a permanent air vent is not required 3 6 Cupboard or Compartment Ventilation Due to the high efficiency and hence low casing temperature of this boiler cupboard or compartment ventilation is not necessary Leave
48. existing air vents 0020107233 00 06 11 Glow worm 5 20 A removable compartment door can be placed a minimum 5 in front of the appliance A clearance CLEARANCES 200 of 600mm is required from a fixed surface 5mm to a non permanent surface 20mm to a permanent surface 5mm clearance to combustible material 5 20 Diagram 3 1 4 Evacuation of combustion Gas 4 1 Regulation T Only flue accessories supplied by Glow worm must be used Different flue outlet configurations can be carried out Consult your supplier for more information about the other possibilities and associated accessories 44 mm m 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 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 Whatever the kind of flue system chosen observe the minimum distances indicated in the chart below to position the flue terminals Toinstall the flue refer to the separate flue instruction supplied with your appliance Explain these requirements to the user of the appliance If necessary you must install terminal pr
49. external controls 1 Fill the heating system Sealed system only fill the system to a pressure of 1 0bar 2 Vent all air from the system repeat as necessary until the system is full and all the air has been vented 0020107233_00 06 11 Glow worm ELECTRICAL CARTRIDGE LOEEL Diagram 9 3 10 3 Gas Supply The gas valve is factory set for natural gas G20 and should need no adjustment Turn on the gas supply at the isolation valve see diagram 10 1 Check the supply pressure at the pressure test point is 20mbar SEALING GAS PIPE BRACKET a GROMMET od UNION NUT a GAS SERVICE ISOLATION VALVE 2 PRESSURE TEST POINT GAS CONDENSE TRAP SUPPLY PIPE IN amp SIPHONIC DRAIN Diagram 10 1 23 13473 VULG bar ADVANCE MODE OFF v e gt PROG a anon ni M Liuius d TOGGLE BUTTON LCD RESET TEMPERATURE MODE and PROG DISPLAY BUTTON USED ADJUSTMENT SYMBOLS DISPLAYED ON THE LCD AND DESCRIPTIONS Central Heating Function f Min burner display Appliance OFF Temperature Max burner display Glow worm control Optional System pressure not applicable Diagram 10 2 10 4 Initial Lighting Note 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
50. gram 8 2 Flush out the heating systems before connecting to the boiler refer to section 5 8 3 Condensate Trap and Siphonic Drain Connection The condensate drain see diagram 8 1 is suitable for use with standard Push fit overflow pipe and couplings DO NOT use adhesive when connecting to the spigot The drain pipe should be non corrosive plastic IMPORTANT Please remove spigot bung before fitting condensate drain connection The condensate drain pipe should have a fall of at least 2 5 44mm metre away from the boiler and if possible be discharged into the household internal drainage system If this is not practicable discharge can be allowed into the external household drains or a purpose designed soak away refer to diagram 8 3 It is recommended that any external condensate drain pipe is protected and also preferably of 32mm diameter to prevent 20 9089 22mm compression is the O E E 9 8 recommended fixing for servicing e not supplied 22 RETURN Diagram 8 2 freezing in adverse weather conditions The condensate is discharged periodically in slugs by siphonic action It is not necessary to provide air breaks or extra traps in the discharge pipe as there is already a 75mm high trap inside the boiler Fitting an extra trap may cause the boiler siphon to work incorrectly Refer to BS5546 or BS6798 for advice on disposal of boiler condensate 0020107233_00 06 1
51. heck column If the combustion reading is not within the acceptable values AND the integrity of the complete flue system and combustion circuit seals have been verified and the inlet gas pressure and gas rate have been verified then it will necessary to adjust the combustion rate of the appliance NOTE Adjustment is made by turning the gas valve throttle an of a turn waiting 1 minute to allow the appliance to stabilise before checking or making further adjustments e Rotate the throttle anti clockwise to increase to the required CO2 refer to diagram 10 5 and the SETTING column in the table e Exit the forced rate function press the mode and buttons simultaneously this will reset the boiler to the default display Now proceed to check the minimum rate adjustment 2 Minimum Rate Check and Adjustment Now check the minimum gas rate CO2 setting Press and release the reset button on the controls fascia then immediately press and hold in either of the buttons After approximately 5 seconds Hi will be displayed Pressing the or buttons will toggle between Hi and Lo Press the mode button when Lo is selected this will force the boiler to minimum rate and the display will flash Lo indicating the boiler is operating at minimum e Wait until the CO2 value is stable and check that the value is within the range specified in table in the check column If adjust
