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Ultracom2 cxi Installation and Servicing Manual Boilers - Glow-worm

Contents

1. 47 19 4 Hydraulic block OONONRWNAK o lt Three way valve electrical plug Three way valve retaining screws Three way valve Flow sensor electrical plug Flow sensor Safety Discharge Valve retaining clip Safety Discharge Valve discharge pipe Safety Discharge Valve Plate to plate heat exchanger retaining arm 48 9 l 11 12 13 14 15 16 17 D Plate to plate heat exchanger retaining screws Heating flow pipe retaining clip Heating flow pipe Heating return pipe Plate to plate heat exchanger Low water pressure sensor connector Low water pressure sensor Low water pressure sensor retaining clip Heating return pipe retaining clip 19 20 21 22 23 24 25 26 27 28 29 Expansion vessel pipe Automatic air vent Pump housing Pump housing retaining clip Bypass retaining clip Bypass screw Pump head earth lead Pump head connector Pump head retaining screws Pump head Automatic air vent retaining clip 0020085231_02 05 10 Glow worm 19 4 1 Pump head only Drain the boiler heating circuit as described in the appropriate chapter Draining Disconnect the electrical plug 26 from the main board Disconnect the electrical plug 25 from the pump head Remove the four cap head screws 27 Carefully remove the pump head 28 together with cable Do not strain cable Reconnect wiring to new pump head and fit cover Fitthe new pump head by rep
2. Clean and replace 0020085231 02 05 10 Glow worm 18 8 Condensate trap Oc R amp ONAOX Warning condensate is mildly acidic Use protective gloves The condensate trap Discharge of condensates Siphon Condensate trap retaining clips Hose Place a container under the condensate trap 1 Remove the siphon 3 from he recoverer and clean Disconnect the condensation discharge 2 Disconnect the heat exchanger hose 5 Remove the condensate trap 1 using the clips 4 Clean the hose the trap and the siphon remove any accumulated dirt Reassemble the components taking care to position the gaskets correctly Start the siphon 3 and fill with water 43 18 9 Combustion block Legend Gas valve connection Grounding cable Spark electrode inlet Spark electrode retaining screw Spark electrode gasket Spark electrode Burner retaining nut Burner retaining screw Thermal fuse connection o o 1000 0 NN 44 10 11 12 13 14 15 16 17 16 17 Coil Heat exchanger Burner gasket Burner Gas valve Fan Fan connection Gas pipe 0020085231 02 05 10 Glow worm 18 9 1 18 9 2 18 9 3 18 9 4 Spark electrode Disconnect the electrode inlet 3 and the grounding cable 2 Remove the 2 spark electrode retaining screws 4 Carefully remove the electrode from the combustion chamber Check that the extremes of the electrode 6 are not dama
3. Clean the interior of the silencer with a dry cloth if necessary taking care not to damage the internal foam Repeat the operation in reverse order to replace the silencer 18 6 Expansion vessel 2 1 Key 1 Silencer retaining screw 2 Fixed silencer 3 Removable silencer Remove the silencer retaining screws 1 and remove the silencer 3 Clean the interior of the silencer with a dry cloth if necessary taking care not to damage the internal foam Repeat the operation in reverse order to replace the silencer Key 1 Expansion vessel 35cxi 2 Expansion vessel pressure inlet Check the expansion vessel s supply pressure see Technical Data chapter by means of the pressure inlet located on the expansion vessel Adjust the pressure if necessary Following the installation of a new expansion vessel fill and purge the appliance or installation if necessary 0020085231 02 05 10 Glow worm 42 18 7 Heating filter K 1 2 3 4 5 The heating filter improves the degassing of the heating circuit ey Plate to plate heat exchanger retaining arm Plate to plate heat exchanger retaining screw Gasket Heating filter Plate to plate heat exchanger Close the flow and return heating stop valves and drain the boiler Remove the retaining screw 2 and arm 1 Remove the plate to plate heat exchanger 5 Remove the gasket 3 Remove the heating filter 4
4. Depending on the design of the system the by pass may need further adjustment It is adjusted clockwise to close and anti clockwise to open This should be balanced to ensure that it operates if the pump output is adjusted Output pressure curve Ultracom 24cxi 1 2 3 eo 50 40 30 20 10 0 500 1000 1500 ey Available pressure between heating flow and return kPa Heating circuit flow rate I h Speed min bypass closed Speed max bypass closed Speed max bypass middle position Speed max bypass opened RON DD gt A 28 Output pressure curve Ultracom 30cxi gt 1000 0 500 1500 K A Available pressure between heating flow and return kPa B Heating circuit flow rate I h 1 Speed min bypass closed 2 Speed max bypass closed 3 Speed max bypass middle position 4 Speed max bypass opened Output pressure curve Ultracom 35cxi 1000 1500 500 K A Available pressure between heating flow and return kPa B Heating circuit flow rate I h 1 Speed min bypass closed 2 Speed max bypass closed 3 Speed max bypass middle position 4 Speed max bypass opened 13 2 Appliance technical settings and parameter list The access to the boilers technical data allows you to adjust the boiler to the exact system requirements Note the heating power decrease has no effect on the domestic hot water power 13 2 1 Installation settings Press for more than
5. advise the user of the precautions necessary to prevent damage to the system appliance and the building remind the user to service the appliance annually Draw attention if applicable to the current issue of the Gas Safety Installation and Use Regulations Section 35 which imposes a duty of care on all persons who let out any property containing a gas appliance in the UK The user shall not interfere with or adjust sealed components It is the Law that any servicing is carried out by a competent person approved at the time by the Health and Safety Executive 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 low flue gas temperature of the boiler Advise the user that the permanent mains electrical supply should not be switched off as the built in frost protection and pump exercise program will not operate Advise the User if the mains electricity and gas are to be turned off for any long periods during severe weather it is recommended that the whole system including the boiler should be drained to avoid the risk of freezing Sealed system The system must be refilled and to the correct pressure as indicated in these instructions Leave these instructions and the Benchmark Installation Commissioning and Service Record with the user 0020085231_02 05 10 Glow worm
6. 15 1 2 Check the gas supply 2 1 Key 1 Gasservice isolation valve 2 Test point Check that there is a gas supply to the boiler and the gas service isolation valve is turned on Check pressure at the gas service isolation valve 33 15 2 Fault memory This menu allows you to display the 10 most recent failure codes registered by the appliance norder to display the fault code memory simultaneously press the buttons and under the symbol lil for more than 7 seconds The screen will display the first fault 01 record and F XX fault code To display the other faults registered by the appliance press the button or under the symbol Fi Press button for more than 3 seconds to exit this menu 05 x Const the Fault codes chapter os 3X Consut the Fault codes chapter o 3X Const the Fault codes chapter To erase the fault memory registered by the appliance consult the Installation adjustments chapter and use code d 94 15 3 Fault codes The faults described in this chapter should be carried out by a qualified engineer and if needed by the After Sales Service ACT O Rem LLL codes Return heating temperature sensor Return heating temperature sensor fault Check the sensor s connections e Check the wiring harness Flow heating temperature sensor fault Sensor short circuit Check the sensor Return heating temperature sensor fa
7. MAINTENANCE 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 isolate the boiler from the electrical supply and turn off the gas supply 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 chapter Trouble shooting Fault diagnosis Check the electrical installation After servicing complete the relevant Service Interval Record section of the Benchmark Checklist located in the centre pages of this document 15 Trouble shooting 15 1 Fault diagnosis The following checks should be performed before proceeding onto specific diagnostics Make sure that the electricity supply has not b
8. Avoid upper body top heavy bending do not lean forward sideways Al ways use assistance if required Recommend wear suitable cut resistant gloves with good grip to protect against sharp edges and ensure good grip when handling appliance Positioning of Appliance for Final Installation within compartment etc restricting installation Recommend 2 persons lift appliance to position into place space per mitting Fit bracket securely onto wall before lifting appliance into posi tion Obtain firm grip on front and sides of appliance lift upwards onto worktop if practicable Ensure stable balance achieved and lift upwards to drop into place onto bracket If 2 persons positioning onto bracket obtain firm grip at front and sides base of boiler Ensure co ordinated movements during 2 person lifts to ensure equal spread of weight of load If 1 person positioning onto bracket recommend obtain firm grip supporting base of boiler Ensure safe lifting techniques are used keep back straight bend using legs when lifting load from floor level Do 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
9. Defective firing electrode and flame Cheek the igniter unit connections F29 Loss of flame during operation ive igni i pup control Defective igniter unit e Check the state of the electrode corrosion Check the entire flue system Ree InSeiPehtati spend Check the fan s electrical connections Fault in EBUS line Check that the eBus controls are fitted and wired F61 Gas valve command fault Gas valve closure fault Fault in the main board memory Check the main boards connections Check the main board FED Me mainboard Check the appliance DSN number is correct heating sensor Reset the appliance No return gas Insufficient gas flow Gas valve incorrectly adjusted Defective firing electrode and flame control Defective igniter unit Check the return gas circuit gas valve open Check the observe the flame picture and check the CO setting Check the igniter unit connections Check the state of the electrode corrosion Fluctuation of flame signal Check that the appliance DSN code on the screen matches the product code of the nameplate in the Incorrect product code event of a fault and the appliance DSN does not appear consult menu d 93 reserved for the code Check the boards reference User interface incompatible with the main board Flow heating temperature sensor Flow heating temperature sensor fault unclipped or defective no temperature variation Check the sensor connecti
10. WMentlaUO i uini erii Re erre RR alee e esee eder ecc e rate EE 9 7 NTE 10 7 1 SCOPES OF dellVery uerit erecto hs ht RERO ide dees usdecssesex eto haa pier eee 10 1 2 Recommendations before installing sse 10 7 3 Bizarre 12 7 4 MOUNT Gj e ccc Ae O 12 8 Hydraulic COMME CUOM E Ei 14 8 1 Gas and water connections cueie ecce anaia a eoo Rx sates 14 9 2 Safety Discharge Valve diane De ied Ee caa c dete ee de Ere aea 14 8 3 Connection to the condensate trap sssssseeenm e 15 9 o nn e e E OA 17 9 1 Bc ico 17 9 2 Flue configuration description sssssssssseeeeeenen nes 19 10 REMOVE the front panel tard 21 11 Electrical connections suicide sas 21 11 4 Access to malin board ini Rhet ea re A ce ee D D Ret 21 12 Main poard s sors e eas aaae a aae Ea aaa a eS aa a E E 11 3 Electrical wiring 11 4 External accessories eiie n ee 23 11 5 Testing the electrical CONNectiONS oonniocicnnnncocccnnnnncnccccnnnnnnnnc cnn nn cnnnn cnn nc nnn nn cnc 23 116 MINING CIA GMA COCO ooo ices ere ERE 24 TABLE OF CONTENTS 12 COMMISSIONING reir Ad ASE RESINAS 25 DNE epo 25 12 2 Filling the CH system Central heating 25 12 3 Filling DAW CIEQUIE eine ett aeree tee entered reor ertet Res 25 124 Filling the Conde
11. bend using legs Keep load as close to body as possible If 2 persons per forming lift ensure co ordinated movements during lift Clear the route before attempting the lift If removing boiler from truck straddle the load and tilt forwards to facilitate secure grip Ensure safe lifting techniques are used keep back straight bend using legs Do not twist repo sition feet instead Take care to avoid trip hazards slippery or wet surfaces and when climbing steps and stairs Always use assistance if required Carriage of carton from point of delivery to point of installation first or higher floor cellar Recommend 2 person lift or 1 person with use of sack truck If 1 person is performing lift straddle the load tilt and place carton into position on truck Recommend secure appliance onto truck with suitable straps Ensure safe lifting techniques are used keep back straight bend us ing legs Keep load as close to body as possible If 2 persons perform ing lift ensure co ordinated movements during 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 Alw
12. 18 6 EXPANSION Ves Olinda 42 18 7 Heating filter ius nia dodo 43 18 9 Condensate rap ort rir rhe edat e our eres 43 18 9 Combustion PICK reote etate iio ai 44 18 10 Service COMPletiON cc comcciniccincotoa cial te ette ri 45 19 Replacement OM Palacios 46 19 1 Generali ic td da 46 19 2 Boller Acces ima aia ls 46 19 3 MEWN WIN O Wi coastal iia rens 46 19 4 Hydraulic DIOCK ccm 48 19 5 Combustion block 1r reir ia 50 19 6 Condensate lap iii aaa 52 197 o TEES 53 EE oor 54 20 1 Short Listot Parts uan cia n ep eod Mae 54 20 2 Short List of Parts either obvi bene UD ester tne etn epulo cue ee env DERE 55 UE E AAA O PEE 56 22 Declaratlamof Confom Y essin ta ndeaucicetediaas dees teen n ENES 57 INTRODUCTION 1 Instructions guidance 1 1 Product documentation The instructions are an integral part of the appliance and must be handed to the user on completion of the installation in order to comply with the current regulation Carefully read the manual to understand all the information to enable safe installation use and servicing No liability can be accepted in the event of damage for not complying with the guidance in this instruction manual 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 a
