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Ultracom sxi Installation & Service Manual Boilers - Glow-worm

1. bes J MAIN CONTROL BOARD 0 BROWN BLUE GREEN YELLOW GREY I INTERFACE BOARD BLACK YELLOW RED WHITE ORANGE PURPLE Diagram 14 4 46 14 Fault Finding START CENTRAL HEATING S Is there anything displayed on LCD Is the power switched on Switch the power on Yes Yes Check wires between Yes i i Is the display flashing F Consult the Fault Codes di display Yes Initiate a CH demand Does the boiler light Does the display flash F Successful ignition during or after a CH 2 Adjust setpoint to 82 C demandi and make sure external control is calling for a demand Does the boiler light No Consult the State List Diagram 14 5 47 14 Fault Finding Fault Codes DESCRIPTION POSSIBLE CAUSE Boiler has attempted to light 5 times and failed on all occasions Gas tap is closed Gas valve connector is loose unconnected faulty or wires are trapped Ignitor connectors are loose unconnected faulty trapped Faulty Ignitor Low gas inlet pressure Incorrect gas valve adjustment Electrode Ignition leads loose unconnected faulty trapped Electrode broken defective or position incorrect Air inlet blocked flue inlet blocked flue duct leaking Earthing connection loose disconnected Condensate blocked Fan fault Fan s
2. EXTENSION PIPE SECURING COLLAR SECURING SCREW 2 it Diagram 10 22 EXTENSION PIPE 13243 FLUE SECURING ADAPTER or SCREW 4 SEALING GASKET Diagram 10 21 12982 SECURING COLLAR SECURING SCREW 2 EXTENSION PIPE Diagram 10 23 12983 EXTENSION DO NOT CUT END DUCT DUCT Diagram 10 24 30 10 Twin Flue Length Preparation and Installation Secure long flue lengths horizontal amp vertical to walls or ceiling at every joint or on straight flue runs at every joint and every metre flue run 15406 100 mm APPROX 100 mm APPROX 21 27 44mm metre Diagram 10 25 31 10 Twin Flue Length Preparation and Installation TWIN FLUE ADAPTOR with gasket supplied stuck to adaptor LITERATURE TWIN FLUE ADAPTOR KIT A2011000 VERTICAL CONCENTRIC TERMINAL Part No 2000460480 Black TWIN PIPE 80mm TO CONCENTRIC ADAPTOR Part No A2011600 1 METRE SINGLE PIPE 0 80mm EXTENSION TO CONCENTRIC Part No A2011100 ADAPTOR 4 METRE EXTENSION Part No A2011500 supplied in packs of 5 Part No 0020065480 C O a mo HORIZONTAL TERMINAL 2011200 0 100mm FIXING 7 FIXING BRACKET x 5 BRACKET Fart No Part A2012800 000460486 PITCHED ROOF F
3. BLANKING SECURING PLATE LH RH HYDROBLOCK HYDROBLOCK MOUNTING BRACKET RETAINING CLIP BLANKING PLATE RUBBER SEAL SPIGOT 4 OFF 4 OFF BYPASS TUBE tJ D LA C AUTOMATIC BYPASS HOUSING RETAINING SEALS CLIP CH OUTLET PIPE Diagram 15 17 58 15 Replacement of Parts 15 23 Access User Interface and Main PCB For access refer to section 15 1 Remove control box retaining screw see diagram 15 18 Hinge down the control box Release the control box cover by carefully pressing the four retaining clips see diagram 15 18 15 24 Main PCB IMPORTANT When replacing the board refer to instructions supplied with the replacement For access refer to section 15 23 Remove the electrical connections to the PCB Ease back the four PCB retaining clips and withdraw the PCB from the retaining lugs see diagram 15 19 When refitting the rear panel ensure the leads are not trapped 15 25 User Interface IMPORTANT When replacing the board refer to instructions supplied with the replacement Refer to section 15 23 for access Remove main PCB refer to section 15 24 Remove electrical connection Gently ease back the retaining clips see diagram 15 20 Withdraw the board 15 26 Fuse Main PCB Control Box For access refer to section 15 23 The fuse is located at top left hand side of the PCB see diagram 15 19 15 27 Control Box
4. The deflector part of the deflector flue terminal can be rotated 45 to allow pluming away from openings people cars windows etc see diagram 10 28 Should the deflector terminal be positioned under a soffit or horizontal surface it is allowed to project the flue 600mm from the wall to allow the discharge of flue gases produced into free air IMPORTANT Do not fit the deflector flue terminal with the deflector positioned downwards 11 Electrical Connection WARNING This appliance must be earthed e This appliance must be wired in accordance with these instructions Any fault arising from incorrect wiring cannot be put right under the terms of the Glow worm guarantee e All system components must be of an approved type Electrical components have been tested to meet the equivalent requirements of the BEAB e Do not interrupt the mains supply with a time switch or programmer e Connection of the whole electrical system and any heating system controls to the electrical supply must be through a common isolator e Isolation should preferably be by a double pole switched fused spur box having a minimum contact separation of 3mm on each pole The fused spur box should be readily accessible and preferably adjacent to the boiler It should be identified as to its use e A fused three pin plug and shuttered socket outlet may be used instead of a fused spur box provided that it is not used in a room containing a fixed bath or
5. The maximum permitted straight flue length is 10 metres plus the terminal for each 87 5 or 2x45 bends fitted the maximum length must be reduced by 1 metre see diagram 10 18 NOTE 2x45 bends can replace 1x87 5 bend if necessary When using 87 5 bends any horizontal extension pipe should be inclined by a minimum of 44mm metre 2 5 towards the boiler to facilitate condense removal see a in diagram 10 18 Alternatively use 45 bends to avoid horizontal runs see b in diagram 10 18 The terminal siting should be as shown in diagram 4 2 Measure the distance of flue length required for the installation The flue must be designed with a continuous fall towards the boiler EN BM NN NI 11 11 T The maximum permitted straight flue length is 10 metres plus the terminal for each 87 5 45 x2 bends 2 fitted the maximum length must be reduced by 1 metre 0 Maximum flue length x y and z 8 metres Maximum flue length x y and z 9metres Diagram 10 18 27 10 Vertical Flue Length Preparation and Installation 6787 EXTENSION PIPE inclusive 70mm securing collar and screws 2 METRE Part No 2000460483 1 METRE Part No 2000460482 0 5 METRE 4 Part No 2000460481 7 RIDGE TILE ee FLUE ADAPTER 2043800 Part No 2024600 Q 4
6. 3 1 Location This boiler is not suitable for outdoor installation This boiler may be installed in any room although particular attention is drawn to the installation of a boiler in a room containing a bath or shower where reference must be made to the relevant requirements This boiler is suitable for installation in bathroom zones 2 and 3 In GB this is the current I E E WIRING REGULATIONS BUILDING REGULATIONS In IE reference should be made to the current edition of 1 5 813 Domestic Gas Installations and the current ETCI rules 3 2 Clearances The boiler should be positioned so that at least the minimum operational and servicing clearances are provided see diagram 3 1 Additional clearances may be beneficial around the boiler for installation and servicing For flue installations where external access is not practicable consideration should be given for the space required to insert the flue internally which may necessitate clearance larger than those specified in diagram 3 1 3 3 Timber Frame Buildings If the boiler is to be installed in a timber frame building it should be fitted in accordance with the Institute of Gas Engineers document IGE UP 7 1998 If in doubt seek advice from local gas undertaking or Glow worm 3 4 Combustible Material The boiler and flue are suitable for installation onto and through combustible materials provided that 1 Minimum 5mm clearance is maintained around the circ
7. 6 Installation Preparation 6 1 Appliance Pack Please check the contents of packs as shown in diagram 6 1 The packs are located in the top polystyrene packing Remove the carton sleeve and top pack then lift the boiler and its polystyrene base support out of the lower pack 6 2 Site Requirements The boiler mounting wall should be suitable for the weight of the appliance and be true and flat NOTE Due to the varied site conditions we do not supply fixings and advise that the installer should supply those which are suitable 6 3 Wall Template Take the wall template from the document pack located within the top polystyrene packing and place in the desired position on the wall giving due consideration to the required boiler clearances see section 3 and the flue you are fitting Mark the position of the flue centre if fitting a side flue extend the flue centre line into the corner then 176mm along the adjacent wall see diagram 6 2 For extended side flues the flue hole centre should be determined by extending the dashed inclined line on the template to the side wall This dashed line is drawn at 44mm metre 2 5 rise from the boiler Where this line reaches the side wall a horizontal line should be marked The vertical centre line of the flue should then be marked at 156mm 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 exter
8. see diagram 10 8 With the flue elbow removed push the flue assembly into the wall externally or internally until the end of the assembly protrudes a short way from the inside face of the wall This will enable the internal trim ring if required to be positioned and allow the flue assembly to be drawn back up to the flue elbow Secure the flue elbow in position on top of the boiler with four screws supplied Draw the flue assembly from wall and engage the flue duct into the elbow and butt fit between the air duct and flue elbow Fit the securing collar into position Ensuring correct alignment of the flue mark through two of the pre drilled holes in the securing collar Remove securing collar and drill two 3mm diameter holes one in the elbow and one in the air duct take care not to pierce the inner flue duct Fit the securing collar and secure with screws provided see diagram 10 9 Slide the internal trim ring back against the wall securing in place with a small amount of sealant if required Insert the flue duct into the air duct terminal assembly remembering to engage the catch within the terminal Check that the outer rubber sealing collar makes an effective seal against the wall face 10 Standard Flue Length Preparation and Installation 10 6 Flue Length The maximum permissible horizontal flue length is 10 metres plus the flue terminal assembly this can be achieved by use of the accessories see diagram 10
9. For access refer to section 15 23 Remove relevant plugs and connectors refer to wiring diagram 14 4 Withdraw grommets and leads so they are hanging loose Unthread the retaining cord and remove the control box by drawing it outwards away from its retaining slots see diagram 15 18 15 28 Inner Casing Panel Seal For access refer to section 15 1 Refer to diagram 13 8 Remove the inner casing panel To replace remove the old seal thoroughly clean the casing surfaces Fit the new seal it is supplied to the correct length Refit the inner casing panel NOTE Ensure the seal is fitted correctly giving an airtight joint RETAINING SECURING SLOTS SCREW gt x SEGEL RETAINING CLIPS REAR PANEL Diagram 15 18 FUSE RETAINING 9EGEL CLIPS 4 OFF MAIN PCB RETAINING LUGS Diagram 15 19 APPLIANCE RETAINING INTERFACE ELECTRICAL CONNECTION Diagram 15 20 59 16 Spare Parts 16 1 Spare Parts When ordering spare parts contact Glow worm s own service organisation using the telephone number on the inside front cover of this booklet Please quote the name of the appliance and serial number to be found on the data label If ordering from British Gas also quote the G C number of the part Key No Part No Description GC Part No 1 2000802463 Burner 18sxi E84021 1 2000802662 Burner 30sxi H36356 2 002001417