52. hould be no ventilation opening in the eaves within 300mm distance of the terminal 2 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 11 4 2 configuration description Each time an additional 90 bend is necessary or 2 at 45 the length L must be reduced by 1 m 4 2 1 Horizontal concentric 60 100 mm 80 125 mm C13 type installation 4 2 2 Vertical concentric flue 60 100 mm or 80 125 mm C33 type installation If the terminal is at less than 1 80 m from the N ground you must install a terminal protection If the terminal is at less than 1 80 m from the kit ground you must install a terminal protection kit 60 100 mm Key 1 Gasket fitted 80 125 mm 560 700 2 80 125 Each time an additional 90 bend is necessary or 2 at 45 the length L must be reduced by 1 m Key 1 Gasket fitted 60 100 80 125 0020107233 00 06 11 Glow worm 12 4 2 3 Multiple boiler chimney flue 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 C43 flue systems must not be a pressurised system but act under natural draught principles C43 type flue systems must have their own condens
53. ht bend using legs Keep load as close to body as possible If 2 persons performing lift ensure co 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 per son is performing lift straddle the load tilt and place carton into posi tion 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 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 reposition feet instead Take care to avoid trip hazards slip pery 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 using legs
54. l Heating System The boiler must be supplied from an unrestricted water supply taken from a feed and expansion cistern situated at a maximum height of 27 metres 90ft above the boiler The cold feed must be 15mm minimum size The vent must rise continuously and be unrestricted It is important that the relative positions of the pump cold feed and open vent are as shown in diagram 5 2 5 9 Combined Feed and Vent For combined feed and vent a 22mm pipe must be fitted in accordance with BS 5449 5 10 Sealed water Systems The installation must comply with the appropriate requirements of the current issue of BS4814 BS5449 56759 56798 and BS7074 Part 1 and 2 See diagram 5 3 for a suggested layout 5 11 Safety Valve A safety valve must be fitted to a sealed system It shall be preset non adjustable with a lift pressure of 3 bar incorporating seating of a resilient material a test device and a connection for drain The drain from the safety valve must be routed outside the building must not discharge above an entrance or window or any type of public access area be clear of any electrical fittings and positioned so that any discharge can be seen 5 12 Expansion Vessel A diaphragm type expansion vessel conforming to the current issue of BS4814 see also BS7074 Part 1 and 2 must be connected at a point close to the inlet side of the circulating pump see the diagrammatic layout diagram 5 3 unless laid down differ
55. lectromagnetic com EN 61000 3 3 patibility Any change to the appliance and or any use not according to the instructions will lead to the invalidation of this Declaration of Conformity Belper October 2006 So _ So _ N S E place date Program Manager Certification Man der S Keeton A Beardsley Glow worm Nottingham Road Belper Derbyshire DE56 1JT 0020107233 00 06 11 Glow worm 45 Please affix the label positioned on the top panel of your boiler over this area COMMISSIONING CHECKLIST GAS BOILER SYSTEM 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 this equipment to the manufacturer s instructions will invalidate the warranty but does not affect statutory rights Customer Name Telephone Number Address Commissioned by print name Engineer ID 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 Tempera
56. lied in the burner door seal kit FRONT SECURING SCREW INSULATION 4 OFF 9921 GASKET SPARK ELECTRODE Diagram 11 6 29 SECTION THROUGH BURNER DOOR SHOWING POSITION OF SEAL SEAL NUTS 5 OFF GAS PIPE BRACKET AND SEAL NYLOC SECURING COMBUSTION CHAMBER v98 L Diagram 11 7 Gently remove the fan gas valve and burner assembly from the combustion chamber Clean the burner with a soft brush taking great care not to damage the front insulation DO NOT use wire or sharp instruments to clean the holes of the burner Inspect the burner for any signs of damage Remove and discard the burner door seal and replace with new see diagram 11 7 11 4 Combustion Chamber and Heat Exchanger Remove loose debris from inside the combustion chamber using a soft brush and vacuum cleaner Carefully flush by spraying water into the heat exchanger any remaining debris should pass through the condensate trap Ensure the water is kept away from electrical components 11 5 Inner Casing Panel Seal check Check the condition of the seal if worn or damaged remove the seal and thoroughly clean the casing surface before fitting the new seal see diagram 11 8 Refit the inner casing panel NOTE Ensure the seal is fitted correctly giving an airtight joint 11 6 Service Completion Re check the combustion as described at the beginning of this sec