13. 20 15 C 1013 25 mbar CO2 at Qmax DHW 9 2 9 2 9 2 tolerance case ON i 0 396 0 396 0 396 CO2 at Qmax DHW 9 Q 9t tolerance case OFF id 0 2 0 2 0 2 CO2 at Qmin 8 9 8 9 8 9 tolerance case ON i 0 396 0 396 0 396 CO2 at Qmin 8 75 8 7t 8 74 tolerance case OFF d 0 296 0 296 0 296 Propane Gas G 31 15 C 1013 25 mbar A an naa CEA Minimum gas flow rate kg h CO2 at Qmax DHW 10 3 10 3 10 3 tolerance case ON ii 0 396 0 396 0 396 CO2 at Qmax DHW 10 1 10 1 10 1 tolerance case OFF P 0 296 0 296 0 296 CO2 at Qmin 9 8 9 8 9 8 tolerance case ON 0 396 0 396 0 396 CO2 at Qmin 9 6 9 6 9 6 tolerance case OFF i 0 296 0 296 0 2 0020085231 02 05 10 Glow worm INSTALLATION All the drawings dimensions are shown in mm 6 Appliance location 6 1 Location 6 1 1 Instructions Before choosing a site for the appliance carefully read the safety warnings and installation manual Ensure that wall to which the appliance will be mounted on is structurally safe in order to support the weight of the appliance Ensure that the space that the appliance is to be installed within allows the appliance to be installed and the clearances maintained This will ensure that the connections to the water gas and flue can be accessed and inspected see chapter Clearances Explain these requirements to the appliance user Donotinstall the appliance
14. 24V and 230V connections Remove the rear panel 2 Ease back the two PCB retaining clips 3 and withdraw the PCB from the retaining lugs Remove the electrical connections to the PCB appliance interface cable When refitting the rear panel ensure the leads are not trapped 2A Fuse Rating For access refer to chapter Main PCB The fuse is located at top right hand side of the PCB see chapter Electrical connection Wiring diagram 0020085231_02 05 10 Glow worm 19 8 3 RONJA a 19 8 4 User interface PCB ey User interface Retaining slots User interface PCB Retainings clips Control Panel Remove the user interface 1 easing back the two retaining slots 2 Ease back the two PCB retaining clips 4 and withdraw the PCB from the retaining lugs Remove the electrical connections to the PCB When refitting the user interface ensure the leads are not trapped Mains supply cable The main supply cable must be replaced by a qualified and competent electrician If the main supply cable is damaged replace it refering to the chapter Electrical connection 53 20 Spare parts In order to guarantee the safe and prolonged life of the product manufacturers genuine spare parts must be used This appliance displays a CE Mark of conformity Only use the manufacturer s genuine new spare parts Ensure that spare parts are correctly mounted in the righ
15. Different flue outlet configurations can be carried out Only flue accessories supplied by Glow worm must be used Consult your supplier for more information about the other possibilities and associated accessories 44 mm m Y Nj Standard flue terminal kits have an in built fall back to the boiler to drain the condensate These can be fitted level between the appliance and the termination position All other extended flues must have a fall of at least 44mm m The maximum length of the flue outlet is defined according to its type for example C13 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 a terminal protection kit Caution The connection between the flue elbow and the flue outlet must be sealed gt bp In GB the minimum acceptable siting dimensions for the terminal from obstructions other terminals and ventilation openings are shown in diagram overleaf In IE the minimum distances for flue terminal positioning must be those detailed in 1 5 813 Domestic Gas Installations The terminal must be exposed to the external air allowing free passage of air across it at all times Bein
16. EEPROM main board appliance interface are reset to factory settings if Factory reset this function is activated 0 deactivated 1 activated 0020085231_02 05 10 Glow worm Device Specific Number 30 13 2 3 Status of the appliance Press button under the symbol Il for more than 3 seconds to learn the current state of functioning of the appliance The screen displays the state of the appliance S XX Press button for more than 3 seconds to exit this menu Status Heating Mode Status Domestichotwatermode Status Domestichotwaterheating Status Specific messages Default status no request for heating or domestic water If an EBUS controller is connected to the boiler check that a wiring link is present on terminals 3 and 4 of the boiler s main board Hot water only mode is outside tolerance Frost protection mode Waiting cycle temperature differential between heating flow and return is too high If AT gt 30 forcing to Pmin Waiting cycle lack of water in the installation temperature S 54 i rise between heating flow and return is too high S96 96 Test temperature sensor for heating return S 98 Test temperature sensors for heating flow and return or the appliance has a fault 0020085231_02 05 10 Glow worm 13 2 4 Test modes By activating these various test modes you can enable special functions on th
17. P max Minimum heating output power at 50 30 C P min Maximum heating output 19 6 power at 50 30 C P max Minimum heating temperature 1 Maximum heating temperature C Minimum heating flow rate l h 4 1 Heating expansion vessel preset pressure 0 75 10 9 Maximum heating system volume approx ac Heating safety valve preset 2 5 2 5 2 5 pressure PMS Ibf in 36 3 36 3 6 3 Domestic Hot Water Minimum DHW output power kW 5 87 P min Maximum DHW output power kW 25 P max wo w 5 9 2x o N BE a o T B ES N a D co 26 7 32 8 H 00 00 400 76 1 76 0 75 10 9 1 76 0 75 10 9 160 160 r i r wo 9 a al Maximum DHW temperature C Specific flow rate AT of 35 K EN 13203 10 4 12 5 14 6 Minimum inlet water pressure bar oS 0 3 Os j psi b ps Maximum inlet water pressure A Appliance NOx class 5 5 5 230V 230V 230V Standby mode electrical W power Operational mode electrical w 151 151 151 power Max Internal fuse rating on main Index of electrical protection EN 60529 mE IPX4D IPX4D IPX4D pecie EEEL copper copper copper connection O D copper copper copper connection O D copper copper copper 21 5 21 5 21 5 connection O D copper copper copper iitwe b 82 es 845 1312 1312 1312 Number of CE certificate BU BU BV 5334 5335 5336 CT EEES Natural Gas G
18. az ves d 47 Exterior temperature Display the temperature measured by the external sensor o mo 67 Time O before Me endonhe min Display the time remaining before the end of the anti cycle anti cycle in heating mode an mua setting for eC Select a value between 50 C and 80 C 75 heating outlet Detection of eBUS controller D 2 Tarde oed 1 Detected y y y y y y y 0020085231 02 05 10 Glow worm 29 13 2 2 After Sales Service settings Press for more than 7 seconds on the button to access the configuration menu The screen displays O Press on button or under the symbol and enter the After Sales Service password Press on to validate The screen displays the parameter 00 and its value XX Press on button or under the symbol fi to access the parameter to modify Press on button or under the symbol I to modify the value of the parameter Repeatthe process for each parameter modified Press for more than 3 seconds on the button to exit the configuration menu Code Parameter Description ICI pu setting parameter 230V room thermostat d 08 Current state of the 230V room thermostat 0 open no heating 1 closed heating mode d 09 Flow temperature set point from external eBus control External eBus set value 24 0z RU d 16 Current state of the 24V room thermostat Open no neatind 1 closed heating mode E s Temperature regul
19. described 0020085231 02 05 10 Glow worm 11 4 External accessories Under no circumstances must any mains voltage be applied to any of the terminals on the 24v connection plug 2 24V room thermostat connector 2 Ebusroom thermostat connector or Ebus radio receiver 3 Outdoor sensor connector 4 Overheating safety connector for heating floor Fit external controls in accordance with the rules in force 11 5 Testing the electrical connections Carry out preliminary electrical system checks as below Resistance to earth 1 Ohm Short circuit test L N Resistance to earth L E Polarity check 2155 11 6 Wiring diagram 6 ok o Green Yellow a I Zz i d Green Yellow Green Yellow Blue Brown JEW oj EH n a 1 Overheating safety connector for heating floor 2 Control accessories connector 3 Reserved for future use 4 Location for 24V optio
20. domestic water circuit hot or cold is not protected by the boiler 2 1 4 Condensate drain blockage During freezing conditions this may be due to the forming of ice in the condense drain external to the house In this case a safety device shuts down the appliance 2 2 Data label The data label certifies the country where the appliance is intended to be installed Data label location Key 1 Data label The data label contains the following data The name of the manufacturer The country of intended destination The commercial name of the appliance and its serial number The types of flues installations authorised The appliance s gas category The gas type group and pressure set in the factory The DHW specific flow rate D The maximum pressure in the heating circuit PMS The maximum pressure in the domestic water circuit PMW The NOx class of the appliance The type and voltage of electricity supply The maximum power rating The electrical protection class The minimum and maximum heat input Q The minimum and maximum power output P The CE number and logo N The appliance shall only be connected to the gas type s indicated on the data label 2 3 Gas category This boiler is for use only on G20 but can be converted for use on G31 To adapt the appliance to another type of gas see the chapter Gas conversion 2 4 Regulation and statutory requirements 2 4 1 CE Ma
21. issue by the manufacturer We recommend you complete and return as soon as possible your guarantee registration card If your guarantee registration card is missing you can obtain a copy or record your registration by telephoning the Glow worm Customer Service number 01773 828100 2 Appliance description 2 1 Safety devices 2 1 1 Overheating safety The appliance is designed to recognise the potential for an overheat lockout and will shutdown before this happens 2 1 2 Safety discharge valve A safety discharge valve and discharge pipe are fitted to the boiler This valve must not be touched The heating safety valve opens when the pressure in the heating circuit exceeds 2 5 bars Should there be any discharge from the pipe isolate the boiler electrical supply and call your installer or Glow worm s own service organisation 2 1 3 Frost protection The frost protection system operates the pump to start as soon as the temperature in the heating circuit falls below 12 C The pump stops as soon as the temperature of the water contained in the heating circuit reaches 15 C If the temperature in the heating system falls below 7 C the burner ignites until it reaches 35 C The frost protection system is active when the appliance is switched on The system alone cannot ensure that the installation is protected against frost An separate frost thermostat is necessary to control the temperature of the system N Your
22. manufacturers requirements Competence can be demonstrated by satisfactory completion of the CPA1 ACS assessment which covers the use of electronic portable combustion gas analysers in accordance with BS 7967 parts 1 to 4 Ensure that the gas analyser is set to the correct fuel setting Select the A Ill constant central heating with DHW function by pressing the mode button repeatedly refer to commissioning section The boiler should fire automatically Safe combustion can only be verified by measuring Li CO CO2 ratio This must not exceed the value shown in the table opposite 18 3 2 Preliminaries Prior to during servicing and after any maintenance or changed parts the following must be checked The integrity of the flue system and flue seals The integrity of the appliance combustion circuit and relevant seals Electrical gas and water connections System pressure The combustion performance refer to the following procedure The operational gas inlet pressure and gas rates refer to the commissioning section paragraph 12 5 Correct any falt before continuing Combustion check and setting the air gas ratio Remove the front casing panel see diagram above and hinge down the control box Taking care not to touch any internal components proceed as follows Connect the CO2 combustion analyser to the relevant test point see diagram opposite 0020085231 02 05 10 G
23. of gas which could be produced following the chemical reactions It is especially important to treat the water in underfloor heating Systems as low temperatures favour bacterial growth This can lead to the formation of sludge which in turn may block some or all of the circuits In order to add the correct dosage of these products you must know the volume of water contained in the installation It is recommended that you note down the volume for future needs The inhibitors must be compatible with the materials employed in the installation 39 18 2 Casing removing 18 2 1 Front panel Key 1 Front panel 2 Front panel retaining screw Undo the two screws 2 on the underside of the front panel and remove the front panel 1 18 2 2 Control box Key 1 Control box Position the control box 1 into the service position 40 18 3 Combustion check and setting the air gas ratio valve 18 3 1 Competency to carry out the check of combustion performance BS 6798 2009 Specification for installation and maintenance of gas fired boilers of rated input not exceeding 70kW net advises that The person carrying out a combustion measurement must be assessed as competent in the use of a flue gas analyser and the interpretation of the results The flue gas analyser used should be one meeting the requirements of BS7927 or BS EN50379 3 and be calibrated in accordance with the analyser