10. Max flue length 590mm Min flue length 380mm 699 OUTSIDE WALL FACE INTERNAL SURFACE Max distance from outside Min distance from outside wall face to min clearance wall face to min clearance LH 346mm LH 136mm RH 374mm RH 164mm Diagram 10 1 Ultracom 18sxi Exhaust mass rate g s Ultracom 30sxi At Min Thermal Load 40C 30 C At Max Thermal Load 80C 60 C Exhaust temperature C At Min Thermal Load 40C 30 C At Max Thermal Load 80C 60 C 10 Telescopic Flue Length Preparation and Installation FLUE Top Outlet Horizontal Concentric Flue Packs ipm amp A2043600 Horizontal telescopic flue pack SECURING SCREW x4 COLLAR SEALING SCREW x 2 TAPE telescopic only SEALING SCREW x 2 GASKET COLLAR fitted HORIZONTAL FLUE FLUE FLUE CN DUCT TERMINAL SCREW 1 2 A gt TELESCOPIC p 4 TERMINAL ASSEMBLY wen ae gt DISCARD 140 7 COLLAR DISCARD FLUE TERMINAL END WHEN USING WITH MULTIPLE BOILER CHIMNEY FLUE Diagram 10 2 DEFLECTOR FLUE TERMINAL KIT 0020060582 BLACK BLACK TERMINAL KIT 2043700 2 77 0 5m 5 2 EXTENSION 45 Bend 2000460481 2000460485 2off im EXTENSION 2000460482 87 59 VERTICAL 7
11. P CONDENSATE 6 OUTLET PIPE 0 VIEW UNDERSIDE OF BOILER Diagram 9 2 17 9 Safety Discharge Valve and Condensate Connections INTERNAL SOIL EXTERNAL SOIL 9 NENT STACK AND VENT STACK 9 MAX 3M 22mm MIN 922mm MIN NO RESTRICTION NO ON LENGTH ON LENGTH Internal Soil and Vent Pipe External Soil and Vent Pipe Rainwater Pipe SINK CONSTITUTES EXTERNAL LENGTH AIR BREAK OF PIPE 22mm MIN 22mm MIN NO RESTRICTION ON LENGTH OPEN END OF PIPE NOTE FOR EXTENDED Internal Termination into Combined Sink Waste DIRECT INTO GULLEY PIPE RUNS 32mm DIA BELOW GROUND BUT PIPE SHOULD BE USED ABOVE WATER LEVEL External Termination to a Gulley or Hopper EXTERNAL LENGTH OF PIPE 3M MAX 22mm MIN TERMINATION FROM APPLIANCE GROUND either or 22mm MIN NO RESTRICTION ON LENGTH 500mm MIN 25mm MIN 100mm PLASTIC TUBE BOTTOM OF OPEN END OF PIPE DIRECT INTO TUBE SEALED GULLEY BELOW GROUND LEVEL LIMESTONE CHIPPINGS BUT ABOVE WATER LEVEL HOLE DEPTH 3 4 MIN 2 ROWS OF 3 12mm HOLES 25mm CENTRES 50mm FROM BOTTOM OF TUBE HOLES Internal Termination Downstream of FACE AWAY FROM HOUSE Sink Waste External Termination into Soakaway NOTE PIPEWORK SHOULD ALWAYS FALL AWAY FROM BOILER BY AT LEAST 2 5
12. min clearance OUTSIDE INTERNAL WALLFACE SURFACE Max distance from outside Min distance from outside wall face to min clearance LH 505mm RH 55mm wall face to min clearance LH RH 75mm 09861 LOSEL Diagram 10 10 23 10 Standard Flue Length Preparation and Installation A2043400 Top Outlet Standard Horizontal Concentric Flue Pack FLUE ELBOW N COLLAR SCREW x2 GASKET fitted FLUE FLUE DUCT TERMINAL STANDARD AIR TERMINAL ASSEMBLY Pi 222 DUCT DO NOT REMOVE DISCARD du DISCARD FLUE TERMINAL END WHEN USING WITH MULTIPLE BOILER CHIMNEY FLUE SEALING COLLAR Diagram 10 11 8 75 BLACK TERMINAL KIT A2043700 Q 0 5m A 2 2 EXTENSION 45 Bend DEFLECTOR FLUE TERMINAL KIT 0020060582 BLACK 0020060583 WHITE 2000460481 2000460485 2off im EXTENSION 3 2000460482 87 5 Bend VERTICAL 7 2m FLUE 2000460484 EXTENSION ADAPTOR 2000460483 A2024600 Diagram 10 12 24 10 Standard Flue Length Preparation and Installation 10 7 Standard Horizontal Flue A2043400 Refer to diagram 10 11 for kit contents 10 8 REAR Flue With the flue elbow temporarily fitted measure the distance from the outside wall to the butt joint see diagram 10 13 If the measurement Y exceeds 665mm then the appropriate leng
13. 12 However should additional 87 5 or 2 x 45 elbows be used then the length MUST be reduced by 1metre The diagram 10 10 shows the length achievable by using the kit A2043400 When extension pipes are used the flue system must be designed to have a continuous fall to the boiler of at least 2 5 44mm metre to allow condensate to run back into the boiler and out via the condensate drain The flue can be installed from inside the building when access to the outside wall face is not practicable Multiple Boiler Chimney Flue Length The flue length must be calculated and installed according to the relevant standards EN 13384 1 and 2 C43 flue systems only with reference to the table below and the manufacturers instructions supplied The appliance maximum flue length must be included when calculating the overall design of the flue system NOTE The horizontal flue terminal must be removed see diagram 10 11 Exhaust mass rate g s At Min Thermal Load 40C 30 C At Max Thermal Load 80C 60 C Exhaust temperature C At Min Thermal Load 40C 30 C At Max Thermal Load 80C 60 C Standard Horizontal Flue WALL THICKNESS 75 min to 554 max OUTSIDE WALL FACE BOILER MOUNTING WALL NOTE If necessary it is permitted to increase this dimension to 600mm max 87min Max flue length 730mm 5mm
14. 15 11 55 15 Replacement of Parts 15 17 Pump head only For access refer to section 15 1 0686 Drain the boiler heating circuit as described in the appropriate paragraph of 15 1 Refer to diagram 15 12 Remove the four cap head screws Carefully remove the pump head together with cable Do not strain cable Support the pump head unscrew cable cover at the side of pump head and take off Disconnect wiring from pump head Reconnect wiring to new pump head and fit cover Fit the new pump head with O ring Complete pump replacement For access refer to section 15 1 Drain the boiler heating circuit as described in the appropriate section of 15 1 UNION Refer to diagram 15 12 15 13 Remove the pump head as described in section 15 17 68SEL Remove the safety discharge valve as described in section 15 18 Disconnect the expansion vessel pipe at the coupling see diagram 15 6 and at the pump housing by removing the retaining clip see diagram 15 12 Disconnect the central heating flow pipe union connection and withdraw the pump securing clip Spring back the rear location bracket to release the pump housing and gently rotate backwards and forwards whilst easing the pump to the right to disengage from the 3 way valve 15 18 Safety Discharge Valve For access refer to section 15 1 Drain the boiler heating circuit as described in the appropriate PUMP EXPANS
15. 2 A flexible condensate outlet pipe is fitted and should be used to couple the condensate trap and siphonic drain to a 22mm to 25mm O D non corrosive plastic pipe overflow pipe see diagram 9 2 IMPORTANT Please remove the bung from the flexible pipe before fitting to a drain outlet pipe NOTE 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 If this is not practicable discharge can be allowed into the external household drains or a purpose designed soak away refer to diagram 9 3 It is recommended that any external condensate drain pipe is protected and also preferably of 32mm diameter to prevent freezing in adverse weather conditions The condensate is discharged periodically in slugs by siphonic action It is not necessary to provide air breaks or extra traps in the discharge pipe as there is already a 75mm high trap inside the boiler Fitting an extra trap may cause the boiler siphon to work incorrectly Refer to BS5546 or BS6798 for advice on disposal of boiler condensate 8 SAFETY DISCHARGE VALVE UNION NUT _ AND SEAL VIEW ON UNDERSIDE OF BOILER Diagram 9 1 CONDENSATE 9 SYPHONIC DRAIN FLEXIBLE CONDENSATE OUTLET PIPE Syys ss SN FLEXIBLE
16. 2m FLUE 2000460484 EXTENSION ADAPTOR 2000460483 A2024600 Diagram 10 3 20 10 Telescopic Flue Length Preparation and Installation 10 2 Horizontal Telescopic Flue A2043600 Refer to diagram 10 2 for kit contents 10 3 REAR Flue If a wall thickness is between 203mm min to 413mm then the flue can be used without extensions With the flue elbow temporarily fitted measure the distance from the outside wall to the butt joint see diagram 10 4 If the measurement Y exceeds 525mm then the appropriate length of extension pipe is required If the dimension is less than 315mm DO NOT cut the flue it can project to a maximum of 600mm see diagram 10 5 If this is not desirable then a Standard flue MUST be used and cut to length 10 4 SIDE Flue With the flue elbow temporarily fitted measure the distance from the outside wall to the butt joint see diagram 10 6 If the measurement Y exceeds 525mm then the appropriate length of extension pipe is required If the dimension is less than 315mm DO NOT cut the flue it can project to a maximum of 600mm refer to diagram 10 5 if this is not desirable then a Standard flue MUST be used and cut to length OUTSIDE WALL FACE WALL THICKNESS INSIDE BUTT JOINT WALL FACE Diagram 10 4 MAXIMUM OUTSIDE WALL FACE LI OUTSIDE WALL FACE SEALING COLLAR e BUTT JOINT 6 66
17. 4 Important Information 4 INTRODUCTION Statutory Requirements 5 Boiler Design 6 Safety Devices 6 Servicing Maintenance and Spare Parts 6 Boiler Specification 1 7 Boiler Dimensions amp Hydraulic Schematic 2 8 Boiler Location Clearances and Ventilation 3 9 Flue Options and Terminal Clearances 4 10 Installation Preparation 6 14 Boiler Fixing T 15 Gas Water Connection 8 16 Safety Discharge Valve and Condensate Connections 9 17 Flue Length Preparation and Installation 10 19 Electrical Connection 11 35 Commissioning 12 37 Servicing 13 41 Fault Finding 14 45 MAINTENANCE Replacement of Parts 15 52 Spare Parts 16 60 Manual Handling 17 62 Declaration of Conformity 63 WARNINGS Gas Leak or Fault Turn off the gas emergency control valve immediately Eliminate all sources of ignition i e smoking blowlamps hot air guns etc Do not operate electrical lights or switches either on or off Open all doors and windows ventilate the area Metal Parts This boiler contains metal parts components and care should be taken when handling and cleaning with particular regard to edges Sealed Components Under no circumstances must the user interfere with or adjust sealed parts Important Information Gas Category This boiler is for use only on G20 natural gas but may be converted for use on G31 gas Propane L P G Gas Safety Installation and Use Regulations In your own interests and that of safety it is the Law that ALL gas a
18. CONNECTION PLUG Connect mains supply and system controls as diagram 11 3 External controls should be fitted in accordance with the rules in force 11 4 Electrical Cartridge Securing Fit electrical cartridge into the interface housing on completion of the wiring see diagram 11 4 Secure with the two cartridge retaining screws provided in the cartridge body 11 5 Electrical Connections Testing Carry out preliminary electrical system checks as below 1 Test insulation resistance to earth of mains cables 2 Test the earth continuity and short circuit of cables 3 Test the polarity of the mains NOTE If you require to test the appliance refer to section 14 e ELECTRICAL CARTRIDGE SECURING SCREW 2 OFF Diagram 11 4 12 Commissioning IMPORTANT At the time of commissioning complete all relevant sections of the Benchmark Checklist located in the centre pages of this document 12 1 Preliminaries All Systems The commissioning should be carried out by a competent person approved at the time by the Health and Safety Executive and in accordance with the current issue of BS6798 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 Isolate the boiler from the mains electrical supply Test for gas tightness and purge air from the gas supply IMPORTANT Before starting the boiler