57. ment is necessary proceed as follows NOTE Adjustment of the CO2 at minimum rate is very coarse and should not be adjusted more than of a turn at a time Wait 1 minute to allow the appliance to stabilise before checking or making further adjustments e Gradually rotate the offset adjustment anti clockwise to decrease to the required CO2 refer to diagram 10 5 and the SETTING column in the table e Exit the minimum rate function press the mode and buttons simultaneously this will reset the boiler to the default display 3 Re Check CO2 and check the CO CO2 combustion ratio e Re check the maximum and minimum CO2 values to ensure that they are within the setting limits in the table then check the CO CO2 combustion ratio does not exceed the value in the CO CO2 column of the table If the CO CO2 setting exceeds the value in the table a complete servicing of the appliance will be necessary refer to section 11 1 If the CO2 and the CO CO2 ratio falls within the tolerances quoted exit the function press the mode and buttons simultaneously this will reset the boiler to the default display Remove the analyser probe and replace the cap on the sampling point replace the controls fascia inner and front casing panels 28 IMPORTANT Remember to replace the sample point on completion of the test GAS RATE CHECK Check the gas rates as described in the commissioning section COMPLETI
58. n The boiler should fire automatically NOTE Safe combustion can only be verified by measuring CO CO2 ratio This must not exceed the value shown in the table below COMBUSTION CHECK AND SETTING THE AIR GAS RATIO VALVE e Remove the front casing panel see diagram 11 2 and hinge down the control box Taking care not to touch any internal components proceed as follows e Connect the CO2 combustion analyser to the relevant test point see diagram 11 1 0020107233 00 06 11 Glow worm COMBUSTION ANALYSER 5 FLUE ELBOW lt COMBUSTION ANALYSER SAMPLE POINT Diagram 11 1 case on case off ratio 0004 30hxi 10 0 to 11 0 0 004 9 2 to 10 2 0 004 G20 BURNER CO2 case on case off ratio 0 004 0 004 30hxi 8 5 to 9 6 0 004 27 1 Maximum Rate Check and Adjustment NOTE To verify the maximum gas rate CO2 setting the appliance must be checked at the maximum rate first Press the reset button on the controls fascia release and immediately press and hold in the button After approximately 5 seconds will be displayed Pressing the mode button when is selected will force the boiler to maximum rate the display will flash between Hi and the default display this will indicate the boiler has been forced to maximum Wait until the CO2 value is stable and check that the value is within the range specified in table in the c
59. note its position on the fan Remove the three securing screws which fix the gas valve and plastic swirl plate to the venturi on the fan see diagram 13 2 Withdraw the gas valve After re fitting check the combustion CO and adjust if necessary refer to section 11 38 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 IGNITER BRACKET IGNITER UNIT SECURING SCREW N IGNITER SECURING SCREWS 2 CONNECTOR BRACKET IGNITION LEAD ELECTRICAL CONNECTIONS PLUG Diagram 13 1 N q NN VENTURI PLATE SECURING SCREW 3 Diagram 13 2 0020107233 00 06 11 Glow worm 13 6 For access refer to section 13 1 Refer to section 11 3 for removal of the fan gas valve and burner assembly Remove the gas valve as described in the relevant parts of section 13 5 Remove the venturi plate secured with three screws see diagram 13 2 and remove the two screws securing the fan to the gas manifold Check the gasket and replace if necessary NOTE The 30hxi and 38hxi fan is secured through an extension piece with two securing screws check and replace any seals or gaskets if necessary 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 13