24. should then be marked at 130mm from the back wall To allow for the flue passing through the wall at this angle a 125mm hole should be drilled irrespective of internal or external installation Hanging bracket fixing Due to the varied site conditions fixings are not supplied and advise that the installer should supply those which are suitable Drill the holes for the fixing screws in accordance with the wall template Fixthe hanging bracket on the wall 0020085231 02 05 10 Glow worm 13 8 Hydraulic connection 8 2 Safety Discharge Valve 8 1 Gas and water connections 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 S 813 Domestic Gas Installations The appliance may contain a small amount of water place a water container beneath the boiler connections Take care to clean the pipes before assembly removing any debris or burrs Grease and oils may need to be removed they are not possible to remove by cleansing and flushing Foreign bodies in the system may enter the appliance and interrupt its operation Do not use any solvent products due to the risk of damaging the circuit Do not perform any hot work directly under the appliance this may cause damage to the appliance base Heat may also damage the isolation valves Always pre assemble pipes before fitting
25. that have associated components that need replacing on removal i e O ring seals gasket etc will be supplied and should be fitted Before replacing any parts of the boiler isolate from the mains electric supply and turn off the gas at the gas service isolation valve on the boiler Unless stated otherwise parts are replaced in the reverse order to removal After replacing any parts always test for gas soundness and if necessary carry out functional test of the controls 19 2 Boiler Access For replacement of parts the front casing panel of the boiler will need to be removed To remove undo the two screws on the underside of the front casing and lift off 46 19 3 Viewing window ARONA Fibre washer Steel washer Glass Steel washer Circlip Remove the circlip 5 Remove the steel washer 4 Remove fibre washer 1 Remove the glass 3 0020085231_02 05 10 Glow worm 19 3 1 Expansion vessel AQRWNAK ey Connector Expansion vessel Upper support bracket Retaining screw Gasket Drain the boiler heating circuit as described in the appropriate chapter Draining Remove the two screws 4 Undo the connector 1 at the base of the vessel Remove upper support bracket 3 Remove the expansion vessel 2 Fit a new gasket between the expansion vessel and connector Refill vent and pressurise the boiler 0020085231_02 05 10 Glow worm MAINTENANCE
26. the sensor connections Check that the sensor is connected to the main board and the shunt is removed Permanent temperature difference between flow and return heating sensors Check temperature sensors connections Replace faulty sensors Underfloor heating contact fault add heating contact open Sensor disconnected or defective Check connection from user interface PCB to main User interface fault Defective user interface PCB Replace user interface 0020085231 02 05 10 Glow worm 35 15 4 Functional flow diagram 15 4 1 Central Heating START Is there anything displayed 9 on the LCD Is the power switched on Switch the power on Yes Yes Check wires between Is the display flashing F Consult the Fault Codes main PCB and display PCB Yes o Initiate a CH demand Does the boiler light Does the display flash F during or after a CH Adjust CH setpoint to 75 C demand and make sure external control is calling for a demand Does the boiler light No Consult the State List Normal operation 15 4 2 Domestic Hot Water START Is there anything displayed Uu 5 EN on the LCD Is the power switched on Switch the power on Yes Yes Yes Check wires between Is the display flashing F Consult the Fault Codes main PCB and display PCB Yes Initiate a DHW demand Does the boiler light Adjust DHW setpoint to 60 C and turn on a hot Does the display flash F Successful i
27. 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 PLEASE NOTE During routine servicing and after any maintenance we recommend that the following must be checked The integrity of the flue system and the flue seals The integrity of the boiler combustion circuit and the relevant seals The operational working gas inlet pressure at maximum rate The gas rate The combustion performance See the Safety instructions chapter for a list of operations to be performed prior to the maintenance of the application Once the maintenance operations have been completed consult the Start Up chapter to restart the appliance 18 1 Annual Maintenance 18 1 1 Verification of components Check that the flow sensor is working properly See chapter Specific adjustment Appliance technical settings and parameter list gt Installation settings and use code d 36 Check that the fan is working properly See chapter Specific adjustment Appliance technical settings and parameter l
28. 2 persons lift appliance to position into place space permit ting Fit bracket securely onto wall before lifting appliance into position Obtain firm grip on front and sides of appliance lift upwards ensure sta ble balance achieved and lift upwards to drop into place onto bracket If 2 persons positioning onto bracket obtain firm grip at front and sides base of boiler Ensure co ordinated movements during 2 person lifts to ensure equal spread of weight of load If 1 person positioning onto bracket rec ommend obtain firm grip supporting base of boiler Ensure safe lifting techniques are used keep back straight bend using legs when lifting load from floor level Do not twist reposition feet instead Keep boiler as close as possible to body throughout lift to minimise strain on back Al ways use assistance if required Recommend wear suitable cut resistant gloves with good grip to protect against sharp edges and ensure good grip when handling appliance It is recommended a risk assessment of the roof space area be carried out before moving the appliance into the area to take into account access stability of flooring lighting and other factors and appropriate measures taken Declaration of Conformity EC declaration of conformity Name and Address of the Glow worm manufacturer Nottingham Road Belper Derbyshire DE56 1JQ Identification of product Glow worm Ultracom 2 Condensing wall hung combination storage boiler Applian
29. 231 02 05 10 Glow worm 14 8 3 Connection to the condensate trap N Condensate produced by the appliance is mildly acidic pH 3 5 5 0 Use protective gloves N Condensate must only be discharged in accordance with these instructions The volume of condensates evacuated can reach about 15 litres per day for a detached house This volume is negligible compared to the volume of waste water discharged by a house because the condensates are diluted in this water Referto BS5546 or BS6798 for advice on disposal of boiler condensate w EEr r A oF WS A a y S S Key 1 Condensate pipe Make sure there is no protective plug fitted Connect the condensate pipe 1 The pipe should have a fall of a least 2 5 44mm metre away from the boiler Condensate should if possible be discharged into the household internal drainage system e If this is not practicable discharge can be allowed into the external household drains or a purpose designed soak away refer to diagram overleaf It is recommended that any external condensate drain pipe is protected and also preferably of 32mm diameter to prevent freezing in adverse weather conditions Always ensure the pipe is installed with the correct fall Use 21 5mm plastic pipe to connect to the condensate outlet do not use metal pipes It is permissible to use a condensate neutraliser providing that it is checked for correct opera
30. 7 seconds on the button to access the configuration menu The screen displays O Press 4 times on the button under the symbol e The screen displays 96 This is the installer s password Press on to validate The screen displays the parameter 00 and its value XX Press on button Y or under the symbol r to access the parameter to modify Press on button or under the symbol II to modify the value of the parameter 0020085231 02 05 10 Glow worm Do likewise for each parameter that needs to be modified Press for more than 3 seconds on the button to exit the configuration menu Code Parameter Description Factory Modifiable setting parameter Choose a value Maximum heating power 24cxi gt 5 to 18 kW 18 yes 30cxi 6 to 25 kW 25 35cxi 8 to 30 kW 30 Pump over run time heating Choose a value between 2 and 60 To prevent the burner frequently switching on and off the reactivation of the burner is electronically blocked for a period that is determined each time the burner stops The burner blocking d Blocking time for burner in heating time can be adapted to the usage conditions for the heating 20 yes mode anti cycle time installation and depends on the temperature that is set for heating at 80 C the period is fixed 2 minutes at 10 C the period is adjustable choose a value between 2 and 60 minutes 01 02 The following menu is displayed if a domestic hot wa
31. Gloweworm Ultracom cxi Installation and Servicing 24cxi G C No 47 019 10 30cxi G C No 47 019 11 35cxi G C No 47 019 12 High Efficiency Condensing Combination Boilers www glow worm co uk TABLE OF CONTENTS INTRODUCTION 1 INSTUCUONS QUID ANCE c S 3 1 1 Product documentation ad pis 3 1 2 ASSOCIALEd documierits e ierit mer Ero iai rte vee neater 3 1 3 Explanation of symibolS 2 5 2 1 ittis nentes a sine ttp ea hava dea ada casis ep rc edis pedea 3 14 Guarantee registration nee cita de 3 2 Appliance descripblOn usse situated Cata Qu ex Nu CN a ca EE D i EN RN i note C 3 2 1 Sale devices cita Lut dire eere Ir ie E is e eccL LEY 3 2 2 Datta label M 4 2 9 Gas category uus ive to rth ELLE paie add 4 24 Regulation and statutory requirements ssssssssssseeeeeeenees 4 2 5 Hydraulic A O 5 3 Safety Insirucians and TOQUISIONS secre 6 3 1 dalety INS MUCTIONS o ia 6 3 2 FROGUIAT ONS aso unfer e eK en idea 6 4 REINO span ita 7 4 1 Appliance duritie uit M uU Ui Ibi A 7 4 2 PACKAGING eR 7 TECHNICAL DATA 5 CITA AA e aeeoa a aiaa aeaaaee ERA viia Eoi aE iaaii kaiaa Naani ia aaia 8 INSTALLATION 6 Appliance ojo ifo Pee 9 6 1 Koi 9 6 2 Olearances eee elena teet eie dede aden 9 6 9
32. Press the reset button Do not use the reset button to purge the installation never press reset more than 3 times Press the III central heating water temperature button and the factory setting temperature will be displayed Press or buttons to adjust Press the hot water temperature button and the factory setting temperature will be displayed Press or buttons to adjust Open a hot water tap the display will indicate the domestic hot water temperature Check that hot water is available at all taps then close 12 6 Gas rates 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 0020085231 02 05 10 Glow worm Oncompletion test the gas installation for tightness using the pressure drop method and suitable leak detection fluid purge in accordance with the above standard Due to the modulating operation of the boiler and the need to check the gas inlet pressure and measure the gas rate at maximum rate it will be necessary to force it to maximum Activate the test mode P 01 and set the value to 100 in order to force the burner at P max See chapter Specific adjustment Appliance technical settings and parameter list gt Test modes 12 6 1 Operational Gas Inlet Pressure 2 1 Key 1 Gas service isolation valve 2 Test point With all other gas appliances operating check the opera
33. above another appliance that could damage it for example above a cooker that might emit steam or grease or in a room which has a lot of dust in the atmosphere which is corrosive The boiler must be fitted inside the property and exposed pipe work may need to be protected from frost by fitting a frost thermostat 6 1 2 Regulations Location This boiler is not suitable for outdoor installation This boiler may be installed in any room although particular attention is drawn to the installation of a boiler in a room containing a bath or shower where reference must be made to the relevant requirements This boiler is suitable for installation in bathroom zones 2 and 3 In GB this is the current I E E WIRING REGULATIONS and BUILDING REGULATIONS In IE reference should be made to the current edition of 1 S 813 Domestic Gas Installations and the current ETCI rules 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 6 2 Clearances Toallow periodic maintenance ensure the distances indicated on the diagram Additional clearances may be beneficial around the boiler for installation and servicing 0020085231 02 05 10 Glow worm For flue installations where external access is not practicable consideration should be given for the spac
34. appliance front panel Note following the replacement of the front panel the CO2 value will change you can check that the value case on is correct by the values in the previous table Key 1 Serial number stickers 2 Data label location Firmly attach the gas replacement label to the appliance in the corresponding location 1 on the electrical box 16 2 Restart re check commissioning Before putting the appliance into operation follow the instructions within the chapter Specific adjustment 38 17 Draining 17 1 Heating circuit Key 1 Length of hose not supplied 2 Drain valve Drain down the heating circuit of the boiler only by closing the heating flow and return isolating valves See chapter Hydraulic connection Gas and water connections Attach a length of hose 1 to the drain point and open the drain valve 2 After draining close the drain valve 2 and remove the hose 17 2 Domestic Hot water circuit Drain the Domestic Hot Water circuit by closing the cold water isolation valve on the wall mounting jig Open one or more hot water taps to drain the hot water circuit 0020085231 02 05 10 Glow worm 18 Servicing To ensure the continued efficient and safe operation of the boiler it is recommended that it is checked and serviced as necessary at regular intervals The frequency of servicing will depend upon the particular installation conditions and usage If