19. KIT MIN SET NM Diagram 10 27 10 13 Plume Management Kit The Plume Management Kit Part No A2044100 white or A2044000 black can be used to overcome many site issues The Plume Management Kit will fit to the Top Horizontal Telescopic Rear Horizontal Telescopic and Standard Horizontal Flue This enables the flue products to exhaust further away from the boiler thereby reducing the impact of pluming NOTE The flue air inlet can be sited closer to doors opening windows and air bricks than stated in section 4 2 see diagram 10 27 The maximum length of the Plume Management Kit must NOT exceed 6m with a horizontal concentric flue length of 2m max For each 90 bend or 2 x 45 bends the maximum length of the Plume Management Kit must be reduced by 1m For more information contact Glow worm refer to page 2 The Plume Management Kit is supplied with installation instructions Refer to BS5546 or BS6798 for advice on disposal of boiler condensate 10 Deflector Flue Terminal Kit a 25 a 2 did d did Diagram 10 28 34 10 14 Deflector Flue Terminal Kit The terminal kit fits onto the telescopic and standard horizontal flue see diagram 4 1 for kit contents The kit is also supplied with installation instructions NOTE The deflector flue terminal kit can be fitted after the boiler and flue have been installed
20. SETTING column of the table 12 If adjustment is required press the reset button on the controls fascia release and immediately press and hold in the button After approximately 5 seconds will be displayed Pressing the or buttons will cycle between Hi and Lo Pressing the mode button when Lo is selected will force the boiler to minimum rate the display will flash between Lo and the default display this will indicate the boiler has been forced to minimum 13 Adjustment of the 96 2 is very coarse so carefully adjust the 2 to the value shown the SETTING column of the table with the offset adjustment see diagram 12 5 and 2 Table Rotate clockwise to increase 14 To exit the function press the mode and buttons simultaneously this will reset the boiler to the default display 15 Repeat 8 and check CO2 at maximum rate adjust if necessary Check that the CO CO2 ratio is less than the value in the table below 16 Remove analyser probe from the test point and replace the cap Refit the control panel 17 IMPORTANT Fit the LPG conversion label supplied in the documentation pack to the inner front panel alongside the data label Refitthe inner door and outer door 18 Continue commissioning from 12 4 G31 BURNER CO2 CHECK SETTING Throttle 9 2to 10 2 10 0 722 0 004 30sxi 10 0to 11 0 10
21. TELESCOPIC PIPE 4 inclusive securing 70mm collar and screws Part No A2036900 SLIDING SLEEVE Part No 2000460487 0 FLAT ROOF WEATHER COLLAR Part No 2000460478 PITCHED ROOF WEATHER COLLAR Part No 2000460479 B FIXING BRACKET PACK of 5 Part No 2000460486 87 5 BEND 45 BEND PACK OF 2 VS 2000460484 Part No 2000460485 Co Diagram 10 19 28 Flue Installation IMPORTANT The flue seals are sensitive to mineral oil based lubricants Do not grease the seals If the seals do need to be lubricated use only water During the installation of the flue system ensure that debris such as mortar filings or swarf are cleared from the flue System before completion Long lengths of flues must be secured to the walls or ceilings they run against Use at least one fixing bracket for every flue extension that is used After cutting inner flue tubes ensure that you de burr and chamfer the male tube end to prevent damage Inspect the flue pipes before fitting and do not install damaged or dented flue components When assembling the flue system ensure that the inner seals are not damaged do not install a flue component with a damaged seal When fitting flue elbows ensure that they are fitted at the correct angle to avoid strain this will ensure that the seal fits correctly preventing leakage Refer to diagram 10 21 and secure the flue adapter in position on top of the boiler with four sc
22. a Press and hold MODE for 5 seconds b When the display shows a flashing 0 press MODE button C Press a button to scroll back through the fault memory Position 1 is most recent see fault memory display To exit this menu press the MODE button 14 4 Diagnostic Menu The Diagnostic Menu provides the ability to view and change certain parameters See diagram 14 7 for available parameters 14 5 Status Codes The status codes provide information about the current operating condition of the boiler and can be accessed through the diagnostic display refer to diagram 14 8 RETAINING SLOTS SECURING y ENS f SESEL RETAINING CLIPS REAR PANEL PANEL Diagram 14 1 MAIN PCB BOARD 2 5 230Vac 50Hz Jez LIVE PIN 3 AND NEUTRAL PIN 1 TEST POINT AT MAIN PCB BOARD Ol POSITION X17 i HA Diagram 14 2 S Indicates memory position Fault code Fault memory display Diagram 14 3 45 14 Fault Finding 19161 CONTROL VALVE IGNITION HEATING ELECTRODE RETURN THERMISTOR euren HEATING 2 FLOW lity b WATER PRESSURE SENSOR CHASSIS INSTALLER INTERFACE S GNF
23. check that all flue connections are secure and sealed correctly 36 12 2 Filling the Heating Circuit With the gas isolation valve closed and with no demand from any external controls switch on the power supply to the boiler The boiler should be in OFF mode this will be indicated on the user interface display refer to diagram 12 2 If not press the Mode button repeatedly until the OFF symbol is displayed then continue as follows 1 Open the Central Heating Flow and Return isolating valves marked A using a screwdriver or a 4mm allen key slot in line with the axis of the valve shown closed in diagram 2 Fill the heating system to a pressure of 1 0bar The System pressure will be displayed on the user interface 3 Vent all air from the system repeat as necessary until the system is full and all the air has been vented 12 Commissioning A PRESSURE TEST POINT CENTRAL HEATING ISOLATION VALVES GAS SERVICE ISOLATION VALVE ALL SHOWN CLOSED UNDERSIDE VIEW OF BOILER Diagram 12 1 13473 mM 1111 bar 5 a MODE BEBE es NE ce OM TOGGLE BUTTON LCD RESET CH TEMPERATURE MODE and PROG DISPLAY BUTTON USED ADJUSTMENT Central Heating Function Min burner display Appliance OFF Temperature Max burner display Glow worm control Optional System pressure
24. 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 techniques are used keep back straight bend using legs when lift ing load from floor level Do not twist reposition feet instead Keep boiler as close as possible to body throughout lift to minimise strain on back Avoid upper body top heavy bending do not lean forward side ways Always use assistance if required Recommend wear suitable cut resistant gloves with good grip to protect against sharp edges and ensure good grip when handling appliance Positioning of Appliance for Final Installation within compart ment etc restricting installation Recommend 2 persons lift appliance to position into place space per mitting Fit bracket securely onto wall before lifting appliance into po sition Obtain firm grip on front and sides of appliance lift upwards onto worktop if practicable Ensure stable balance achieved and lift upwards to drop into place onto bracket If 2 persons positioning onto bracket obtain firm grip at front and sides base of boiler Ensure co ordinated movements during 2 person lifts to ensure equal spread of weight of load If 1 person posit
25. outlet pipe and gas pipe at the connections between the top and bottom modules Undo the locknuts retaining the CH outlet pipe and the gas pipe to the boiler chassis Rotate the gas pipe upwards and clear of the chassis panel Remove the 3 screws which retain the automatic bypass housing refer to section 15 21 Grip the LH and RH hydroblocks simultaneously and lift clear of the spigots on the mounting bracket The RH hydroblock should be drawn upwards past the plastic three way valve body NOTE Before removing the bypass tube from the hydroblocks take note of the tube position and orientation Fit the new bypass tube with new O ring seals and re assemble to hydroblocks NOTE Before lowering the assembly onto the bracket spigots ensure that the two port axis in each hydroblock run parallel to each other and also that the bottom faces of the hydroblocks are level and aligned Lower the assembly onto the bracket ensuring that the brass washers on the DHW and DCW pipes are not displaced Check also that the seals on the front of the RH hydroblock remain in place as it slides past the automatic bypass housing Before refitting the plate to plate heat exchanger ensure that the four rubber seals are in place two in the LH and two in the RH hydroblock Fit new O rings to pipes Refill system vent and pressurise the boiler SCREW PRIMARY FLOW PIPE CH FILTER in Hydroblock
26. reached 35 C The burner will activate if the boiler temperature does not reach 10 C after 30 minutes or at any time if the temperature drops to 5 C The burner will switch off when the temperature reaches 35 C Condensate Drain Blockage As a Safety feature the boiler will stop working if the condensate drain becomes blocked During freezing conditions this may be due to the forming of ice in the condense drain external to the house Release an ice blockage by the use of warm cloths on the pipe the boiler should then restart Servicing Maintenance and Spare Parts Servicing and Maintenance To ensure the continued efficient and safe operation of the boiler it is recommended that it is checked and serviced as necessary at regular intervals The frequency of servicing will depend upon the particular installation conditions and usage If this appliance is installed in a rented property there is a duty of care imposed on the owner of the property by the current issue of the Gas Safety Installation and Use Regulations Section 35 Servicing maintenance should be carried out by a competent person approved at the time by the Health and Safety Executive in accordance with the rules in force in the countries of destination To obtain service please call your installer or Glow worm s own service organisation using the telephone number on the inside front cover of this literature Spare Parts Remember when replacing a part on
27. 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 a part is required contact Glow worm s own service organisation Please quote the name of the boiler this information will be on the name badge on the front of the appliance If in doubt seek advice from the local gas company or Glow worm s own service organisation using the telephone number on the inside front cover of this booklet 1 Boiler Specification BOWER SPECIFICATION Mm hg 6 41kg 9015 44 5kg 9815 Condensate connection 1 0 21 5mm plastic 21 5mm plastic Safety valve bar 43 5Ibf in2 bar 43 5Ibf in2 Safety valve discharge Expansion vessel capacity 8 litres 1 76 gallons 15mm copper 15mm copper Expansion vessel charge pressure 0 5bar 7 3Ibf in2 Electrical supply 230V 50Hz fused 8 litres 1 76 gallons O 5bar 7 3Ibf in2 230V 50Hz fused 3A Electrical rating 180W fused 3A 180W fused 3A EN60529 IP clasification IPX4D IPX4D Internal fuse rating on main PCB 2A 2A 2 G20 natural gas 112 G20 natural gas Inlet gas working pressure 20mbar 20mbar Burner 96 case on 9 3 nominal 9 3 nominal Burner 96 CO case off 9 1 nominal 9 1 nominal 2 0 m3 h 3 0 m3 h 71 107 ft3 h 0 53 m3 h 0 53 m3 h 18 7 18