60. ns 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 I S 813 Domestic Gas Installations and the current Building Regulations must be followed Boiler Design Boiler Design These boilers are designed to provide central heating from a fully pumped open vented or sealed water system and domestic hot water using a fully indirect cylinder Once the controls are set the boiler operates automatically Range Rating These boilers are fully modulating it is therefore not necessary to range rate them however if desired it is possible to range rate the 38hxi max CH output in 1KW increments refer to section 10 Condensate Drain A plastic drain pipe must be fitted to allow discharge of condensate to a drain Condensate should if possible be discharged into the internal household draining system If this is not practical discharge can be made externally into the household drainage system or a purpose designed soak away see section 8 for more details Pluming from flue terminal Like all condensing boilers this appliance will produce a plume of condensation from the flue terminal in cool weather This is due to the high efficiency and hence low flue gas temperature of the boiler This is normal and not an indication of a fault Safety Devices Electrical Supply Failure The boiler will not work without an electrical s
61. ntified 0 unidentified eBUS Address lt 1 0 0 9 91 Internal Programmer type 9 92 Enable Disable Internal Programmer DHW Off default DHW On DHW Off DHW On d 97 Activation of the second diagnostic level Password needed d 99 State List see State Lists table Indicates read and write function all other diagnostics are read only Diagram 12 7 0020107233 00 06 11 Glow worm 36 State list Accessed through Diagnostic Codes Level 1 Installer Access 9 99 m 8 STATE LISTS Central heating mode Priority 3 Description no heating required fan pre run pump pre run ignition burner on NORMAL OPERATING pump fan overrun STATE FOR CENTRAL HEATING fan overrun pump overrun Anti cycling period Special cases of status messages No Heating demand from external controls 230V Check wiring in external controller Check wiring at Installer Interface summer mode Check CH setpoint Check external controls Fan speed variation too high Check fan connection waiting during blocking function frost protection active Priority 4 Temperature below 89 C check thermistor connection if this is not true Accesory Module is blocking burner operation Check accessory module waiting time temperature difference flow Check flow amp return thermistor connections to pipes return sensor too high Check thermistor fit Check harness connection to
62. o account access stability of flooring lighting and other factors and appropriate measures taken 44 Unpacking of 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
63. om of heat exchanger Carefully ease heat exchanger out 40 OLSEL CONDENSE HOSE _ SECURING CLIP Diagram 13 6 A Az ADAPTER FLOAT CONDENSATE TRAP AND SIPHONIC DRAIN lt gt Sym Diagram 13 7 SECURING SCREWS AND CLAMPS CCGEL Diagram 13 8 0020107233_00 06 11 Glow worm 13 13 Flue Hood For access refer to section 13 1 Remove heat exchanger as described in section 13 12 Remove the two securing screws and pull the flue hood down and away from the flue hood bracket and flue elbow see diagram 13 9 13 14 Heating Flow Thermistor For access refer to section 13 1 Refer to diagram 13 10 Remove the electrical connections from the thermistor Remove the retaining clip from the flow pipe NOTE When reconnecting the polarity of the wiring to thermistors is not important 13 15 Heating Return Thermistor For access refer to section 13 1 Refer to diagram 13 10 Remove the electrical connections from the thermistor Remove the retaining clip from the return pipe NOTE When reconnecting the polarity of the wiring to thermistors is not important 0020107233_00 06 11 Glow worm m S BRACKET FLUE HOOD SECURING SCREWS Diagram 13 9 RETURN FLOW THERMISTOR THERMISTOR FLOW
64. ompletion of the test 6 Make sure that the external controls are calling for heat then turn the mains electrical supply and gas service isolation valve on 7 Switch the boiler on The boiler should fire automatically NOTE If the appliance does not light amp goes to lockout F1 turn the throttle anti clockwise a further turn and press the reset button The appliance will after a short delay again attempt to fire Repeat this procedure up to a total of 2 extra turns on the throttle screw until the appliance lights Several ignition attempts may be needed to purge gas through the appliance before a successful ignition is achieved G31 BURNER CO2 CHECK SETTING Throttle 0 5 898 0 3 24hxi 9 2 to 10 2 10 1 08 5 0 004 26 8 Check and adjust the burner CO at maximum rate Press the reset button on the controls fascia release and immediately press and hold in the button After approximately 5 seconds will be displayed Pressing the mode button when is selected will force the boiler to maximum rate the display will flash between Hi and the default display this will indicate the boiler has been forced to maximum 9 If necessary adjust the burner CO to the value shown in the SETTING column of the table by turning the throttle screw anti clockwise to increase see diagram 10 5 no more than 1 8 of a turn waiting a minute to allow for the appliance to sta