35. ards 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 CE 1312BV5336 92 42 EEC including amendments Directive of efficiency relating to boiler burning Designed and built according to European Stan gaseous fuels dards 2006 95 EEC including amendments EN 483 Directive on the harmonization of the laws of EN 677 Member States relating to electrical equip EN 625 ment designed for use within certain voltage limits EN 60335 1 EN 60335 2 102 EN 60529 2004 1 08 EEC including amendments EN 50165 Directive on the approximation of the law of the EN 55014 member states relating to electromagnetic com EN 61000 3 2 patibility EN 61000 3 3 Any change to the appliance and or any use not according to the instructions will lead to the invalidation of this Declaration of Conformity Nantes February 2010 place date Program Manager Certification Manager 0020085231_02 05 10 Because of our constant endeavour for improvement details may vary slightly from those shown in these instructions Glow worm Nottingham Road Belper Derbyshire DE56 1JT
36. ation on flow radiator or return d 17 Flow or Return temperature monitoring C yes under floor heating temperature sensor dot Warmstart status 0 E warmstart function disabled io 1 warmstart activated 3 0 off d 22 DHW demand active tapping a no 0 aid not Vie summer dis d 25 Warm start Loading enabled or disabled 2 Appliance Interface or Ebus or external controls gt Fan speed is displayed between 0 and 99 Speed setpoint ortan Multiply the displayed value by 100 no Digitalized ionisation voltage Display the digitalized ionisation voltage o m d 68 Unsuccessfull ignitions at first attempt Display the number of unsuccessfull ignitions at first n attempt Unsuccessfull ignitions at second attempt Display the number of unsuccessfull ignitions at i5 second attempt T Display the number of operating hours in heating Operating hours in heating mode mode Multiply the displayed value by 100 no Display the number of operating hours in domestic Operating hours domestic hot water mede hot water mode Multiply the displayed value by 100 ne Display the number of burner starts in heating Number of burner starts in heating mode ES mode Multiply the displayed value by 100 no Display the number of burner starts in DHW mode Number of burner starts in DHW mode EI Multiply the displayed value by 100 fm Select the product code of the appliance 24cxi 15 30cxi 22 35cxi 17 All parameters stored in
37. ax thermal load 80 C 60 C system but act under natural draught principles gt C43 type flue systems must have their own condensate drain fitted and not allow condensate to mix into other appliances gt D Y NE 3 I WN ii A X pe i ener s o lt Pressure balancing system Air inlet pipe Collector pipe Boiler Inspection hatch Final storey Ground floor Waciengih 1 60 100 Each time an additional 90 bend is necessary or 2 at 45 the length L must be reduced by 1 m U pcoBRoONAX 0020085231 02 05 10 Glow worm 20 10 Remove the front panel Key 1 Front panel 2 Front panel retaining screw Undo the two screws 2 on the underside of the front panel and remove the front panel 1 11 Electrical connections Incorrect installation can cause electric shock or appliance damage The electrical connection of the appliance must be made only by a qualified engineer The appliance must be connected directly to an accessible fixed switched electrical outlet The external wiring must be earthed with correct polarity and in accordance with current standards The manufacturer declines a
38. ays use assistance if required Carriage of carton from point of delivery to point of installation roofspace Recommend 2 person lift Ensure co ordinated movements during lift Avoid upper body top heavy bending do not lean forward side ways Clear the route before attempting the lift Take care to avoid trip hazards slippery or wet surfaces and when climbing steps and stairs When transferring appliance into roofspace recommend 1 person to be in roofspace to receive the appliance and other person to be below to pass up and support appliance Ensure safe lifting techniques are used keep back straight bend using legs Keep load as close to body as possible Always use assistance if required It is assumed safe access flooring and adequate lighting are provided in the roof space It is recommended a risk assessment of the roof space area be carried out before moving the appliance into the area to take into account access stability of flooring lighting and other factors and appropriate measures taken Unpacking of 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 positi
39. ce type 18 SXI A 1 amp 24 CXI A 1 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 CE 1312BU5334 92 42 EEC including amendments Directive of efficiency relating to boiler burning Designed and built according to European Stan gaseous fuels dards 2006 95 EEC including amendments EN 483 Directive on the harmonization of the laws of EN 677 Member States relating to electrical equip EN 625 ment designed for use within certain voltage limits EN 60335 1 EN 60335 2 102 EN 60529 2004 108 EEC including amendments EN 50165 Directive on the approximation of the law of the EN 55014 member states relating to electromagnetic com EN 61000 3 2 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 Nantes January 2010 H LAMI Y GAUDIN place date Program Manager Certification Manager _S e a EC declaration of conformity Name and Address of the Glow worm manufacturer Nottingham Road Belper Derbyshire DE56 1JQ Identification of product Glow worm Ultracom 2 Condensing wall hung combination Appliance type 30 CXI A 1 The appliance types satisfy the essential req
40. checked adjusted and preset at the factory for operation on natural gas G20 as defined on the appliance data label No measurement of the combustion is necessary Should the appliance require to be converted to LPG gas ensure you follow the gas conversion section before lighting the boiler e Check that the appliance has been installed in accordance with the instructions e Check the integrity of the flue system and flue seals 26 e Check the integrity of the appliance combustion circuit and relevant seals Check that all internal external controls are calling for heat Check that the gas service isolation is open To adapt the appliance to another type of gas see chapter LPG conversion 12 5 2 Adjusting the temperature K 1 Domestic hot water temperature control buttons 2 Display 3 Reset button 4 On Off button 5 Central heating temperature control button 6 Mode selection button Light the appliance by following the procedure below Select the Heating domestic hot water function by pressing the Mode button repeatedly to scroll through your options until II Hi are shown The appliance will enter a self checking routine then the fan will start and the ignition sequence commence The boiler if necessary will automatically repeat the ignition sequence a further 4 times If the burner fails to ignite F28 will be displayed initially this may be due to air in the gas supply line
41. e x1 Heating flow valve x1 Domestic hot water connection x1 Gas isolation valve x1 2 3 Hanging bracket x1 2 4 Filling loop extensions x2 2 5 Seals bag x1 Flat seal Y x2 Flat seal Y x5 Flat seal for cold water inlet Y x4 2 6 Compression fitting x1 3 Wall template x1 4 Documents bag x1 4 1 Installation and servicing manual x1 4 2 Flue book x1 4 3 Instructions for use x1 10 4 4 Extended guarantee leaflet x1 4 5 Guarantee envelope pack x1 4 6 Magnetic lighting instruction label x1 4 7 Gas conversion label x1 7 2 Recommendations before installing 7 2 1 Domestic hot water circuit design Water pressure The minimum working pressure to obtain the maximum domestic flow is 1 0 bar The maximum working pressure of the domestic hot water circuit is 10 bar If the cold water supply pressure exceeds this then a pressure reducing valve must be fitted in the supply to the boiler Hard water areas The temperatures within the heat exchanger are limited by the boiler control system to minimise scale formation within the hot water pipework However in areas where the water is hard i e more than 200 mg L of calcium carbonate it is recommended that the hot water setting is reduced and that a scale reducer is fitted refer to the manufacturer s instructions or consult the local water company for additional advice Domestic water flow rate The domestic hot water fl
42. e appliance Press the on off button to switch off the appliance While keeping the button pressed for more than 5 seconds press the on off button The screen displays the first test mode P01 and Off Press button or under the symbol r to choose the test mode that you wish to launch Test mode P 01 Press button to display the burner forcing setting The Screen displays P 01 and O Press on button or under the symbol Il to modify the value of the setting from 0 0 to 100 100 Press on button for 1 second to exit the submenu or for more than 7 seconds to access the configuration menu Test mode P 02 to P 07 Press to launch the test mode The screen displays P 0X and On The test mode will be automatically stop after 15 minutes When you have finished press the reset button l or the On Off button to exit the test modes The appliance functions at a power adjustable from 0 0 Pmin to 100 100 Pmax by using buttons or under the symbol 1 after successful ignition Forcing the adjustable power burner when heating Forcing the burner to The appliance functions at ignition power heating ignition after successful ignition power Forcing the The appliance functions at its maximum burner to MM power after successful ignition Heating Pmax The 3 way valve is in the central position the pump and the burner stop so that the a
43. e following lift operation exceeds the recommended weight for a one man lift General recommendations when handling Clear the route before attempting the lift Ensure safe lifting techniques are used keep back straight bend using legs Keep load as close to body as possible Do not twist reposition feet instead If 2 persons performing lift ensure co ordinated movements during lift Avoid upper body top heavy bending do not lean forward sideways Recommend wear suitable cut resistant gloves with good grip to protect against sharp edges and ensure good grip Always use assistance if required Removal of carton from delivery van Recommend 2 person lift or 1 person with use of sack truck If 1 person is performing lift straddle the load tilt and place carton into position on truck Recommend secure appliance onto truck with suitable straps Ensure safe lifting techniques are used keep back straight bend using legs Keep load as close to body as possible If 2 persons performing lift ensure 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 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
44. e 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 1 5 813 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 Regulations guide published by the Water Regulations Advisory Service WRAS gives full details of the requirements In IE the requirements given in the current edition of 1 5 813 Domestic Gas Installations and the current Building Regulations must be followed Electrical Supply The boiler MUST be earthed All system components shall be of an approved type and all wiring to current 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 supp
45. e required to insert the flue from inside the property which may necessitate clearance larger than those specified in diagram below Key A removable compartment door can be placed a minimum 5 mm in front of appliance A clearance of 600 mm is required from a fixed surface The boiler and flue are suitable for installation onto and through combustible materials provided that Minimum 5mm clearance is maintained around the circumference of the flue air intake The combustible surface and fixings are suitable for supporting the load The minimum clearances from the boiler case are maintained 6 3 Ventilation 6 3 1 Room Ventilation The boiler is room sealed so a permanent air vent is not required 6 3 2 Cupboard or Compartment Ventilation Due to the high efficiency and low casing temperature of this boiler cupboard or compartment ventilation is not necessary Existing ventilation should be investigated for its purpose before removing 7 Appliance installation 7 1 Scope of delivery The appliance is delivered in a single carton with a document pack and fittings The flues package will be ordered according to the configuration of the installation Please check the contents Key 1 Boiler x1 2 Accessories bag x1 2 1 Pressure relief valve connecting pipe x1 22 Connection bag x1 Heating return valve x1 Cold water inlet valv
46. eating the operations in reverse 19 4 2 Safety discharge valve Drain the boiler heating circuit as described in the appropriate chapter Draining Undo the safety discharge valve union and remove from the pipework 7 Remove the securing clip 6 and withdraw the safety discharge valve 8 Fitnew O ring Refill vent and pressurise the boiler 19 4 3 Automatic air vent Drain the boiler heating circuit as described in the appropriate chapter Draining Remove the retaining clip 29 Remove the automatic air vent 20 Fitthe new automatic air vent and O ring ensuring the vent cap is left loose Refill vent and pressurise the boiler 19 4 4 Low water pressure sensor Drain the boiler heating circuit as described in the appropriate chapter Draining Disconnect the electrical lead 15 Remove the retaining clip 17 remove the low water pressure sensor 16 Fitthe new low water pressure sensor Refill vent and pressurise the boiler 0020085231 02 05 10 Glow worm 19 4 5 Flow sensor Drain the boiler hot water circuit as described in the appropriate chapter Draining Remove the side securing clip and the electrical connection 4 Disengage the flow sensor 5 After replacing the flow sensor open the cold water isolation valve and slowly open a hot water tap to remove air 19 4 6 Bypass Drain the boiler heating circuit as described in the app