28. very coarse and should not be adjusted more than an of a turn at a time Wait 1 minute to allow the appliance to stabilise before checking or making further adjustments e Gradually rotate the offset adjustment anti clockwise to decrease to the required CO2 refer to diagram 12 5 and the SETTING column in the table e Exit the minimum rate function press the mode and buttons simultaneously this will reset the boiler to the default display 3 Re Check CO2 and check the CO CO2 combustion ratio e Re check the maximum and minimum CO2 values to ensure that they are within the setting limits in the table then check the CO CO2 combustion ratio does not exceed the value in the CO CO2 column of the table If the CO CO2 setting exceeds the value in the table a complete servicing of the appliance will be necessary refer to section 13 1 If the CO2 and the CO CO2 ratio falls within the tolerances quoted exit the function press the mode and buttons simultaneously this will reset the boiler to the default display Remove the analyser probe and replace the cap on the sampling point replace the controls fascia inner and front casing panels IMPORTANT Remember to replace the sample point cap on completion of the test GAS RATE CHECK Check the gas rates as described in the commissioning section 42 COMPLETION If it is not possible to achieve the required results for either the combustion or gas
29. wall to engage the final pipe piece and pull back ensuring the grey wall seals are fully pulled up to the outside and inside wall faces Vertical Pipes Completion of Installation Refer to diagram 10 25 For installation of a attach the twin pipe to concentric flue adaptor part number A2011600 to the base of vertical terminal assembly For installation of b attach the single pipe to concentric adaptor part number A2011500 to the base of vertical terminal assembly With the vertical terminal assembly positioned in the roof the length of the final pipe can be determined Cut the flue to the desired length measuring from the O ring seal end and discard the plain end of the tube The cut end should be square and free from burrs Carefully push the terminal assembly upwards to allow room for fitting the final flue piece s Fit a 100mm fixing bracket to the terminal assembly Part No 2000460486 Pull the terminal assembly down and join to the flue system Ensure that the terminal is making a weather tight seal on the weather collar Secure the fixing bracket fitted to the terminal to the roofing struts or a purpose made batton 33 from an opening air brick opening windows FLUE KOAN YN OUTLET OPENING WINDOW _ OR DOOR IMPORTANT The flue outlet must not be positioned within 300mm 10 Plume Management Kit 12997 PLUME S MANAGEMENT
30. 3 Pressure Relief Valve H42758 3 0020014161 Automatic Air Vent H42758 4 0020014171 Pump H42760 5 801655 Igniter H84015 6 0020038061 User Interface H52596 7 0020023825 Main PCB H42783 8 0020037309 Fan H53083 9 2000802664 Gas Valve E84004 10 0020014169 Bypass H42768 11 0020020781 NTC 720340 12 2000802462 Electrode H53089 13 801635 Burner Door Seal Kit E85008 60 16 Spare Parts 13861 12 TTo Diagram 15 21 61 17 Manual Handling IMPORTANT With regards to the Manual Handling Operations 1992 Regulations the following lift operation exceeds the recommended weight for a one man lift General recommendations when handling Clear the route before attempting the lift Ensure safe lifting techniques are used keep back straight bend using legs Keep load as close to body as possible Do not twist reposition feet instead If 2 persons performing lift ensure co ordinat ed movements during lift Avoid upper body top heavy bending do not lean forward sideways Recommend wear suitable cut resistant gloves with good grip to protect against sharp edges and ensure good grip Always use assistance if required Removal of carton from delivery van Recommend 2 person lift or 1 person with use of sack truck If 1 person is performing lift straddle the load tilt and place carton into position on truck Recommend secure appliance onto truck with suitable straps Ensure safe lifting te
31. 44mm FOR EVERY 1M Diagram 9 3 18 10 Telescopic Flue Length 10 1 Flue Length The maximum permissible horizontal flue length is 10 metres plus the flue terminal assembly this can be achieved by use of the accessories see diagram 10 3 However should an additional 90 or 2 x 45 elbows be used then the length MUST be reduced by 1metre The diagram 10 1 shows the length achievable by using the kit A2043600 When extension pipes are used the flue system must be designed to have a continuous fall to the boiler of at least 2 50 44mm metre to allow condensate to run back into the boiler and out via the condensate drain The flue can be installed from inside the building when access to the outside wall face is not practicable Preparation and Installation Multiple Boiler Chimney Flue Length The flue length must be calculated and installed according to the relevant standards EN 13384 1 and 2 C43 flue systems only with reference to the table below and the manufacturers instructions supplied The appliance maximum flue length must be included when calculating the overall design of the flue system Horizontal Telescopic Flue Rear 380 min to 590 max FLUE LENGTH 203 min to 413 max WALL THICKNESS 85656 OUTSIDE WALL FACE BOILER MOUNTING WALL NOTE If necessary it is permitted to increase this dimension to 600mm max Horizontal Telescopic Flue Side
32. 5 0 3 5 0 004 0 8 OFFSET ADJUSTMENT o THROTTLE ELECTRICAL SEALING d GROMMET GAS PIPE RETAINING CLP Diagram 12 5 13 Servicing IMPORTANT NOTES To ensure the continued efficient and safe operation of the boiler it is recommended that it is checked and serviced at regular intervals The frequency of servicing will depend upon the particular installation and usage but in general once a year should be enough It is the Law that any servicing is carried out by a competent person approved at the time by the Health and Safety Executive Before commencing with a service or replacement of parts the boiler should be isolated from the electrical supply and the gas supply should be turned off at the gas isolation valve When replacing a part on this appliance use only spare parts that you can be assured conform to the safety and performance specification that we require Do not use reconditioned or copy parts that have not been clearly authorised by Glow worm If any electrical connections have been disconnected and after their connection checks to the earth continuity polarity short circuit and resistance to earth must be repeated using a suitable multimeter as described in section 14 After servicing complete the relevant Service Interval Record section of the Benchmark Checklist located in the centre pages of this document General Inspection Prior to during servicing and after any maintenanc
33. 7 C33 C43 C13 C33 C43 C53 Class 5 Class 5 Heat output condensing mode 20 02kW 30 58kW Heat input Nett Q kw 18 9 min 5 max 28 6 min 5 3 Heat output P kW max 18 57 min 4 95 max 28 17 5 25 SEDBUK rating BandA 90 4 BandA 90 6 Table 1 Flow Rate MINIMUM FLOW RATE 18sxi 774 litres hr 30sxi 1289 litres hr This is equal to 20 C differential at maximum heat input Gas supply governed meter only Approximate max gas rate after 10 mins from cold Approximate min gas rate after 10 mins from cold Flue type NOx 2 Boiler Dimensions and Hydraulic Schematic 120 726 9 BOILER CONDENSATE CONNECTION lt 100 450 RETURN LEN SDV outlet 100 140 Diagram 2 1 N HEAT EXCHANGER EXPANSION VESSEL BURNER FLOW THERMISTOR RETURN THERMISTOR CONTROL FAN AUTOMATIC AIR VENT DRAIN TAP SAFETY C H RETURN FILTER CH C H FLOW RETURN Diagram 2 2 2 1 Boiler Dimensions amp Hydraulic Schematic All dimensions are given in millimetres except as noted The general arrangement of the boiler is shown in diagram 2 1 and the hydraulic and gas schematic diagram 2 2 The data label is positioned on the front of the inner casing panel 3 Boiler Location Clearances and Ventilation
34. Diagram 10 5 vecel Diagram 10 6 21 10 Telescopic Flue Length Preparation and Installation 62601 EI SECURING 222222222222222 1 TELESCOPIC HOLE ON TERMINAL ASSEMBLY Diagram 10 7 S i SEALING COLLAR vSCEL SEALING COLLAR SECURING COLLAR TRIM RING PP Diagram 10 9 22 10 5 Flue Fitting IMPORTANT The flue seals are sensitive to mineral oil based lubricants Do not grease the seals If the seals do need to be lubricated use only water During the installation of the flue system ensure that debris such as mortar filings or swarf are cleared from the flue system before completion Inspect the flue pipes before fitting and do not install damaged or dented flue components When assembling the flue system ensure that the inner seals are not damaged do not install a flue component with a damaged seal When fitting flue elbows ensure that they are fitted at the correct angle to avoid strain this will ensure that the seal fits correctly preventing leakage With the air duct seams aligned and the flue set to the required length Y mark the securing hole position the air duct Drill a 3mm diameter hole at this position take care not to pierce the inner flue duct Secure with screw provided and tape the joint see diagram 10 7 Fit the sealing collar onto the locating ring on the flue terminal
35. ED e E TO THE APPLIANCE SHOULD BE N PERMANENTLY FIXED TO THE WALL L 230Vac 50Hz PERMANENT SUPPLY Diagram 11 2 e DESCRIPTION 230Vac ROOM THERMOSTAT AND 230Vac FROST STAT N MAINS NEUTRAL EXTERNAL PROGRAMMER L MAINS LIVE e MAINS EARTH R SWITCH LIVE 230v FROST STAT 230v switchable Ov LOW VOLTAGE 0v DEMAND EBUS 24v LOW VOLTAGE DEMAND 24v INSTALLER INTERFACE DATA BUS FOR APPROVED Ebus GW ACCESSORIES on 0 OUTDOOR SENSOR CONNECTION 1 eeleeeee OUTDOOR SENSOR 2 CONNECTION 2 oro ON LR F 230Vac FROST STAT VOLTAGE 24v FREE Ebus CONTACTS Lov 230Vac NOTE This appliance will not operate without a link or system SYSTEM CONTROLS TTT JUNCTION controls 111411 BOX NOTE ALL CABLES 3 AMP FUSE CONNECTED TO THE APPLIANCE SHOULD DOUBLE BE PERMANENTLY POLE FIXED TO THE WALL ISOLATOR 230Vac 50 E PERMANENT N SUPPLY L Diagram 11 3 35 11 Electrical Connection 11 2 System Controls 24V WARNING UNDER NO CIRCUMSTANCES MUST ANY MAINS VOLTAGE BE APPLIED TO ANY OF THE TERMINALS ON THE 24V CONNECTION PLUG Connect the mains supply and system heating controls e g room thermostat as diagram 11 2 External controls should be fitted in accordance with the rules in force 11 3 Mains Voltage System Controls WARNING UNDER NO CIRCUMSTANCES MUST ANY MAINS VOLTAGE BE APPLIED TO ANY OF THE TERMINALS ON THE 24V