65. otection 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 1 5 813 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 10 If the flue terminal is positioned near a light source insects may enter the flue system Where safe and practical to do so advise the homeowner to check the flue outlet and clear visible insects from the terminal end H and J See diagram 4 2 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 Terminal Guard A
66. pany Name Company Name Telephone Number Telephone Number Engineer ID Number Engineer ID Number Comments Comments Signature Signature SERVICE 7 Date Energy Efficiency Checklist completed ves No SERVICE 8 Date Energy Efficiency Checklist completed ves Engineer Name Company Name Company Name Telephone Number Telephone Number Engineer ID Number Engineer ID Number Comments Comments Signature Signature SERVICE 9 Date Energy Efficiency Checklist completed Yes No SERVICE 10 Date Energy Efficiency Checklist completed Yes No Engineer Name Engineer Name Company Name Company Name Telephone Number Telephone Number Engineer ID Number Engineer ID Number Comments Comments Signature Signature 0020107233 Subject to engineering changes 0020107233 00 06 11 GLOW WORM Nottingham Road Because of our constant endeavour for Belper Derbyshire improvement details may vary slightly DE56 1 from those shown in these instructions G low e WO rm www glow worm co uk
67. pporting 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 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 per mitting Fit bracket securely onto wall before lifting appliance into po sition Obtain firm grip on front and sides of appliance lift upwards 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 po sitioning 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 not twist repo sition feet instead Keep boiler as close as possible to body throughout lift to minimise strain on back Always use assistance if required Rec ommend wear suitable cut resistant gloves with good grip to protect agains
68. r a one man lift refer to section 15 Manual Handling 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 see diagram 7 2 Remove the polystyrene base support 0020107233 00 06 11 Glow worm Preferred WALL fixing points TEMPLATE 9 WALL HANGING PLUG BRACKET SCREW N 12 x 50mm Diagram 7 1 S HANGING BRACKET Diagram 7 2 19 GAS SERVICE o ISOLATION VALVE A shown open a TEST POINT GAS PIPE IN Qo Qo 0 UNION YZ CONNECTOR GAS SERVICE ISOLATION VALVE LINER vOSEL A COUPLING CONDENSATE DRAIN PIPE Diagram 8 1 Gas Water amp Condensate Connection 8 1 Gas Connection Before connection check the supply of local gas Refer to diagram 8 1 the gas supply can be connected from below or through the wall at the rear of the boiler 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 1 5 813 Domestic Gas Installations 8 2 Water Connections Provision is made for the water connections to be made from above the boiler see dia
69. rnal controls are on Check the functional flow diagram 12 5 12 2 Fault Codes Fault codes take priority over all other display functions in the event of a fault occurring refer to diagram 12 6 If multiple faults occur the codes will be displayed for approx 2 seconds alternatively 12 3 Fault Memory The Fault memory stores details of the ten most recent faults To access this menu refer to diagram 12 3 a Press and hold MODE for 5 seconds b When the display shows a flashing 0 press MODE button Press a button to scroll back through the fault memory Position 1 is most recent see fault memory display To exit this menu press the MODE button 12 4 Diagnostic Menu The Diagnostic Menu provides the ability to view and change certain parameters See diagram 12 7 for available parameters 12 5 Status Codes The status codes provide information about the current operating condition of the boiler and can be accessed through the diagnostic display refer to diagram 12 8 0020107233 00 06 11 Glow worm CHASSIS FRONT S Y REAR PANEL CONTROL BOX CLIPS SERVICE POSITION Diagram 12 1 MAIN PCB BOARD m NEUTRAL PIN 1 TEST POINT AT MAIN PCB BOARD POSITION X17 Diagram 12 2 cavel Indicates position Fault code Fault memory display Diagram 12 3
70. s been checked at all outlets Yes Temperature C Water Flow Rate CONDENSING BOILERS ONLY The condensate drain has been installed in accordance with the manufacturer s instructions and or BS5546 BS6798 Yes ALL INSTALLATIONS If required by the manufacturer record the following CO OR CO ppm 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 installations in England and Wales must be notified to Local Authority Building Control either directly or through a Competent Persons Scheme A Building Regulations Compliance Certifi cate will then be issued to the customer 9 enchmaern Heating and Hotwater Industry Council HHIC THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS www centralheating co uk SER