47. ed Disconnect the spark electrode cap 7 from the igniter unit Disconnect the gas supply pipe 36 at the gas valve Remove the electrical connectors from the gas valve 37 and the fan 34 Remove the retaining screw of the silencer Loosen the 4 nuts 12 Remove the combustion burner door assembly from the heat exchanger 11 The studs 19 must not be damaged If damaged you will need to replace the heat exchanger The combustion burner door assembly insulation should be inspected and replaced if damaged 19 5 4 Burner Remove the 3 burner retaining screws 16 Remove the burner 15 and the gasket 14 Fitthe new burner and the new gasket 19 5 5 Heat exchanger A There will be water in the heat exchanger Carefully ease heat exchanger out Drain the boiler heating and hot water circuits as described in the appropriate chapter Draining Remove the flue connection Undo the two screws located on the top of each side panel Remove the thermal fuse connector 20 Remove the 2 heating pipe retaining clips 25 and 29 Release the heating pipes 24 and 27 from the heat exchanger Release the condensate trap pipe from the heat exchanger Remove the combustion burner door assembly 11 refering to chapter Removing the combustion burner door assembly Unscrew the 4 retaining screws 17 and 23 and remove the 2 retaining plates 18 and 22 from the heat exc
48. een interrupted and that the appliance is connected correctly See chapter Trouble shooting gt Fault diagnosis gt Check the electrical installation Check the appliance s gas supply See chapter Trouble shooting gt Fault diagnosis Check the gas supply Ensure that the isolating valves are open Ensure that the pressure indicator displays a value of 0 8 bar if the pressure falls below 0 4 bar the air vent function will run automatically for a period of 5 minutes until you see 0 5 bar on the pressure indicator If not fill the appliance Check that all external controls are connected correctly If the symbol l and the message rE SEt are displayed on the screen display the fault code memory see chapter Trouble shooting Fault memory Press the reset button to restart the appliance e Check the functional flow diagram 0020085231 02 05 10 Glow worm 15 1 1 Check the electrical installation Key 1 Main board 2 Neutral 3 Live 4 Multimeter Remove the front casing panel e 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 main board e Check the electrical installation and appliance carry out tests for earth continuity polarity short circuit and resistance to earth using a suitable multimeter Bare metal points such as screws or rivets will act as suitable earth check points on the appliance
49. emical cleanser can be used either Sentinel X300 X400 or Fernox F3 are suitable It is recommended to flush existing systems first before fitting the new boiler Ensure all cleanser is removed from the whole system before adding an inhibitor For long term corrosion protection after flushing an inhibitor suitable for stainless steel heat exchangers can be used Either Sentinel X100 or Fernox F1 inhibitor can be used The boiler is suitable for use on systems using softened water 7 3 Dimensions 2 12 7 4 Mounting de Make sure that the equipment used for implementing the installation is compatible with that of the appliance Determine the assembly location See the Appliance location chapter W 160 160 lt q 602 Gel 80 125 flue gt 150mm 80 125 flue gt 130mm 80 125 flue 156mm Take the wall template and place in the desired position on the wall giving due consideration to the required boiler clearances see chapter Appliance location Clearances and the flue you are fitting 0020085231 02 05 10 Glow worm 7 4 1 Fixing to the wall 7 4 2 Boiler hanging With regards to the Manual Handling Operations 1992 Regulations the following lift operation exceeds the recommended weight for a one person lift refer to chapter Manual Handling K 1 Wa
50. g taps The DHW and CH circuits can then be filled flushed and tested independantly 12 2 Filling the CH system Central heating Make sure that the installation s cold water inlet isolating valve is open Open the isolating valves located on the connections they must be positioned in the direction of the flow DISCONNECTOR Filling position p and hold rotate locking collar Disconnect osition pull 1 P 0020085231 02 05 10 Glow worm Key 1 Air vent 2 Pump 3 Screw for the pump shaft Open the plug on the air vent located on the pump and the automatic air vents on the installation If the Central Heating C H pressure falls below 0 4 bar the display will flash the current pressure and the boiler will not operate To increase the pressure the CH circuit requires Topping up Push the disconnector up then turn the green locking collar to lock the disconnector in the filling position Fully open the Lhd filling tap then gradually open the Rhd tap When the operating pressure is achevied close both taps unlock the disconnector and pull down to disengage When turning the 230Vac supply on to the boiler should the water pressure be less than 0 5 bar an automatic air vent function will be activated for a period of 5 minutes During this time the pressure should be increased and air vented from the system Note that the burner will not fire in either CH or DHW mode and the d
51. g 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 0020085231 02 05 10 Glow worm 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 17 UNDER CAR PORT etc Position Position of the flue terminal Horizontal flues m directly below an opening air brick opening windows IB above an opening air brick opening windows horizontally to an opening air brick opening windows ID below gutter drain soil pipe above adjacent ground or balcony level 300 J from surface or a boundary facing the terminal 600 18 Position of the flue terminal mm from opening door window in car port 200 into dwelling vertical from a terminal 1500 horizontally fr
52. ged Clean away any accumulation of dirt and check that the distance between the two electrodes is between 3 5 and 4 5 mm Check that the gasket 5 is not damaged Replace if necessary Dismantling the burner Warning The gasket 12 must be replaced each time the burner is dismantled Disconnect the spark electrode connector 6 from the igniter unit Remove the gas pipe 17 Remove the connectors from the gas valve 1 and the fan 15 Remove the retaining screw of the silencer Loosen the 4 nuts 7 Remove the burner group from the heat exchanger 11 The studs 8 fixed to the heat exchanger must not be damaged Should it be damaged replace the heat exchanger The burner gate insulation should not be damaged Replace if damaged Cleaning the heat exchanger Clean the coil 19 in the heat exchanger 11 with water Burner control The burner 13 does not require maintenance and should not be cleaned Check that its surface is not damage Replace the burner if necessary Following the verification or replacement of the burner assemble the burner group as described in the following chapter 0020085231 02 05 10 Glow worm 18 9 5 Re assembling the burner group Place the burner group on the heat exchanger 11 Progressively tighten the 4 nuts 7 in an alternate order Reassemble the silencer Connect the gas tube 17 with a new gasket to the burner group Connect the spark electrode con
53. gnition during or after a DHW demand water tap Does the boiler light No Consult the State Table Normal operation 0020085231 02 05 10 Glow worm 36 16 Gas conversion adjustments In order to operate with a gas other than that provided from the factory it is necessary to some adjustments to the gas valve This conversion should only be carried out by a competent person approved at the time by the Health and Safety Executive During the conversion to Propane use of a suitable flue gas analyser is necessary The person carrying out a combustion measurement should have been assessed as competent in the use of a flue gas analyser and the interpretation of the results The flue gas analyser used should be one meeting the requirements of BS7927 or BS EN50379 3 and be calibrated in accordance with the analyser manufacturers requirements Competence can be demonstrated by satisfactory completion of the CPA1 ACS assessment which covers the use of electronic portable combustion gas analysers in accordance with BS 7967 parts 1 to 4 16 1 Settings Li Steps Switching on to Re pressurising System will need to be completed before the appliance can be converted See chapter Commissioning Tools required to make the conversion are a 2mm Allen key and an electricians screwdriver Having checked the appliance and system have been installed in accordance with the instructions the integrity of the fl
54. hanger Pullthe heat exchanger towards you to extract it from its 2 side rails 51 19 5 6 Re assembling the burner group Place the burner assembly on the heat exchanger 21 Progressively tighten the 4 nuts 12 in an alternate order Reassemble the silencer e Connect the gas pipe 36 with a new gasket to the burner group Connect the spark electrode connector 5 to the igniter unit e Connect the connector to the gas valve 37 and the fan 34 Open the appliance s gas input Check the tightness of the gas connection 19 5 7 Heating Flow Thermistor Remove the electrical connections from the thermistor 28 Remove the retaining clip from the flow pipe 27 When reconnecting the polarity of the wiring to thermistors is not important 19 5 8 Heating Return Thermistor Remove the electrical connections from the thermistor 26 Remove the retaining clip from the return pipe 24 When reconnecting the polarity of the wiring to thermistors is not important 19 5 9 Gas valve Remove the burner door 11 refering to chapter Dismantling the burner door Remove the two gas valve retaining screws 30 Remove the gas valve 31 and the gasket 32 Fit the new gas valve and the new gasket by repeating the operations in reverse After assembly test for gas tightness and purge in accordance with the current issue of BS6891or in IE the current edition of 1 S 813 Domes
55. ion burner door assembly gasket 14 Burner gasket 15 Burner 16 Burner retaining screw 17 Heat exchanger retaining screw 18 Heat exchanger retaining bracket 19 Burner gate retaining screw 20 Thermal fuse connection 21 Heat exchanger 22 Heatexchanger retaining bracket 23 Heat exchanger retaining screw 24 Heating return pipe 25 Heating return pipe retaining clip 26 Return heating temperature sensor 27 Heating flow pipe 28 Flow heating temperature sensor 29 Heating flow pipe retaining clip 30 Gas valve retaining screw 31 Gas valve 32 Gas valve gasket 33 Fan 34 Fan electrical connection 35 Fan burner gasket 36 Gas pipe 37 Gas valve electrical connection 38 Fanretaining screw o o 100 00 0 19 5 1 Spark electrode Disconnect the electrode cap 7 and the earthing cable 6 Remove the 2 spark electrode retaining screws 8 Carefully remove the electrode 10 from the combustion chamber Remove the gasket 9 Check that the distance between the 2 electrodes is between 3 5 and 4 5 mm Install the electrode and a new gasket 19 5 2 Igniter unit Remove the ignition lead 2 Remove electrical connections 4 Loosen the screws 3 located on the igniter unit 2 Remove the igniter unit 2 0020085231 02 05 10 Glow worm 19 5 3 Removing the combustion burner door assembly Warning The gasket 13 must be replaced each time the combustion burner door assembly is remov
56. isplay will blink displaying the current water pressure Ventair from each radiator until the water flows normally then close the vents Leave the pump s air vent open The following two operations will unblock the pump s engine after a prolonged storage period and will purge the air from the pumps circuit Remove the screw from the pump shaft and introduce a flat screwdriver A trickle of water under no pressure should normally come out of the pump Rotate the pump shaft through several turns then replace the screw 1233 Filling DHW Circuit Open the various hot water taps to fill the DHW circuit 25 12 4 Filling the Condensate Trap 1 Filling trap 2 Condensate trap Fill the trap 3 4 full with water 1 Activate the Heating and Domestic Hot Water functions Run the appliance for at least 15 minutes with a heating temperature set to greater than or equal to 50 C not applicable for an installation with underfloor heating Ventair from each radiator again until the water flows normally then close the vents f you have difficulties in removing the air launch the air removal programs in the heating circuit see the chapter Technical settings for the appliance and list of parameters Make sure that the pressure indicator shows a value of 0 8 bars otherwise fill the appliance again 12 5 Initial lighting 12 5 1 Control The combustion for this appliance has been
57. ist gt Installation settings and use code d 34 Check that the temperature sensors are working properly See chapter Specific adjustment Appliance technical settings and parameter list gt Installation settings and use code d 3 d 4 d 40 d 41 Check the ionisation quality Check that the thermal fuse protects the appliance against dry fire Disconnect the thermal fuse and check if F76 fault code is displayed on the screen 0020085231 02 05 10 Glow worm Check that the pressure sensor is working properly The pressure must be displayed on the screen Check the pressure of the expansion vessel 18 1 2 Other checks e Check the CO2 rate in the fuel and compare with the values indicated in the chapter CO2 Measurement Check that there are no leaks in the joints and the safety valves Check that there are no gas leaks Verify that the flue system is sound and complete Check the appliance s electrical safety 18 13 Cleaning of the components Clean the following components The heating filter The condensate trap The heat exchanger The burner The fan 18 1 4 Corrosion and anti sludge protection In order to avoid corrosion the addition of a corrosion inhibiter to the heating circuit water is recommended The inhibiter will stop electrolytic reaction and bacterial growth between the different metals used in the installation It will also avoid the formation