36. Gloweworm Ultracom Installation and Servicing 18sxi G C No 41 019 07 30sxi G C No 41 019 08 High Efficiency Condensing System Boilers www glow worm co uk Guarantee Registration Thank you for installing a new Glow worm appliance in your home Glow worm appliances are manufactured to the very highest standard so we are pleased to offer our customers a Comprehensive Guarantee This product is guaranteed for 24 months from the date of installation or 30 months from the date of manufacture whichever is the shorter for parts and labour The second year of the parts guarantee from the beginning of the 13th month onwards after installation or manufacture is conditional upon the boiler having been serviced by a competent person approved at the time by the Health and Safety Executive in accordance with the manufacturer s recommendations We strongly recommend regular servicing of your gas appliance but where the condition is not met any chargeable spare parts or components issued within the applicable guarantee period still benefit from a 12 month warranty from the date of issue by the manufacturer We recommend you complete and return as soon as possible your guarantee registration card If your guarantee registration card is missing you can obtain a copy or record your registration by telephoning the Glow worm Customer Service number 01773 828100 Customer Servi
37. ION VESSEL section of 15 1 SECURING CLIP PIPE SECURING CLIP Refer to diagram 15 13 Diagram 15 12 Undo the safety discharge valve union and remove from the pipework Remove the securing clip and withdraw the safety discharge valve 992 Fit new O ring Refill vent and pressurise the boiler 15 19 Automatic Air Vent For access refer to section 15 1 Drain the boiler heating circuit as described in the appropriate section of 15 1 Refer to diagram 15 14 and gain access through the plastic maintenance cover Remove the retaining clip Remove the automatic air vent SAFETY Fit the new automatic air vent and O ring ensuring the vent DISCHARGE cap is left loose VALVE Refill vent and pressurise the boiler Diagram 15 13 56 15 Replacement of Parts 15 20 Low Water Pressure Sensor For access refer to section 15 1 Drain the boiler heating circuit as described in the appropriate section of 15 1 Refer to diagram 15 15 Disconnect the electrical leads Remove the retaining clip remove the low water pressure sensor Fit new O ring Fit the new low water pressure sensor Refill vent and pressurise the boiler 15 21 Automatic Bypass and Housing For access refer to section 15 1 Drain the boiler heating circuit as described in the appropriate section of 15 1 Refer to diagram 15 16 Remove the retaining clip to remove the automatic by
38. LAT ROOF WEATHER COLLAR Part No 2000460478 WEATHER COLLAR Part No 2000460479 0 80mm 90 ELBOW Part No A2011400 0 80mm 45 ELBOW x2 Part No A2011300 6987 Diagram 10 26 32 10 12 Twin flue The twin flue system is available as an option when the top horizontal or vertical flue system is not appropriate The system can provide an independent horizontal air inlet and flue outlet horizontal air inlet and vertical flue outlet or vertical air inlet and flue outlet via a concentric terminal The system is made up from accessories see diagram 10 26 NOTE The air and flue outlets do not have to be equal lengths 2x45 bends can replace 1x90 bend if necessary The maximum permitted combined air inlet flue outlet flue length is 40 metres plus terminal assemblies for each 90 or 45 x 2 bends fitted the maximum length must be reduced by 1 metre see diagram 10 25 NOTE When using 90 bends any horizontal run should be inclined by a minimum of 44mm metre 2 5 towards the boiler to facilitate condense removal Alternatively use 45 bends to avoid horizontal runs in the flue pipe Multiple Boiler Chimney Flue Length The flue length must be calculated and installed according to the relevant standards EN 13384 1 and 2 C43 flue systems only with reference to the table below and the manufacturers instructions supplied The appliance maximum flue length must be included when calculating th
39. 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 Boiler Design Boiler Design This boiler is designed to provide central heating from a sealed water system with a fully indirect cylinder pumped circulation The pump expansion vessel and associated safety devices are all fitted within the boiler The integral programmer is designed for both simple operation and maximum control Once the controls are set the boiler will operate automatically Condensate Drain A plastic drain pipe must be fitted to allow discharge of condensate to a drain Condensate should if possible be discharged into the internal household draining system If this is not practical discharge can be made externally into the household drainage system or a purpose designed soak away see section 9 for more details Pluming from flue terminal Like all condensing boilers this appliance will produce a plume of condensation from the flue terminal in cool weather This is due to the high efficiency and hence low flue gas temperature of the boiler This is normal and not an indication of a fault Safety Devices Electrical Supply Failure The boiler will not work without an electrical supply Normal operation of the boiler should resume when the electrical supply is restored Reset an
40. S ELECTRICAL PLUG Diagram 13 5 SECURING SCREW 4 OFF FRONT INSULATION 9926 GASKET SPARK ELECTRODE Diagram 13 6 43 13 Servicing SECTION THROUGH BURNER DOOR SHOWING POSITION OF SEAL SEAL 2 SS if 2 NYLOC SECURING NUTS 5 OFF GAS PIPE BRACKET AND SEAL 13 4 Combustion Chamber and Heat Exchanger Remove loose debris from inside the heat exchanger using a soft brush and vacuum cleaner Carefully flush by spraying water into the heat exchanger any remaining debris should pass through the condensate trap Ensure the water is kept away from electrical components 13 5 Inner Casing Panel Seal check Check the condition of the seal if worn or damaged remove the seal and thoroughly clean the casing surface before fitting the new seal see diagram 13 8 Refit the inner casing panel NOTE Ensure the seal is fitted correctly giving an airtight joint 13 6 Service Completion Re check the combustion as described at the beginning of this section On completion of the service the Benchmark Service Record should be completed 44 N COMBUSTION yp CHAMBER Diagram 13 7 5 FRONT CASING PANEL gt CASING Diagram 13 8 14 Fault Finding 14 1 Preliminary fault finding The following checks should be performed before proceeding onto specific diagnostics Check the ext
41. S6700 BS7074 Part 1 and 2 BS7593 BS7671 IE 1 5 813 BS5546 BS 5449 BS 7074 BS 7593 NOTE For further information see the current issue of the Building Regulations approved document L1 in the UK and the following current issues of 1 Central heating system specification CheSS and 2 Controls for domestic central heating system and hot water BRECSU Gas Supply The gas installation must be in accordance with the relevant standards In GB this is 56891 In IE this is the current edition of I S 813 Domestic Gas Installations The supply from the governed meter must be of adequate size to provide a steady inlet working pressure of 20mbar 8in wg at the boiler On completion test the gas installation for tightness using the pressure drop method and suitable leak detection fluid purge in accordance with the above standard 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
42. agnetic com EN 61000 3 3 patibility Any change to the appliance and or any use not according to the instructions will lead to the invalidation of this Declaration of Conformity Belper September 2006 0 place date Program Manager Certification Manager S Keeton A Beardsley Vaillant GmbH Berghauser Str 40 D 42859 Remscheid main phone no 49 21 91 18 0 1 Telefax 49 21 91 18 28 10 Ltd company Registered office Remscheid Registry court Amtsgericht Wuppertal HRB 11775 Directors Dr Michel Brosset Claes G ransson Chairman of the Supervisory Board Gert Kr ger Commerzbank Remscheid code 340 400 49 account no 621 833 300 USt Ident Nr DE 811142240 H Work DataDelaration of Conformity Dec Ulttracom sxi doc 10 12 2001 shr 63 0 020020821 0020020821 04 09 09 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
43. ce 01773 828100 Technical Helpline 01773 828300 General and Sales enquiries Tel 01773 824639 Fax 01773 820569 To register your Glow worm appliance call 0800 0732142 Benchmark places responsibilities on both manufacturers and installers The purpose is to ensure that customers are provided with the correct equipment for their needs that it is installed commissioned and serviced in accordance with the manufacturer s instructions by competent persons and that it meets the requirements of the appropriate Building Regulations The Benchmark Checklist can be used to demonstrate compliance with Building Regulations and should be provided to the customer for future reference Installers are required to carry out installation commissioning and servicing work in accordance with the Benchmark Code of Practice which is available from the Heating and Hotwater Industry Council who manage and promote the Scheme Visit www centralheating co uk for more information pen chinan THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS These instructions consist of Installation Servicing Fault Finding Replacement of Parts and Spares The instructions are an integral part of the appliance and must to comply with the current issue of the Gas Safety Installation and Use Regulations be handed to the user on completion of the installation CONTENTS DESCRIPTION SECTION PAGE Warnings
44. centric stack flue suitable for use with Top horizontal telescopic flue Top standard horizontal flue Twin Flue as specified by the manufacturer Vertical Flue Vertical Flue Adapter concentric flue 60 100 Part No A2024600 Section 10 page 28 Vertical flue terminal kit concentric flue 060 100 Part No 2000460480 Section 10 page 27 Diagram 4 1 10 4 Flue Options and Terminal Clearances UNDER CAR PORT etc 11508 HORIZONTAL FLUES A DIRECTLY BELOW AN OPENING AIR BRICK OPENING WINDOWS 300 B ABOVE AN OPENING AIR BRICK OPENING WINDOWS 300 C HORIZONTALLY TO AN OPENING AIR BRICK OPENING WINDOWS 300 D BELOW GUTTER DRAIN SOIL PIPE 25 E BELOW EAVES 25 F BELOW A BALCONY OR CAR PORT 25 G FROM VERTICAL DRAIN PIPES AND SOIL PIPES 25 FROM INTERNAL EXTERNAL CORNERS 25 H TOABOUNDARY ALONGSIDE THE TERMINAL 300 ABOVE ADJACENT GROUND OR BALCONY LEVEL 300 J FROM SURFACE OR A BOUNDARY FACING THE TERMINAL 600 FACING TERMINALS 1200 L FROM OPENING DOOR WINDOW IN CAR PORT INTO DWELLING 1200 M VERTICAL FROM A TERMINAL 1500 N HORIZONTALLY FROM A TERMINAL 300 VERTICAL FLUES P FROM ANOTHER TERMINAL 600 Q ABOVE ROOF LEVEL 300 R FROM ADJACENT OPENING WINDOW 1000 S FROM ADJACENT WALL TO FLUE 300 Diagram 4 2 4 1 Flue Options There are various flue options to choose from as illustrated in diagram 4 1 The flue l
45. ch as mortar filings or swarf are cleared from the flue system before completion Long lengths of flues must be secured to the walls or ceilings they run against Use at least one fixing bracket for every flue extension that is used After cutting inner flue tubes ensure that you de burr and chamfer the male tube end to prevent damage Inspect the flue pipes before fitting and do not install damaged or dented flue components When assembling the flue system ensure that the inner seals are not damaged do not install a flue component with a damaged seal When fitting flue elbows ensure that they are fitted at the correct angle to avoid strain this will ensure that the seal fits correctly preventing leakage Remove the flue elbow Separate the flue duct from the terminal by twisting to release the terminal catch then pull out of the retaining seal refer to diagram 10 16 The flue duct cutting length L 11mm is shown in diagram 10 16 The air duct should be cut at the opposite end to the terminal The plastic flue duct MUST be cut at the opposite end to the terminal catch The plastic flue duct extensions MUST be cut at the opposite end to seal Insert the flue duct into the air duct terminal assembly remembering to engage the catch within the terminal Fit the sealing collar behind the locating lugs on the flue terminal see diagram 10 17 Push the flue assembly into the wall externally or internally initially unt