71. sate pump NO DISPLAY displayed Check connection from display PCB to main PCB connector X51 Diagram 12 6 Diagnostic Menu The Diagnostic Menu provides the ability to view and change certain parameters Diagnostic See Diagram 12 7 for available parameters value To enter the diagnostic menu a Press and hold the MODE button for 5 seconds The display will change to flashing O Diagnostic b Use the or buttons to scroll to 96 This is the number installer level access password c Press MODE to confirm see diagnostic display 1 Use the or buttons to view the appropriate diagnostic number see diagram 12 7 If necessary the values can be changed by Pressing the MODE button b The diagnostic value flashes see diagnostic display 2 Use the and buttons to cycle through available values d The change is saved by pressing MODE once more NOTE Only certain parameters can be adjusted To exit the diagnostic menu press and hold the MODE button for 5 seconds 0020107233 00 06 11 Glow worm Diagnostic display 1 vay E 7 amp LL Diagnostic display 2 235 Diagnostic Menu Level 1 Installer Access 199 Display Description Range 9 0 Heating part load Adjustable heating part load in kW factory setting max output d 1 Water pump over run time for heating mode 2 60 min factory se
72. se the heating or buttons to set the heating design value required f Press the MODE button to confirm the diagnostic number flashes see diagnostic display 1 9 Hold MODE for 5 seconds to save and exit 10 7 Heating System Check that all external controls are calling for heat The boiler will fire automatically Fully open all radiator valves flow control valve A and bypass valve B see diagram 5 3 Balance the radiators as required and if fitted adjust valve A to give the required system differential Turn off all radiators that can be shut off by the user and check to see if less than the maximum differential allowed of 209C can be achieved across flow and return Allow the system to reach maximum temperature then switch off the boiler by isolating from the electrical supply The pump overrun will continue for 5 mins 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 Lock or remove the handle from control valve A to prevent unauthorised adjustment 10 8 Completion Fit the base coverplate see diagram 10 3 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 itis necessary to complete a Declaration of Conformity to in
73. shed New system For optimum performance after installation the boiler and its associated central heating system should also be flushed Flushing should be carried out in accordance with BS7593 2006 using a cleanser such as Sentinel X300 or X400 Fernox Restorer or Salamander corrosion guard cleaner IMPORTANT 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 exchangers should be used refer to the current issue of BS 5449 and BS 7593 on the use of inhibitors in central heating systems Examples are Sentinel X100 Fernox Protector or Salamander corrosion guard inhibitor Where a storage system will not have a vent to atmosphere the installation must comply with the building regulations and the Water Supply water fittings regulations 1999 and water byelaws 2000 Scotland see also the current issue of BS5546 and BS6700 If fitting to an existing system the local authority should be informed 5 7 Vented DHW System General All domestic hot water circuits connections fittings must be in accordance with the relevant standards and water supply regulations For GB Guidance G17 to G24 and recommendation R17 to R24 of the Water Regulations Guide for Scotland the Water Byelaws 2000 Scotland For IE The current edition of 1 5 813 Domestic Gas Installations 15 Water System Open Vented Centra
74. t sharp edges and ensure good grip when handling appliance It is recommended a risk assessment of the roof space area be car ried out before moving the appliance into the area to take into account access stability of flooring lighting and other factors and appropriate measures taken 0020107233 00 06 11 Glow worm MAINTENANCE Gloweworm EC declaration of conformity Name and Address of the Glow worm manufacturer Nottingham Road Belper Derbyshire 56 1JT Identification of product Glow worm Ultracom Series Condensing Wall Hung Heating Only Boilers Appliance type Ultracom 12hxi 15hxi 18hxi 24hxi 30hxi amp 38hxi The appliance types satisfy the essential requirements of the relevant directives and Standards 90 396 EEC including amendments Designed and built to CE type examination certifi Directive on the approximation of the law of the cate member states relating to appliances burning gaseous fuels PIN no 87BO41 92 42 EEC including amendments Directive of efficiency relating to boiler burning Designed and built according to European Stan gaseous fuels dards 73 23 including amendments EN 483 Directive on the harmonization of the laws of EN 677 Member States relating to electrical equip EN 60335 1 ment designed for use within certain voltage limits EN 60529 EN 50165 89 336 EEC including amendments EN 55014 Directive on the approximation of the law of the EN 61000 3 2 member states relating to e