58. ith an automatic bypass which can be adjusted to suit your system requirements Ensure that under no circumstances does the flow rate drop below the figure specified refer to chapter Technical data Filling the sealed system The water pressure at the boiler must be at least 1 2bar to operate the filling loop If the pressure is less than 1 2bar an external filling loop must be fitted If this pressure is not available contact the local water authority Suitable external filling systems are shown diagrammatically see diagram below Im iat Heating flow circuit Heating return circuit Boiler Double check valve assembly Domestic cold water supply in Temporary filling loop remove immediately after filling Drain point Back flow prevention device Tundish F k lt OMONONRWON AK The system should be pressurised to 0 8bar indicated on the digital display with no heating demand 11 Drain points Drain taps must be provided at all low points of the system which will allow the entire system to be drained Drain taps shall be to the current issue of BS2879 Water treatment Existing system It is essential that prior to installing the new boiler the system is thoroughly flushed New system For optimum performance after installation the boiler and its associated central heating system should also be flushed Flushing shall be carried out in accordance with BS 7593 a ch
59. lace the cap on the sampling point replace the controls fascia and the front casing panel Remember to replace the sample point cap on completion of the test 18 3 4 Gas rate check e Check the gas rates as described in the commissioning section 18 3 5 Completion If itis 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 18 4 Servicing If the Combustion CO2 CO CO2 ratio amp Gas rate checks did not require adjustment then it will not be necessary to complete a full service All routine servicing requirements can be achieved by the removal of the front panel Position the control box into the service position Before commencing with a service or replacement of parts isolate the boiler from the electrical and gas supplies 18 4 1 Service interval record Referto benchmark book stapled in the centre pages of this manual 41 MAINTENANCE 18 5 Silencer Key 1 Fixed silencer 24cxi 30cxi 2 Silencer retaining clip 3 Removable silencer Unclip and remove the silencer 3
60. ld be readily accessible and preferably adjacent to the boiler It should be identified as to its use A fused three pin plug and shuttered socket outlet may be used instead of a fused spur box provided that it is not used in a room containing a fixed bath or shower Key 1 Power supply cable Connect the appliance s power cable to the 230 V single phase network earth Connect the appliance in accordance with the live and neutral connections 22 11 3 1 230V permanent supply All cables connected to the appliance should be permanently fixed to the wall This appliance will not operate without a link or system controls fitted 3 4 230V permanent supply Main board terminal block Mains earth N Mains neutral L Mains live Fuse Double pole connector Connect mains supply as described 0020085231 02 05 10 Glow worm 11 3 2 230V permanent supply 230V system controls N All cables connected to the appliance should be permanently fixed to the wall This appliance will not operate without a link or system controls fitted a Ds 250Vac Key 1 230V permanent supply 2 System controls 3 Frost stat 4 Main board terminal block FP Frost stat 230V switchable RT Switch live 230V Mains earth N Mains neutral L Mains live Junction box Fuse 7 Double pole connector ou Connect the mains supply and system heating controls e g room thermostat as
61. lding 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 1 S 813 Domestic Gas Installations the current Building Regulations and reference should be made to the current ETCI rules for Electrical Installation GB the following Codes of Practice apply BS4814 BS6798 BS5440 Part 1 and 2 BS5546 Part 1 BS5449 BS6891 BS6700 BS7074 Part 1 and 2 BS7593 BS7671 IE 1 S 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 0020085231 02 05 10 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 b
62. liance must not be put into operation A Incorrect installation can cause electric shock or appliance damage Never disable security devices and do not try to adjust them With regards to the Manual Handling Operations 1992 Regulations the appliance exceeds the recommended weight for a one person lift The handling of the boiler may involve lifting pushing and pulling the use of a sack truck may be required Be sure to consider the following handling techniques and precautions Grip the appliance at its base Use safety clothing where appropriate e g gloves safety footwear Ensure safe lifting techniques are used Keep back straight Avoid twisting at the waist Avoid upper body top heavy bending Always grip using the palm of the hand Use designated hand holds Keep load as close to body as possible Always use assistance if required Under no circumstances must the user interfere with or adjust sealed parts When assembling the connections correctly position the seals to avoid any leakage of gas or water This appliance contains metal parts components and care should be taken when handling and cleaning with particular regard to edges The basic safety instructions must be followed before attempting to maintain or replace spare parts Stop the appliance Electrically isolate the appliance from the power supply Turn off the appliance gas isolation valve Hydra
63. ll template 2 Standard flue length horizontal 3 2 5 44mm metre inclined extended flue length 4 Wall plug 5 Hanging bracket 6 Screw not supplied Flue hole cutting Mark the position of the flue centre Remove the wall template then drilling the flue hole The flue is designed with an internal fall of 44mm i metre 2 5 therefore the hole can be drilled horizontally Usea 105mm diameter core drill for external access flue installation 60 100 flue 80 125 flue gt 130mm Key Use a 125mm diameter core drill for internal access only flue T Boller y 2 Hanging bracket installation 60 100 flue 80 125 flue gt 150mm Lifting the boiler into position lean the top of the boiler If flue extension pipes are to be used then a core slightly to the wall and position just above the hanging drill size of 125mm is required This will allow the bracket extension pieces to slope at 44mm metre 2 5 towards the boiler Lower the boiler slowly and engage onto the hanging bracket If fitting a side flue extend the flue centre line into the corner then 130mm along the adjacent wall If fitting an extended side flue determine the flue hole centre by extending the dashed inclined line on the template to the side wall This dashed line is drawn at 44mm metre 2 5 rise from the boiler Where this line reaches the side wall a horizontal line should be marked The vertical centre line of the flue
64. low worm Key 1 Throttle 2 Combustion analyser sample point 2A Flue elbow 2B Vertical flue adaptor 3 Cap 18 3 3 Maximum rate check and adjustment To verify the maximum gas rate CO2 setting the appliance must be checked at the maximum rate Activate the test mode P 01 and set the value to 100 in order to force the burner at P max See chapter Specific adjustment gt Appliance technical settings and parameter list gt Test modes Wait approximately 5 minutes to read a stabilised CO2 value e Check that the value is within the range specified in table in the check column G31 Burner CO2 0020085231 02 05 10 Glow worm 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 Adjustment is made by turning the throttle an of a turn waiting 1 minute to allow the appliance to stabilise before checking or making further adjustments Remove the sticker covering the throttle adjustment screw if fitted Rotate the throttle 1 anti clockwise to increase to the required CO2 refer to previous diagram and the Setting column in the table When you have finished press the On Off button to exit the test modes Remove the analyser probe and rep
65. ly Connection of the whole electrical system of the boiler including any heating controls to the electrical supply MUST be through one common isolator and must be fused 3 Amp maximum Isolation should be by a double pole switched fused spur box with a minimum gap of 3mm for both poles The fused spur box should be readily accessible and preferably adjacent to the appliance It should be identified as to its use Alternatively connection can be made through an unswitched shuttered socket and 3A fused 3 pin plug both to the current issue of BS 1363 provided they are not used in a room containing a bath or shower Wiring to the boiler must be PVC 850C insulated cable not less than 0 75mm2 24 0 20mm 0020085231 02 05 10 Glow worm 3 2 2 Other regulations Gas Safety Installation and Use Regulations In your own interests and that of safety it is the Law that ALL gas appliances are installed by a competent person approved at the time by the Health and Safety Executive in accordance with the current issue of these regulations Control of Substances Hazardous to Health Under Section 6 of The Health and Safety at Work Act 1974 we are required to provide information on substances hazardous 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
66. 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 f you do suffer irritation to the eyes or severe irritation to the skin seek medical attention 4 Recycling The recycling of the packaging must be carried out by the qualified professional who installed the appliance 4 1 Appliance Most of the appliance is made of recyclable materials This symbol indicates that this appliance must not be disposed of with household waste that it should be selectively collected for energy recovery reuse or recycling Take the appliance to an appropriate collection point By complying with this directive you will contribute to the preservation of natural resources and the protection of human health 4 2 Packaging We recommend that you recycle the packaging of the appliance in a responsible fashion Sort the waste in order to separate those elements which can be recycled cardboard plastics and those which cannot be recycled Eliminate the waste in accordance with existing regulations TECHNICAL DATA 5 Ultracom cxi Boiler type C13 C33 C43 C53 Gas category T 90 3 2H3P 90 4 25 Maximum heating input power kW Minimum heating output power at 80 60 C P min Maximum heating output power at 80 60 C
67. n card 5 Location for external programmer 6 User interface 7 Fuse 2A 8 Connector for 230 V option 9 Main supply 230V 1 24 11 12 13 15 16 18 19 Combined spark and flame recognition electrode Heating outlet temperature sensor Heating return temperature sensor Gas valve Fan Thermal fuse Water flow sensor Three way valve Water pressure sensor 0020085231 02 05 10 Glow worm 12 Commissioning At the time of commissioning complete all relevant sections of the Benchmark Checklist located in the centre pages of this document The commissioning should be carried out by a competent person approved at the time by the Health and Safety Executive and in accordance with the current issue of BS6798 12 4 Switching on Do not operate the boiler without water Make sure that the system has been thoroughly flushed out with cold water and that all cleanser if used has been removed With the gas service isolation valve closed with no demand from any external controls and the power supply to the boiler Switched off Test for gas soundness and purge air from the gas supply Press the on off button to activate the appliance Make sure that the domestic hot water and heating functions on your appliance are not activated Before turning on the cold mains supply to the boiler turn off the cold water inlet to the boiler lock the filling loop in the closed position and close its fillin
68. nd Use Regulations be handed to the user on completion of the installation 1 2 Associated documents 1 Instructions for use 1 magnetic lighting instruction label 1 flue guide 1 extended guarantee leaflet 1 guarantee envelope pack 1 wall template 1 gas conversion label 1 3 Explanation of symbols DANGER Risk of injuries DANGER Risk of electric shock bb A ATTENTION Risk of damage to the appliance or to its surroundings IMPORTANT Important information 1 4 Guarantee registration Thank you for installing a new Glow worm appliance in your home Glow worm appliances are manufactured to the very highest standard so we are pleased to offer our customers 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 0020085231_02 05 10 Glow worm The second year of guarantee from the beginning of the 13th month onwards after installation or manufacture is conditional upon the boiler having been serviced by a competent person approved at the time by the Health and Safety Executive in accordance with the manufacturer s recommendations We strongly recommend regular servicing of your gas appliance but where the condition is not met any chargeable spare parts or components issued within the applicable guarantee period still benefit from a 12 month warranty from the date of