46. chniques 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 per son is performing lift straddle the load tilt and place carton into posi tion on truck Recommend secure appliance onto truck with suitable straps Ensure safe lifting techniques are used keep back straight bend using legs Keep load as close to body as possible If 2 persons performing lift ensure co ordinated movements during lift Clear the route before attempting the lift If removing boiler from truck straddle the load and tilt forwards to facilitate secure grip Ensure safe lifting techniques are used keep back straight bend using legs Do not twist reposition feet instead Take care to avoid trip hazards slip pery or wet surfaces and when climbing steps and stairs Always use assistance if required Carriage of carton from point of delivery to point of installation first or higher floor cellar Recommend 2 person lift or 1 person with use of sack truck If 1 person is performing lift straddle the load tilt and place carton into position on truck Recommend secure appliance onto truck with suitable straps Ensure safe lifting techniques are used k
47. consideration to terminal clearances mentioned in Section 4 2 drill the one or two holes as required with a 90mm core drill Push the horizontal terminal through the wall allowing approx 100mm to protrude outside Push a grey rubber wall seal onto either side of the wall ensuring that both wall seals are pushed up to the wall surface see examples b and c diagram 10 25 SECURING SCREW 4 SEALING PLUG 13240 TWIN FLUE 9 ADAPTER Diagram 10 27 Vertical Terminal Installation With due consideration to terminal clearances mentioned in Section 4 2 project the rise of the flue pipe to roof level and cut 150mm hole in the roof a Pitched Roof Fit the required pitched roof weather collar over the 150mm hole in the roof Make good the tiling or slating around the collar incorporating the flashing of the weather collar Position the angle cap over the weather collar in the correct orientation to attain the correct angle for your roof One way round gives a pitch of 25 38 and the other gives 37 50 b Flat Roof Fit the aluminium weather collar over the 150mm hole in the roof ensuring a weather tight seal Horizontal Pipes Completion of Installation Having built the pipe s from the boiler to the terminal s the length of the final pipe piece can be determined Cut pipes at the opposite end to the O ring seal making square and free from burrs Push the horizontal terminal through the
48. d if persons could come into contact with the terminal or the terminal could be subject to damage If a terminal guard is required it must be positioned to provide minimum of 50mm clearance from any part of the terminal and be central over the terminal The guard should be similar to that shown in diagram 4 3 A suitable guard is manufactured by Tower Flue Components Morley Rd Tonbridge Kent TN9 1RA Size 280mm x 165mm Part No CGDK3 6864 Diagram 4 3 11 5 Water System 5 1 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 An options board accessory is available to link the internal programmer with a Honeywell S or Y plan system 5 2 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 not discharge above an entrance window or any type of public access area 5 3 Expansion Vessel The boiler has an integral expansion vessel with a capacity of 8 litres 1 76 gallons with a charge pressure of 0 5bar NOTE The expansion vessel volume depends on the total water system volume and the initial system design pressure In 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 Dom
49. d in accordance the rules in force in the countries of destination Manufacturer s instructions must not be taken as overriding statutory requirements Statutory Requirements In GB the installation of the boiler must comply with the requirements of the current issue of BS6798 and be carried out by a competent person approved at the time by the Health and Safety Executive and as described in the following regulations The manufacturer s instructions supplied The Gas Safety Installation and Use Regulations The appropriate Buildings Regulations either The Building Regulations The Building Regulations Scotland The Building Regulations Northern Ireland The Water Supply water fittings Regulations 1999 and water byelaws 2000 Scotland The Health and Safety at Work Act Control of Substances Hazardous to Health COSHH The Current I E E Wiring Regulations Where no specific instructions are given reference should be made to the relevant British Standard Code of Practice In IE the installation must be carried out by a competent person approved at the time by the Health and Safety Executive and installed in accordance with the current edition of 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 B
50. e or changed parts the following must be checked e The integrity of the flue system and flue seals e The integrity of the appliance combustion circuit and relevant seals e Electrical gas and water connections e System pressure e the combustion performance refer to the following procedure e The operational gas inlet pressure and gas rates refer to the commissioning section paragraph 12 5 Correct any fault before continuing COMPETENCY TO CARRY OUT THE CHECK OF COMBUSTION PERFORMANCE NOTE BS 6798 2009 Specification for installation and maintenance of gas fired boilers of rated input not exceeding 70kW net advises that e The person carrying out a combustion measurement must be assessed as competent in the use of a flue gas analyser and the interpretation of the results e The flue gas analyser used should be one meeting the requirements of BS7927 or BS EN50379 3 and be calibrated in accordance with the analyser manufacturers requirements e Competence can be demonstrated by satisfactory completion of the CPA1 ACS assessment which covers the use of electronic portable combustion gas analysers in accordance with BS 7967 parts 1 to 4 e Ensure that the gas analyser is set to the correct fuel setting e Select the central heating function by pressing the Mode button repeatedly refer to commissioning section The boiler should fire automatically NOTE Safe combustion can only be verified by measurin
51. e overall design of the flue system Terminal Position The clearances for a flue outlet are given in the Flue Location and Ventilation section In addition the horizontal air inlet must not be closer than 300 mm from a flue outlet on the same wall or 1200mm from an opposing flue outlet Exhaust mass rate g s At Min Thermal Load 40C 30 C At Max Thermal Load 80C 60 C Exhaust temperature C At Min Thermal Load 40C 30 C At Max Thermal Load 80C 60 C 10 Twin Flue Length Preparation and Installation Installation Details The parts available for a twin flue system installation are shown in diagram 10 26 Boiler Connection IMPORTANT The flue seals are sensitive to mineral oil based lubricants Do not grease the seals If the seals do need to be lubricated use only water Push the twin flue adaptor onto the outlet of the boiler with the air inlet to the left hand side see diagram 10 27 Secure the adaptor to the top panel with the screws provided Care should be taken when inserting the screw through the hole in adaptor top Air and Flue Pipe Installation The air and flue pipes can now be built up from the boiler The flue must be designed with a continuous fall towards the boiler If using the horizontal flue pipe or 90 bends the pipe must be inclined at 44mm metre 2 5 minimum see diagram 10 25 Alternatively if space allows use 45 bends in place of 90 be
52. eep back straight bend using legs Keep load as close to body as possible If 2 persons performing lift ensure co ordinated movements during lift Avoid upper body top heavy bending do not lean forward sideways Clear the route before attempting the lift If removing boiler from truck straddle the load and tilt forwards to facilitate secure grip Ensure safe lifting techniques are used keep back straight bend using legs Do not twist reposition feet instead Take care to avoid trip hazards slippery or wet surfaces and when climbing steps and stairs Always use assistance if required Carriage of carton from point of delivery to point of installation roofspace Recommend 2 person lift Ensure co ordinated movements during lift Avoid upper body top heavy bending do not lean forward sideways Clear the route before attempting the lift Take care to avoid trip hazards slippery or wet surfaces and when climbing steps and stairs When transferring appliance into roofspace recommend 1 person to be in roofspace to receive the appliance and other person to be below to pass up and support appliance Ensure safe lifting techniques are used keep back straight bend using legs Keep load as close to body as possible Always use assistance if required It is assumed safe access flooring and adequate lighting are provided in the roof space It is recommended a risk assessment of the roof space area be carried out before moving
53. egrity of the complete flue system and combustion circuit seals have been verified and the inlet gas pressure and gas rate have been verified then it will necessary to adjust the combustion rate of the appliance NOTE Adjustment is made by turning the gas valve throttle an of a turn waiting 1 minute to allow the appliance to stabilise before checking or making further adjustments e Rotate the throttle anti clockwise to increase to the required CO2 refer to diagram 12 5 and the SETTING column in the table e Exit the forced rate function press the mode and buttons simultaneously this will reset the boiler to the default display Now proceed to check the minimum rate adjustment 2 Minimum Rate Check and Adjustment e Now check the minimum gas rate 2 setting Press and release the reset button on the controls fascia then immediately press and hold in either of the buttons After approximately 5 seconds Hi will be displayed Pressing the or buttons will toggle between and Lo Press the mode button when Lo is selected this will force the boiler to minimum rate and the display will flash Lo indicating the boiler is operating at minimum e Wait until the CO2 value is stable and check that the value is within the range specified in table in the check column If adjustment is necessary proceed as follows NOTE Adjustment of the CO2 at minimum rate is
54. engths and installation are described in section 10 4 2 Flue Terminal Position In GB the minimum acceptable siting dimensions for the terminal from obstructions other terminals and ventilation openings are shown in diagram 4 2 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 Being a condensing boiler some pluming may occur from the flue outlet This should be taken into consideration when selecting the position for the terminal Carports or similar extensions of a roof only or a roof and one wall require special consideration with respect to any openings doors vents or windows under the roof Care is required to protect the roof if made of plastic sheeting If the carport comprises of a roof and two or more walls seek advice from the local gas supply company before installing the boiler H and J See diagram 4 2 These dimensions comply with the building regulations but they may need to be increased to avoid wall staining and nuisance from pluming depending on site conditions NOTE 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 4 3 Terminal Guard A terminal guard is require