75. ter circuit bar 43 5lbf in2 bar 43 5lbf in2 bar 43 5lbf in2 Electrical supply 230V 50Hz fused 3A 230V 50Hz fused 3A 230V 50Hz fused 3A Electrical rating 60W fused 3A 60W fused 3A 60W fused 3A EN60529 IP clasification IPX4D IPX4D IPX4D Internal fuse rating on main PCB 2A 2A 2A Gas supply governed meter only category G20 natural gas G20 natural gas G20 natural gas Inlet gas working pressure 20mbar 20mbar 20mbar Burner 2 case 9 3 nominal 9 3 nominal 9 0 nominal Burner 2 case off 9 1 nominal 9 1 nominal 8 8 nominal Approximate max gas rate after 10 mins from cold 2 58 m3 h 91 1 ft3 h 3 02 m3 h 107 ft3 h 4 06 m3 h 143 ft3 h Approximate min gas rate after 10 mins from cold 0 56 m3 h 19 8 ft3 h 0 56 m3 h 19 8 ft3 h 0 67 m3 h 23 8 ft3 h Flue type C13 C33 C33 C13 NOx Class 5 Class 5 Class 5 Heat output condensing mode 25kW 30 6kW 41kW Heat input Nett Q kW max 24 4 min 5 3 max 28 6 min 5 3 max 38 35 min 6 7 Heat output P kW max 24 min 5 25 max 28 2 min 5 25 max 38 min 6 3 SEDBUK rating 2005 90 5 90 6 90 8 SEDBUK rating 2009 0020107233_00 06 11 Glow worm 88 9 88 7 89
76. the igniter unit as described in section 13 3 to improve accessibility Remove the securing clip from the heat exchanger adapter then disconnect the adapter and flexible hose Lift the siphon adapter and hose out of the condensate trap and siphonic drain do not disconnect the hose Disconnect the drain connection Slacken to disengage but do not remove the two securing Screws The condense trap will contain water lift taking care not to spill the water After replacement and before fitting the adapter fill the trap with water Cleaning Remove the condense trap as previously described Remove the float to clean it Remove any solids found Flush water through the trap to remove any remaining solids Check for any debris in the outlet hose of the condensate drain and clean as necessary 13 12 Heat Exchanger Refer to Manual Handling section For access refer to section 13 1 Refer to section 11 3 for removal of the fan gas valve and burner assembly Drain the boiler Remove the securing clip from the heat exchanger adapter then disconnect the adapter and flexible hose Undo the two nuts of the flow and return pipes from the heat exchanger Move the hoses away from the heat exchanger Loosen the three heat exchanger securing screws and clamps two at the top and one at the bottom to remove the heat exchanger see diagram 13 8 CAUTION There will be water in the heat exchanger Remove condense pipe connector from bott
77. the mains electric supply and the gas should be turned off at the gas service isolation valve on the boiler see diagram 10 1 Unless stated otherwise parts are replaced in the reverse order to removal After replacing any parts always test for gas tightness and if necessary carry out functional test of the controls Boiler Access For replacement of parts the front casing and the inner 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 Undo the two screws on the front of the inner front panel and lift off The side panels can be hinged sideways and removed to aid replacement of parts To hinge a side panel undo and remove the three screws securing each side panel to the boiler two at the front and one at the top 13 2 Spark Electrode For access refer to section 13 1 Refer to section 11 2 for removal 13 3 Igniter Unit For access refer to section 13 1 Remove ignition lead and electrical connections then remove igniter unit by removing two securing screws see diagram 13 1 13 4 Ignition Lead For access refer to section 13 1 Refer to diagram 11 4 and 11 5 Pull the spark plug style connector off the spark electrode and the spade connector connected to the igniter unit 13 5 Gas Valve For access refer to section 13 1 Refer to section 11 3 for removal of the fan gas valve and burner assembly Before removing the gas valve