69. nector 6 to the igniter unit Connect the connector to the gas valve 1 and the fan 15 Open the appliance gas input Check the watertightness of the gas connection 18 10 Service completion Re check the combustion see chapter Combustion check On completion of the service the Benchmark Service Record sould be completed 45 19 Replacement of Parts Do not use reconditioned or copy parts only use original parts supplied by Glow worm If apart is required contact the Glow worm service organisation 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 competent person approved at the time by the Health and Safety Executive PLEASE NOTE During change of part of the combustion circuit we recommend that the following is the following must be checked Replacement of parts must be carried out by a The integrity of the flue system and the flue seals The integrity of the boiler combustion circuit and the relevant seals The operational working gas inlet pressure at maximum rate The gas rate The combustion performance 19 1 General The replacement of parts described in sections Combustion block will require the removal of the burner module assembly and the replacement of seal and self locking nuts Replacement parts
70. nsate Trap aai 25 USE H 26 126 GAS Tate MEE 26 12 7 Testing heating system cccccceccecece cece ceeeeaeceeeeceeaeeeeeeeeeaeaeeeeeeseneaeeseeeeeaeaeess 27 12 8 Testing domestic hot water system sssseee eem 27 12 9 Completo iniciara ri di da a eee ae ES DER Ud en 27 13 Speciicadustinent sieci atada las 28 13 1 Heating circuit adjustment ciere ek tenete tnnt 28 13 2 Appliance technical settings and parameter list sees 28 19 3 AGOZIMEASUNEMENE siii isis 32 19 44 Re check and restart csiis epe eter ee nint enitn ee 32 14 User information RN 32 MAINTENANCE 15 Wey Gases see tate EET 33 15 1 Fault GIAQNOSIS eet a sad re sies Dev Y eters 33 152 Fault MEMON oen c cde eco ie MA eee kas cce tie edet ex 34 15 3 Fault Codes 23 eer ner ea veo e eins 34 154 Functional flow diaga cios ios tata ra detenti rR secu kann 36 16 GAS conversion adjustments efte A e e e FX e a 37 16 1 QUIN GS ccc eio etre ESI etate df uie dites 37 16 2 Restart re check commissioning esee 38 17 IDEN eT 38 11 pepe 38 17 2 Domestic Hot water CIrCuit a m cocino e sek oin 38 19 ASSP VICING aneen a NC oia dis 39 18 1 AnnuallMainten ncCe isis o iaaa vun 39 18 2 Casing remloving eerie iine a eat EE ERA ER cen 40 18 3 Combustion check and setting the air gas ratio valve ece 40 18 4 SeIVICIIDG tartas ciet 41 DO EE 42
71. ny responsibility for damages to persons or others caused by the incorrect installation of the appliance earthing This includes failure to comply with current standards Electrical components have been tested to meet the equivalent requirements of the BEAB Do not use cable greater than 10 mm in diameter for the electrical connections All system components must be of an approved type Do not interrupt the mains supply with a time switch or programmer The boiler is suitable for installation in bathroom zones 2 and 3 0020085231 02 05 10 Glow worm 11 1 Access to main board Key 1 24V access cover 2 Terminal blocks for 24 V connection 3 Terminal blocks for 230 V connection 4 230V access cover 11 2 Main board Key 1 Connector 2 Electrical wires 3 Insulation When you connect the electrical wires to a connector on the electronic board Keep a distance of a maximum of 30 mm between connector 1 and the start of the insulation 3 e If using single core wires are used 2 ensure that the are wrapped together in an insulating sheath Fixthe cables in the cable clamp on the eBox 21 11 3 Electrical wiring Connection of the whole electrical system and any heating system controls to the electrical supply must be through a common isolator Isolation should preferably be by a double pole switched fused spur box having a minimum contact separation of 3mm on each pole The fused spur box shou
72. om a terminal 300 from another terminal Po iQ above roof level IR rom adjacent opening window rom adjacent wall to flue 00 Vertical flues aa 600 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 0020085231 02 05 10 Glow worm 9 2 Flue configuration description Each time an additional 90 bend is necessary or 2 at 45 the length L must be reduced by 1 m 9 2 1 Horizontal concentric flue 60 100 mm or Y 80 125 mm C13 type installation 9 2 2 Vertical concentric flue 60 100 mm or Y 80 125 mm C33 type installation N If necessary you must install a terminal protection kit 60 100 mm Key 1 Gasket ited Max enath L 80 125 mm 960100 10m 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 00 89 125 0020085231 02 05 10 Glow worm 19 9 2 3 Multiple boiler chimney flue Mode 24exi 30cxi 35e 60 100 mm C43 type installation E xhaust mass rate g s The flue connecting from the appliance to AMAIA AP An the flue system must be supplied from the At max thermal load 80 C 60 C manufacturer of the boiler Exhaust temperature C o At min thermal load 40 C 30 C C43 flue systems must not be a pressurised At m
73. on Obtain firm grip on front and sides of appliance lift upwards ensure stable bal ance achieved and lift upwards to position in place on bracket Ensure safe lifting techniques are used keep back straight bend using legs when lifting load from floor level Do not twist reposition feet instead Keep boiler as close as possible to body throughout lift to minimise strain on back Ensure co ordinated movements to ensure equal spread of weight of load Always use assistance if required Recommend wear suitable cut resistant gloves with good grip to protect against sharp edges and ensure good grip when handling appliance Positioning of Appliance for Final Installation above worktop foreseeable obstructions etc Recommend 2 persons lift appliance to position into place Fit bracket securely onto wall before lifting appliance into position Obtain firm grip on front and sides of appliance lift upwards onto worktop if practicable Ensure stable balance achieved and lift upwards to position in place on bracket If 2 persons positioning onto bracket obtain firm grip at front and sides base of boiler Ensure co ordinated movements during 2 person lifts to ensure equal spread of weight of load Ensure safe lifting tech niques are used keep back straight bend using legs when lifting load from floor level Do not twist reposition feet instead Keep boiler as close as possible to body throughout lift to minimise strain on back
74. ons Make sure that the sensor is clipped to the tube Mismatch between the flow and return heating temperatures permanent difference Heating circuit pressure sensor fault The sensor is shorted or disconnected Check the sensor s connections Heating circuit pressure sensor fault Fault in pressure sensor Check the sensor Thermal fuse fault Thermal fuse disconnected Check the fuses connections Defective thermal fuse Replace the heat exchanger Check the gas valve connections Check the operation of the gas valve Check the operation of the condensate pump option Permanent temperature difference between flow and return heating sensors Check temperature sensors connections Fie Replace faulty sensors F73 F74 76 F F77 Fault in gas valve motor Defective gas valves Defective condensate pump option Fill the installation Purge the installation Check the pump connections Check the flow and return heating sensor connections Check that there are no leaks Return water valve closed Pump disconnected Leak in the installation No water in the installation the temperature does not increase when the burner is lit Inverted or disconnected flow and return heating temperature sensors Defective temperature sensors F85 Flow and return heating sensors fault ony ane fetum heating vem pereuife ji Check temperature sensors connections sensor connected to same tube Check
75. ow has a restrictor factory fitted which reduces the flow to a maximum of 24cxi P 8 l min 30cxi 10 l min 35cxi 12 l min 0020085231 02 05 10 Glow worm 7 2 2 Heating circuit design Drain point External bypass if required Domestic hot water out Domestic cold water supply in Filling loop to be unlocked and disconnected after use Double check valve assembly Additional expansion vessel if required Heating return circuit 1 2 3 4 5 Boiler 6 7 8 9 10 Heating flow circuit General This boiler is designed for use as part of a sealed water central heating system with fully pumped circulation The pump expansion vessel and associated safety devices are all fitted within the boiler Safety valve The safety valve is an integral part of the boiler and it cannot be adjusted The pipe from the safety discharge valve must discharge safely in accordance with standards Expansion vessel The boiler has an integral expansion vessel with a capacity of 8 litres 1 76 gallons with a charge pressure of 0 75bar i The heating system volume should be calculated to ensure that the expansion vessel is suitable it may be necessary to add an additional vessel n GB Guidance on vessel sizing is also given in the current issue of BS5449 and BS7074 Part 1 In IE current edition of 1 5 813 Domestic Gas Installations 0020085231 02 05 10 Glow worm Bypass The boiler is fitted w
76. ppliance can be filled Filling the appliance The function is activated for a period of 5 minutes on the heating circuit Make sure that the air vent is open Venting the installation The function is activated for a period of 5 minutes on the short circuit Make sure that the air vent is open Venting the appliance 31 13 3 CO2 measurement The combustion for this appliance has been pre set at the factory for operation on Natural Gas G20 as defined on the appliance data label No adjustment of the combustion is necessary If you wish to check the combustion then follow the instructions in the Servicing section 13 4 Re check and restart e Once the appliance is installed check the operation of the appliance Start the appliance to ensure that any adjustments operate correctly and check that the appliance operates safely Check the gas tightness and water tightness of the appliance and eliminate any leaks e Check that the flue joints are tested for tightness and fitted in accordance with the instructions e Check the entire control and safety system its settings and its operation 32 14 User information At the end of the installation the installer must explain the operation of the appliance and its safety devices to the user if necessary provide a demonstration and answer any questions hand over to the user all the required documentation fill in the documents where necessary
77. rk This boiler meets the requirements of Statutory Instrument No 3083 The Boiler Efficiency Regulations and therefore is deemed to meet the requirements of Directive 92 42 EEC on the efficiency requirements for new hot water boilers fired with liquid or gaseous fuels Type test for purposes of Regulation 5 certified by Notified body 1312 Product production certified by Notified body 0086 The CE mark indicates that the appliances described in this manual are in compliance with the following directives European directive n 2009 142 relative to gas appliances European directive n 2004 108 from the European Parliament and Council relative to electromagnetic compatibility European directive n 2006 95 from the European Parliament and Council relative to low voltage European directive n 92 42 relative to the yield of boilers 2 4 2 Local regulations Benchmark places responsibilities on both manufacturers and installers The purpose is to ensure that customers are provided with the correct equipment for their needs that it is installed commissioned and serviced in accordance with the manufacturer s instructions by a competent person approved at the time by the Health and Safety Executive and that it meets the requirements of the appropriate Building Regulations The Benchmark Checklist can be used to demonstrate compliance with Building Regulations and should be provided to the customer for future reference In
78. ropriate chapter Draining Remove the retaining clip 23 to remove the bypass screw 24 After replacing the bypass refill vent and pressurise the boiler 19 4 7 Three way valve Drain the boiler heating circuit as described in the appropriate chapter Draining Disconnect the electrical plug 1 Remove the two retaining screws 2 Remove the three way valve 3 Fitnew three way valve assembly Refill vent and pressurise the boiler 19 4 8 Plate to plate heat exchanger Drain the boiler heating and domestic hot water circuits as described in the appropriate chapter Draining Remove the two securing screws 10 Open the two retaining brackets 9 Remove the plate to plate heat exchanger 14 by lifting it up When replacing the plate to plate heat exchanger ensure that the four rubber sealing washers are fitted into the hydroblock NOTE The plate to plate heat exchanger only fits one way Refill vent and pressurise the boiler 49 19 5 Combustion block 0020085231 02 05 10 Glow worm Legend Igniter unit retaining bracket Igniter unit Igniter unit retaining screw Igniter unit electrical connector Electrode igniter unit connection cable Earth cable Spark electrode cap Spark electrode retaining screw Spark electrode gasket 10 Spark electrode 11 Combustion burner door assembly 12 Combustion burner door assembly nut 13 Combust
79. stallers 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 centralheating co uk for more information THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS 0020085231 02 05 10 Glow worm 2 5 Hydraulic schematic 14 2 o lt Gas isolating valve Heating flow isolating valve Heating safety valve Filter on cold water inlet By pass DHW flow sensor Domestic plate to plate heat exchanger Heating filter Heating return thermistor 10 Condensate trap 11 Ignition and control electrode 12 Burner 13 Main heat exchanger 14 Thermal fuse 15 Flue outlet 16 Silencer 17 Heating expansion vessel 0 0 00 ROQGN OX 0020085231 02 05 10 Glow worm oQmmoo Fan Gas control valve Ignition module Heating flow thermistor Air vent Pump Three way valve Water pressure sensor Filling taps Heating return isolating valve Domestic cold water isolating valve Heating flow Pipe for heating safety valve Domestic hot water outlet Gas Cold water inlet Heating return Condensate drain 3 Safety instructions and regulations 3 1 Safety instructions If the gas pressure at the input of the appliance is outside the range specified the app