55. ernal electrical supply to the boiler is on and a supply of 230V is present at the L and N terminals on the installer interface refer to section 11 4 for access and diagram 14 4 Check the electrical installation and appliance carry out tests for earth continuity polarity short circuit and resistance to earth using a suitable multimeter An aid to test Remove the front casing panel see diagram 13 2 and the control panel securing screw then lower into service the position Remove the rear panel by prising the retaining clips see diagram 14 1 Carry out the tests at connector plug X17 see diagram 14 2 Check chassis earth at a bare metal point on the boiler Check that there is a gas supply to the boiler and the gas service isolation valve is turned on see diagram 12 1 Check pressure at the gas service isolation valve refer to section 12 5 Check that the heating system pressure indicates at least 1mb if not fill and vent the system as described in section 12 6 Check that all external controls are on Check the functional flow diagram 14 5 14 2 Fault Codes Fault codes take priority over all other display functions in the event of a fault occurring refer to diagram 14 6 If multiple faults occur the codes will be displayed for approx 2 seconds alternatively 14 3 Fault Memory The Fault memory stores details of the ten most recent faults To access this menu refer to diagram 14 3
56. estic Gas Installations 5 4 Flow Rate If itis necessary to alter the flow rate the system can be fitted with a lockable balancing valve in the main flow or return pipes shown as valve A in diagram 5 1 The flow rate through the boiler must not be allowed to fall below that given in section 1 Specification Table 5 5 Bypass The boiler is fitted with 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 section 1 Specification Table 5 6 Filling the Sealed System Provision for filling the system at low level must be made see diagram 5 2 There must be no permanent connection to the mains water supply even through a non return valve NOTE It is important that fittings used for connection to potable water comply with the water undertakings requirements 5 7 Draining Points Draining taps must be provided at all the low points of the system which will allow the entire system to be drained Draining taps shall be to the current issue of BS2879 Drain points for the appliance are provided at the positions shown in diagram 8 1 5 8 Domestic Hot Water Cylinder SINGLE FEED INDIRECT CYLINDERS ARE NOT SUITABLE AND SHOULD NOT BE USED The domestic hot water cylinder must be of the double feed indirect coil type It must be suitable for working at a gauge pressure of 0 35bar above the safety valve settin
57. g 12 gt BOILER 222 ADDITIONAL EXPANSION VESSEL if required HEATING CIRCUIT FLOW CONTROL VALVE DRAIN POINT Diagram 5 1 5 9 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 should be carried out in accordance with BS7593 2006 using a cleanser such as Sentinel X300 or X400 Fernox Restorer or Salamander corrosion guard cleaner IMPORTANT Ensure all cleanser is removed from the whole system before adding an inhibitor For long term corrosion protection after flushing an inhibitor suitable for stainless steel exchangers should be used refer to the current issue of BS 5449 and BS 7593 on the use of inhibitors in central heating systems Examples are Sentinel X100 Fernox Protector or Salamander corrosion guard inhibitor 5 Water System BOILER FLOW RETURN HEATING CIRCUIT CONTROL HOSE VALVE UNION DRAIN POINT Method 1 SUPPLY PIPE CONTROL VALVE DOUBLE CHECK VALVE HOSE UNION J TEMPORARY CONNECTION LOSEL BOILER TYPE CA BACKFLOW PREVENTION DEVICE FLOW RETURN CONTROL VALVE CONTROL SUPPLY PIPE HEATING CIRCUIT m GAP DRAIN TUNDISH POINT Method 2 Diagram 5 2 13
58. g CO CO2 ratio This must not exceed the value shown in the table opposite COMBUSTION CHECK AND SETTING THE AIR GAS RATIO VALVE e Remove the front casing panel see diagram 13 2 and hinge down the control box Taking care not to touch any internal components proceed as follows e Connect the CO2 combustion analyser to the relevant test point see diagram 13 1 FLUE ELBOW ch o VERTICAL FLUE ADAPTOR COMBUSTION ANALYSER SAMPLE POINT Diagram 13 1 G31 BURNER CO2 CHECK SETTING CO CO2 10 1 0 3 10 0 to 11 0 0 004 G20 BURNER CO2 CHECK SETTING CO CO2 0 2 85t09 6 9 1 os 0 004 0 2 30sxi 851096 9 1 0 004 41 13 Servicing 1 Maximum Rate Check and Adjustment NOTE To verify the maximum gas rate CO2 setting the appliance must be checked at the maximum rate first Press the reset button on the controls fascia release and immediately press and hold in the button After approximately 5 seconds will be displayed Pressing the mode button when Hi is selected will force the boiler to maximum rate the display will flash between and the default display this will indicate the boiler has been forced to maximum Wait until the CO2 value is stable and check that the value is within the range specified in table in the check column If the combustion reading is not within the acceptable values AND the int
59. he MODE button for 5 seconds The display will change to flashing 47 b Use the or buttons to scroll to 85 This is the installer level access password c Press MODE to confirm see diagnostic display 1 Diagnostic value D E asse number 097 Diagnostic display 1 Diagram 14 6 E Use the or buttons to view the appropriate diagnostic number see diagram 14 7 If necessary the values can be changed by a Pressing the MODE button b The diagnostic value flashes see diagnostic display 2 Diagnostic display 2 Use the and buttons to cycle through available values d The change is saved by pressing MODE once more NOTE Only certain parameters can be adjusted To exit the diagnostic menu press and hold the MODE button for 5 seconds 49 14 Fault Finding 50 Diagnostic Menu Level 1 Installer Access 2 Display Description Range 4 0 Heating part load Adjustable heating part load in kW factory setting max output d 1 Water pump over run time for heating mode 2 60 min factory setting 5 min d 2 Max burner anti cycling period at 20 C Flow temperature 3 60 min factory setting 20 min d 4 Tank temperature in C 99 will be displayed Reserved for future use d 5 Flow temperature setpoint In 9C min 38 and max 82 d 8 External cont
60. he gas valve note its orientation in relationship to the fan Remove the three securing screws which also secures the plastic swirl plate to the venturi on the fan see diagram 15 2 Withdraw the gas valve After assembly test for gas tightness and purge in accordance with the current issue of BS6891or in IE the current edition of 1 5 813 Domestic Gas Installations Check the combustion CO and adjust if necessary see section 13 15 6 Fan For access refer to section 15 1 Refer to section 13 3 for removal of the fan gas valve and burner assembly Remove the gas valve as described in section 15 5 Remove the two securing screws nuts and washers to separate the fan from the gas manifold extension tube and gas manifold see diagram 15 3 After assembly test for gas tightness and purge in accordance with the current issue of BS6891or in IE the current edition of 1 5 813 Domestic Gas Installations 15 7 Burner For access refer to section 15 1 Refer to section 13 3 for removal of the fan gas valve and burner assembly Remove the four screws that secure the burner see diagram 13 6 NOTE The burner will require a new gasket 15 8 Front Insulation For access refer to section 15 1 Refer to section 13 3 for removal of the burner module Remove burner as described in section 15 7 Remove spark electrode see section 15 2 NOTE The burner will require a new gasket when refitted 15 9 Rear Insulation Fo
61. id replacement of parts To hinge a side panel undo and remove the three screws securing each side panel to the boiler two at the front and one at the top Draining of Boiler Heating Circuit Drain down the Heating Circuit of the boiler only by closing the heating flow and return isolating valves see diagram 12 2 Attach a length of hose to the drain point and open the drain valve see diagram 12 1 After servicing or replacing parts close the drain valve and remove the hose Open the heating flow and return isolating valves and refill vent and pressurise the heating circuit See section 12 1 Check for leaks 15 2 Spark Electrode For access refer to section 15 1 Refer to section 13 2 for removal 15 3 Igniter Unit For access refer to section 15 1 Remove ignition lead and electrical connections then remove igniter unit by removing two securing screws see diagram 15 1 15 4 Ignition Lead For access refer to section 15 1 Pull the spark plug style connector off the spark electrode refer to diagram 13 5 and the spade connector connected to the igniter unit see diagram 15 1 52 IGNITER BRACKET IGNITER UNIT 5 SECURING SCREW R IGNITER SECURING BRACKET IGNITION LEAD ELECTRICAL CONNECTIONS PLUG Diagram 15 1 15 Replacement of Parts 15 5 Gas Valve For access refer to section 15 1 Refer to section 13 3 for removal of the fan gas valve and burner assembly Before removing t
62. il the end of the assembly protrudes a short way from the inside face of the wall This will enable the internal trim ring if required to be positioned and allow the flue assembly to be drawn back into the flue elbow Secure the flue elbow in position on top of the boiler with four torque headed screws supplied Draw the flue assembly from wall and engage the flue duct into the elbow and butt fit between the air duct and flue elbow Fit the securing collar into position Ensuring correct alignment of the flue mark through two of the pre drilled holes in the securing collar Remove securing collar and drill two 3mm diameter holes one in the elbow and one in the air duct take care not to pierce the inner flue duct Fit the securing collar and secure with screws provided see diagram 10 17 Slide the internal trim ring back against the wall securing in place with a small amount of sealant if required NOTE If the air and flue ducts have been correctly cut to the instructions the sealing collar should fit flush with the outside wall 10 Vertical Flue Length Preparation and Installation 10 11 Vertical flue The vertical flue system is available as an option where the boiler position does not permit the use of the top horizontal flue system The system is made up from accessories The accessories include terminal assembly bends 45 87 59 flue extensions fixing bracket and appropriate weather collar see diagram 10 19