78. tion On completion of the service the Benchmark Service Record should be completed 30 FRONT CASING PANEL gt c4c l INNER CASING PANEL Diagram 11 8 0020107233 00 06 11 Glow worm Fault Finding 12 1 Preliminary fault finding The following checks should be performed before proceeding onto specific diagnostics Check the external electrical supply to the boiler is on and a supply of 230V is present at the L and N terminals on the installer interface refer to section 10 4 for access and diagram 12 4 e Check the electrical installation and appliance carry out tests for earth continuity polarity short circuit and resistance to earth using a suitable multimeter An aid to test Remove the front casing panel see diagram 11 2 and the control panel securing screw see diagram 12 1 then lower into service the position Remove the rear panel by prising the retaining clips see diagram 12 1 Carry out the tests at connector plug X17 see diagram 12 2 Check chassis earth at a bare metal point on the boiler Check that there is a gas supply to the boiler and the gas service isolation valve is turned on see diagram 10 1 Check pressure at the gas service isolation valve refer to section 10 5 Check that the heating system pressure indicates at least 1mb if not fill and vent the system as described in section 10 2 Check that all exte
79. tting 5 min 9 2 Max burner anti cycling period at 209 C Flo w temperature 3 60 min factory setting 20 min d 4 Tank temperature in C 99 will be displayed Reserved for future use d 5 Flow temperature setpoint In min 38 and max 82 d 8 External controls heat demand 0 no heat request open 1 heat request closed d 9 Flow target temperature from external In C intelligent control 910 Status central heating pump 1 2 on 0 off d 11 Status additional heating pump option 1 to 100 on 0 off d 13 Hot water circulation pump via accessory module 1 to 100 on 0 off d 23 Summer Winter function 1 2 Winter 0 Summer d 25 Hot water activation via eBUS Control 1 yes 0 no 9 27 Relay 1 Reserved for future use 9 28 Option Relay 2 Reserved for future use d 33 Fan speed target value in rpm 10 d 34 Fan speed actual value in rpm 10 d 40 Flow temperature Actual value in 9C d 44 lonisation current Actual value 10 gt 80 no flame 40 good flame d 60 Number of safety temperature limiter cut offs 461 Number c lock outs d 64 Average ignition time In seconds d 65 Maximum ignition time In seconds d 67 Remaining burner anti cycling time block time Minutes d 76 Appliance variant device specific number 00 to 99 d 80 Heating operating hours in h d 82 Cycles in heating mode Quantity d 90 External intelligent control connected 1 ide
80. ture Control to Heating Room Thermostat and Programmable Load Weather Optimum Start Programmer Timer Room Thermostat Compensation Control Time and Temperature Control to Hot Water Cylinder Thermostat and Programmer Timer a 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 m hr OR ft3 hr Burner Operating Pressure if applicable mbar OR Gas Inlet Pressure mbar Central Heating Flow Temperature Central Heating Return Temperature COMBINATION BOILERS ONLY Is the installation in a hard water area above 200ppm Yes No If yes 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 m hr OR ft hr Burner Operating Pressure at maximum rate mbar OR Gas Inlet Pressure at maximum rate mbar Cold Water Inlet Temperature C Hot water ha
81. upply Normal operation of the boiler should resume when the electrical supply is restored Reset any external controls to resume normal operation of the central heating If the boiler does not resume normal operation press the reset button If the boiler does not resume normal operation after this call your Installation Servicing company or Glow worm service Overheating Safety The boiler software is designed to recognise the potential for an overheat lockout and will shutdown before this happens To restart the boiler press the reset button on the controls fascia If the boiler fails to resume normal operation and all external controls are calling for heat then call your Installation Servicing company or Glow worm service Frost protection The appliance has a built in frost protection device that protects the boiler from freezing With the gas and electric supplies ON and irrespective of any room thermostat setting the frost protection device will operate the pump when the temperature of the boiler water falls below 89C A timer is used so that the temperature can be checked periodically After 10 minutes the pump will be stopped if the temperature is higher than 10 or has already reached 35 The burner will activate if the boiler temperature does not reach 109C after 30 minutes or at any time if the temperature drops to 5 C The burner will switch off when the temperature reaches 35 Condensate Drain Blockage
82. upwards onto worktop if practicable Ensure stable balance achieved and lift upwards to position in place on 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 Ensure safe lifting techniques are used keep back straight bend using legs when lift ing 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 side ways 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 within compart ment etc restricting installation Recommend 2 persons lift appliance to position into place space per mitting Fit bracket securely onto wall before lifting appliance into po sition 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 su

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