80. t position and direction After fitting any spare part or servicing the appliance must be tested for its safe operation 20 4 Short List of Parts When ordering spare parts contact Glow worm s own service organisation Please quote the name of the appliance and serial number to be found on the data label If ordering from British Gas also quote the G C number of the part 1 ooze Fan ee Oe 3 2000801935 Thermistor flow and return 0020097279 Gas valve 24 J 0020097278 Gas valve s0 0020038071 Gas valve 38 J s 0020038441 Electrode assembly 6 0020097209 User interasepee 0020059452 Plate to plate heat exchanger 2809 7 0020097179 Plate to plate heat exchanger 30c 0020097181 Plate to plate heat exchanger 35c e 0020097214 3 way valve assembly 0020097216 Pump head assembly 24cxi 73054 0020097220 Pump head assembly 35 70 0020097207 Waterfowsense S 0020075428 Flow restrictor 24 Mesa L 0020075429 Flowrestictors ca Fiz owoow4o WemPcS Oooo 713 Ao00024135 Lowwaterpressuresensor Pia 801635 Bumer Dorset 54 0020085231 02 05 10 Glow worm 20 2 Short List of Parts 0020085231 02 05 10 Glow worm 55 Manual Handling IMPORTANT With regards to the Manual Handling Operations 1992 Regulations th
81. t can be shut off by the user and check to see if less than the maximum differential allowed of 20 C can be achieved across flow and return Should the appliance require adjustment refer to the Specific adjustment section overleaf Allow the system to reach maximum temperature then switch off the boiler by isolating from the electrical supply Drain the entire system rapidly whilst hot using the drain taps at all the low points of the system Fill and vent the System as described previously in chapter Commissioning gt Filling the CH system Central heating Adjust the boiler temperature controls and any system controls to their required settings 12 8 Testing domestic hot water system Open a hot water tap Check that the temperature obtained is compliant with the setting on the appliance 12 9 Completion Ensure that the magnetic lighting instruction label is placed on the surface of the boiler casing GB It is a requirement that the Benchmark Installation Commissioning and Service Record is completed and left with the user IE it is necessary to complete a Declaration of Conformity to indicate compliance to 1 S 813 An example of this is given in the current edition of 1 5 813 27 13 Specific adjustment 13 4 Heating circuit adjustment It may be necessary to adjust the by pass to the design of the system The boiler is delivered pre set open 1 2 turn 1 1 Screw for by pass
82. ter tank is connected to the appliance 20 Temperature of the DHW outlet Display the temperature of the DHW outlet Display tank water temperature no Mode gt 0 With the burner 950 PUMP functo 1 Continuous with ambient temperature 2 Continuous B Functioning mode 0 Automatic maximum speed when the burner is switched on 19 Speed of the pump 1 Minimum speed 2 Automatic automatic speed when the burner is switched on 3 Maximum speed Maximum temperature setting for The recommended maximum temperature setting for domestic hot d E f domestic hot water water is 60 C Choose a value suitable for your needs The following 2 menus are displayed if an option card not supplied is installed on the appliance EN Reserved for future use yes Function relay 2 Reserved for future use 2 yes Fan speed is displayed between 0 and 99 Ro peed nan Multiply the displayed value by 100 no Temperature of water in the tank no es es es es es no Domestic hot water flow Display domestic hot water flow no i no no es no no es no d 27 Function relay 1 m Heating flow temperature Display the heating flow temperature Heating return temperature Display the heating return temperature The following 2 menus are displayed if an outdoor sensor not supplied is installed on the appliance See the instructions for the external sensor connected to the d 43 Heating curve K appliance
83. them to the boiler Only use original seals supplied with the appliance Check that there are no leaks Repair if necessary Compression fitting PRV pipe Draining outlet PRV outlet to outside K 1 2 3 Pipe for PRV 4 A B Appliance drain tap This must be extended using not less than 15mm o d pipe to discharge in a visible position outside the building facing downwards preferably over a drain To ease future servicing it is advisable to use a compression type fitting to extend the safety discharge valve tube The pipe must have a continuous fall and be routed to a 1 position so that any discharge of water possibly boiling or steam cannot create any danger to persons damage to roperty or external electrical components and wiring 1 Heating return isolating valve sealing washer 3 4 property p 9 2 Cold water inlet isolating valve sealing washer 3 4 3 Gas service isolating valve with pressure test point sealing washer Y 4 Domestic hot water outlet isolating valve sealing washer 3 4 5 Heating flow isolating valve sealing washer 4 6 Connection Y O D 22 mm 7 Connection O D 15 mm Remove the protective caps from the boiler connections Flush out the domestic hot water and the heating systems Before turning on the cold mains supply to the boiler i turn off the cold water inlet to the boiler lock the filling loop in the closed position and close its filling taps 0020085
84. tic Gas Installations Check the combustion CO2 19 5 10 Fan Remove the burner door 11 refering to chapter Dismantling the burner door Remove the gas valve 31 see previous paragraph Loosen the 3 screws 38 located on the burner door 11 Remove the fan 33 and the gasket 35 Fitthe new gasket 35 Screw the new fan to the burner door 11 52 After assembly test for gas tightness and purge in accordance with the current issue of BS6891or in IE the current edition of 1 S 813 Domestic Gas Installations 19 6 Condensate trap N Warning condensate is mildly acidic Wear protective gloves Condensate trap Condensate outlet pipe Condensate reservoir Condensate reservoir retaining clips Hose ARONA Place a container under the condensate trap 1 Remove the condensate 3 from the reservoir Disconnect the condensation discharge 2 Disconnect the heat exchanger hose 5 The condense trap will contain water lift taking care not to spill the water Remove the condensate trap 1 using the clips 4 IMPORTANT Partially fill the condensate trap with water before replacing Start the siphon 3 and fill with water 0020085231 02 05 10 Glow worm 19 7 PCB 19 8 1 19 8 2 When replacing the board refer to instructions supplied with the spare part Main PCB Control panel Rear panel Retainings clips Main PCB Remove the
85. tion 0020085231 02 05 10 Glow worm 15 INTERNAL SOIL AND VENT STACK 22mm MIN NO RESTRICTION ON LENGTH Internal Soil and Vent Pipe EXTERNAL LENGTH OF PIPE 3M MAX pe OPEN END OF PIPE DIRECT INTO GULLEY BELOW GROUND BUT ABOVE WATER LEVEL 22mm MIN NOTE FOR EXTENDED PIPE RUNS 32mm DIA PIPE SHOULD BE USED External Termination to a Gulley or Hopper 22mm MIN NO RESTRICTION ON LENGTH OPEN END OF PIPE DIRECT INTO GULLEY BELOW GROUND LEVEL BUT ABOVE WATER LEVEL Internal Termination Downstream of Sink Waste 44mm FOR EVERY 1M 16 EXTERNAL SOIL AND VENT STACK EXTERNAL MAX 3M 22mm MIN NO RESTRICTION ON LENGTH External Soil and Vent Pipe SINK CONSTITUTES AIR BREAK 22mm MIN NO RESTRICTION ON LENGTH Internal Termination into Combined Sink Waste EXTERNAL LENGTH OF PIPE 3M MAX 22mm MIN TERMINATION FROM APPLIANCE GROUND either or 500mm MIN 25mm MIN 100mm PLASTIC TUBE BOTTOM OF TUBE SEALED LIMESTONE CHIPPINGS 4 HOLE DEPTH d 400mm MIN Rows OF 3 x 42mm HOLES AT 25mm CENTRES 50mm FROM BOTTOM OF TUBE HOLES TO FACE AWAY FROM HOUSE External Termination into Soakaway NOTE PIPEWORK SHOULD ALWAYS FALL AWAY FROM BOILER BY AT LEAST 2 5 0020085231 02 05 10 Glow worm 9 Evacuation of combustion gas 9 1 Regulation
86. tional supply pressure at the gas service isolation valve test point The nominal supply pressure for Natural Gas G20 is 20mbar The nominal supply pressure for LPG G31 is 37mbar Turn the taps and appliances off then disconnect the pressure gauge Additionally the safe nominal maximum heat input of the appliance can be achieved at an inlet pressure down to 15mbar The burner pressure cannot be measured and is not used to measure the gas rate 12 6 2 Gas Rate Make sure that all other gas burning appliances and pilot lights are off e Check the gas rate using the gas meter test dial and stop watch at least 10 minutes after the burner has lit see table below for approximate rates Gas rates G20 Gas rates G31 approx after 10 mins from cold 0020085231 02 05 10 Glow worm 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 reset button to reset the boiler 12 7 Testing heating system Ensure that the external controls and programmer are calling for heat Fully open all radiator valves see chapter Appliance installation gt Recommendations before installing Heating circuit design Activate the C H function on the appliance s control panel Balance the radiators as required to give the required system differential Turn off all radiators tha
87. ue system and flue seals the integrity of the appliance combustion circuit and relevant seals that all internal external controls are calling for heat the gas service isolation valve is opened 0020085231 02 05 10 Glow worm 2A Key 1 Throttle 2 Combustion analyser sample point 2A Flue elbow 2B Vertical flue adaptor 3 Cap Remove the front panel first Remove the cap 3 and connect a CO2 analyser to effect the measurement 2 16 1 1 Adjusting the gas valve Press the on off button to turn the appliance off Turn the screw in the direction and the number of times indicated in the following table omo ema ens on ono RRA A OS Ml CN ull RO 7 ums p A cg 16 1 2 Adjusting the maximum power setting Z 24cxi 2 turns gt d 30cxi 3tums turns Activate the test mode P 01 and set the value to 100 in order to force the burner at P max See chapter Specific adjustment gt Appliance technical settings and parameter list gt Test modes Wait approximately 5 minutes to read a stabilized CO2 value lt 37 Compare the value measured with the values indicated in the table below 940 2 10 140 2 9 2 0 3 10 3 0 3 Safe combustion can only be verified by measuring CO CO 2 ratio This must not exceed the value shown in the table under the section Maximum Rate and Adjustment 16 1 3 Restarting Replace the cap Replace the
88. uirements 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 CE 1312BU5335 92 42 EEC including amendments Directive of efficiency relating to boiler burning Designed and built according to European Stan gaseous fuels dards 2006 95 EEC including amendments EN 483 Directive on the harmonization of the laws of EN 677 Member States relating to electrical equip EN 625 ment designed for use within certain voltage limits EN 60335 1 EN 60335 2 102 EN 60529 2004 108 EEC including amendments EN 50165 Directive on the approximation of the law of the EN 55014 member states relating to electromagnetic com EN 61000 3 2 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 Nantes January 2010 H LAMI Y GAUDIN place date Program Manager Certification Manager Oe ee EC declaration of conformity Name and Address of the Glow worm manufacturer Nottingham Road Belper Derbyshire DE56 1JQ Identification of product Glow worm Ultracom 2 Condensing wall hung combination storage boiler Appliance type 30 SXI A 1 amp 35 CXI A 1 The appliance types satisfy the essential requirements of the relevant directives and Stand
89. ulically isolate the appliance using the isolation valves if provided Should you need to replace hydraulic components drain the appliance Protect all the electrical components from water while working on the appliance Useonly original spare parts Useonly new O rings and gaskets After having completed work on gas or water carrying components check for their tightness When work on the appliance is completed perform an operational test and check for safety 3 2 Regulations 3 2 1 Statutory requirements 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 Executive and in accordance with the rules in force in the countries of destination Manufacturer s instructions must not be taken as overriding statutory requirements Statutory Requirements In GB the installation of the boiler must comply with the requirements of the current issue of BS6798 and be carried out by a competent person 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 Bui
90. ult nerd temperare Sengon Check the operation of the pump Overheating safety device activated Check the wiring harness 97 C Check that the flow and return heating isolation valves are open Overheating fault Leak in the installation connections Check that there are no leaks Check the flow and return heating sensor Water circulation fault connection Check the pump speed Malfunction of the pump excessively Check that the flow and return heating isolation Water circulation fault rapid temperature increase valves are open 0020085231 02 05 10 Glow worm Maximum temperature difference reached between return and flow heating Fill the installation Purge the installation Return water valve closed Check the pump connections F22 Water pressure of the installation 0 3 bar Pump disconnected Check the flow and return heating sensor 34 AC CO codes Check the gas valve connections Fault in gas valve motor Disconnected or defective cables Check the operation of the gas valve Check the operation of the condensate pump option Check the flame detection electrode Flame detection fault Abnormal flame detection Check the main board Check the igniter unit E c Check the return gas circuit gas valve open Ignition fault Fio velum gas SUMIEN gas flow Check the observe the flame picture and check Gas valve incorrectly adjusted EE the CO setting

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