63. inal in cool weather This is due to the high efficiency and hence low flue gas temperature of the boiler e Advise the user of the precautions necessary to prevent damage to the system boiler and the building in the event of the heating system being out of use during frost or freezing conditions e Advise the user that the permanent mains electrical supply SHOULD NOT be switched off as the built in frost protection and pump valve saver program will not operate e Advise the User if the mains electricity and gas are to be turned off for any long periods during severe weather it is recommended that the whole system including the boiler should be drained to avoid the risk of freezing NOTE Contact your installation servicing company as draining refilling and pressurising MUST be carried out by a competent person approved at the time by the Health and Safety Executive e Leave these instructions and the Benchmark service record with the user COVER PLATE Diagram 12 4 39 12 Commissioning Nat Gas G20 to LPG G31 Conversion 12 9 LPG CONVERSION all models As an option a chargeable boiler only commissioning service can be provided by Glow worm Service by calling telephone No 01773 828100 NOTE Steps 12 1 and 12 3 will need to be completed before the appliance can be converted This conversion should only be carried out by a competent person approved at the time by the Health and Safety Executi
64. ioning 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 2 persons lift appliance to position into place space per mitting Fit bracket securely onto wall before lifting appliance into po sition Obtain firm grip on front and sides of appliance lift upwards ensure stable balance achieved and lift upwards to drop into place onto bracket If 2 persons positioning onto bracket obtain firm grip at front and sides base of boiler Ensure co ordinated movements during 2 person lifts to ensure equal spread of weight of load If 1 person po sitioning onto bracket recommend obtain firm grip supporting base of boiler Ensure safe lifting techniques are used keep back straight bend using legs when lifting load from floor level Do not twist repo sition feet instead Keep boiler as close as possible to body throughout lift to minimise strain on back Always use assistance if required Rec ommend wear suitable cut
65. is 3 5 to 4 5 mm Check the electrode gasket for signs of damage and replace if necessary SPARK GAP 4mm EZZEL GASKET 13 3 Burner NOTE The following procedure will require that you replace the burner door seal and nyloc nuts e Removal of the burner is not necessary during a normal service but if it is removed it will require a new gasket see diagram 13 6 e When replacing ensure that the sealing grommet situated below the gas valve is correctly re seated Remove the gas pipe retaining clip Disconnect the gas valve electrical plug at the gas valve see diagram 13 5 Disconnect the electrical plug from the fan Disconnect the spark electrode plug and earth lead refer to diagram 13 5 Remove the five combustion chamber burner door securing nuts see diagram 13 7 these should be discarded and replaced with the new nylocs nuts supplied in the burner door seal kit Gently remove the fan gas valve and burner assembly from the combustion chamber Clean the burner with a soft brush taking great care not to damage the front insulation DO NOT use wire or sharp instruments to clean the holes of the burner Inspect the burner for any signs of damage Remove and discard the burner door seal and replace with new see diagram 13 7 SECURING SCREW 2 OFF EARTH LEAD Diagram 13 4 SPARK ELECTRODE EARTH LEAD PLUG NN JT 2 FAN ELECTRICAL GAS VALVE PLUG amp LEAD
66. is blocked Check flow amp return thermistor connections to pipes Check harness connection to thermistor Check harness wires are not trapped between any internal components Diagram 14 8 15 Replacement of Parts 15 1 General IMPORTANT The replacement parts described in sections 15 5 to 15 9 and section 15 12 will require the removal of the burner module assembly and the replacement of the burner door seal and self locking nuts Replacement parts that have associated components that need replacing on removal i e O ring seals gasket etc will be supplied and should be fitted Replacement of parts must be carried out by a competent person approved at the time by the Health and Safety Executive Before replacing any parts of the boiler it should be isolated from the mains electric supply and the gas should be turned off at the gas service isolation valve on the boiler see diagram 12 1 Unless stated otherwise parts are replaced in the reverse order to removal After replacing any parts always test for gas tightness and if necessary carry out functional test of the controls Boiler Access For replacement of parts the front casing and the inner casing panel of the boiler will need to be removed To remove undo the two screws on the underside of the front casing and lift off Undo the two screws on the front of the inner front panel and lift off The side panels can be hinged sideways and removed to a
67. le hose see diagram 15 7 Undo the two nuts of the flow and return pipes from the heat exchanger Move the pipes away from the heat exchanger Slacken the three heat exchanger securing screws and clamps two at the top and one at the bottom to remove the heat exchanger see diagram 15 8 CAUTION There will be water in the heat exchanger Remove condense pipe connector from bottom of heat exchanger Carefully ease heat exchanger out FIBRE WASHER Goas 9 1 gt B WESS CIRCLIP STEEL WASHER Diagram 15 5 54 15 13 Flue Hood For access refer to section 15 1 Remove heat exchanger as per section 15 12 Remove the two securing screws and pull the flue hood down and away from the flue hood bracket and flue elbow see diagram 15 9 SECURING BOLT UPPER SUPPORT BRACKET EXPANSION VESSEL LOWER SUPPORT BRACKET COUPLING Diagram 15 6 a ENSE HOSE ECURING CLIP Diagram 15 7 15 Replacement of Parts 15 14 Heating Flow Thermistor For access refer to section 15 1 Refer to diagram 15 10 Remove the electrical connections from the thermistor Remove the retaining clip from the flow pipe NOTE When reconnecting the polarity of the wiring to thermistors is not important 15 15 Heating Return Thermistor For access refer to section 15 1 Refer to diagram 15 10 Remove the electrical connections from the thermistor Remove the retaining c
68. lip from the return pipe NOTE When reconnecting the polarity of the wiring to thermistors is not important 15 16 Condense Trap and Siphonic Drain For access refer to section 15 1 Refer to diagram 15 11 Remove the igniter unit as described in section 15 3 to improve accessibility SECURING SCREWS 2 AND CLAMPS S PA Diagram 15 8 4 FLUE HOOD SECURING SCREWS Diagram 15 9 Remove the securing clip from the heat exchanger adapter then disconnect the adapter and flexible hose Lift the siphon adapter and hose out of the condensate trap and siphonic drain do not disconnect the hose Disconnect the drain connection Slacken to disengage but do not remove the two securing screws The condense trap will contain water lift taking care not to spill the water After replacement and before fitting the adapter fill the trap with water Cleaning Remove the condense trap as previously described Remove the float to clean it Remove any solids found Flush water through the trap to remove any remaining solids Check for any debris in the outlet hose of the condensate drain and clean as necessary 2 EXCHANGER Z2 HEATING RETURN THERMISTOR HEATING FLOW THERMISTOR in Diagram 15 10 5 R ADAPTER FLOAT CONDENSATE TRAP AND SIPHONIC DRAIN gt g 0 TUR Diagram
69. n heating mode Quantity d 90 External intelligent control connect 1 identified 0 unidentified eBUS Address lt 1 0 d 91 Internal Programmer type 0 24 hour default 1 7 day d 92 Enable Disable Internal Programmer 0 CH Off DHW Off 1 CH Off DHW On 2 CH On DHW Off Default 3 CH DHW On d 97 Activation of the second diagnostic level Password needed d 99 State List see State Lists table Indicates read and write function all other diagnostics are read only Diagram 14 7 14 Fault Finding State list Accessed through Diagnostic Codes Level 1 Installer Access d 99 STATE LISTS Central heating mode Priority 3 Possible Causes no heating required fan pre run pump pre run ignition burner on pump fan overrun fan overrun pump overrun Anti cycling period Domestic hot water mode Priority 2 domestic hot water demand fan pre run ignition burner on pump fan overrun fan overrun pump overrun Cycling preheat mode Priority 1 domestic hot water cycling mode active fan pre run Pump pre run ignition burner on pump fan overrun fan overrun pump overrun Anticycling period Special cases of status messages No Heating demand from external controls 230V Check wiring in external controller Check wiring at Installer Interface summer mode Check CH
70. nal installation Remove the wall template whilst drilling the flue hole Base Coverplate Hanging Bracket 3 Pipe Pack 0020029672 Electrical A Central Heating x 2 Cartridge B Gas C Saftey Discharge A 9 11 Retaining Screws Stored in cartridge Gas and Water Isolating Valves Loose Items Pack 0020036801 discard addtional items within this pack A Large Sealing Washers B Union Nut and Sealing Washer D ion Pack C Gas ocumentation ac A Q S not illustrated N B Wall Template User Instructions C Installation and Servicing Instructions Diagram 6 1 14 6 Installation Preparation WALL TEMPLATE 2 5 44mm metre inclined extended flue length zT 6 90 9861 Preferred fixing points Standard flue length Horizontal Diagram 6 2 6 4 Flue Hole Cutting External access flue installation can use a 105mm diameter core drill Internal access only flue installation will need a 125mm diameter core drill NOTE The flue is designed with an internal fall of 44mm metre 2 52 therefore the hole can be drilled horizontally If flue extension pipes are to be used then a core drill size of 125mm is required This will allow the extension pieces to slope at 44mm metre 2 5 towards the boiler 7 Boiler Fixing 7 1 Hanging Bracket Fixing The Wall Hanging Bracket is supplied in the main boiler packaging at the rear
71. nal 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 37 12 Commissioning Additionally the safe nominal maximum heat input of the appliance can be achieved at an inlet pressure down to 15mbar NOTE The BURNER PRESSURE cannot be measured and is not used to measure the gas rate Gas Rate Make sure that ALL other gas burning appliances and pilot lights are off 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 approx after 10 mins from cold MAX m h MIN MAX kg hr kg hr 71 0 0 39 1 47 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 mh ft h On completion press the mode and buttons simultaneously this will reset the boiler 12 6 Heating Systems Ensure that the external controls are calling for heat Fully open all radiator valves flow control valve if fitted see diagram 5 1 Switch on the appliance and ensure that the central heating is calling for heat Balance the radiators as required and if fitted adjust valve to give the required system differential Turn off all radiator
72. nce It is therefore important that no alteration is made to the boiler without permission in writing by Glow worm Any alteration not approved by Glow worm could invalidate the certification boiler warranty and may also infringe the current issue of the statutory requirements Statutory Requirements CE Mark This boiler meets the requirements of Statutory Instrument No 3083 The Boiler Efficiency Regulations and therefore is deemed to meet the requirements of Directive 92 42 EEC on the efficiency requirements for new hot water boilers fired with liquid or gaseous fuels Type test for purposes of Regulation 5 certified by Notified body 0087 Product production certified by Notified body 0086 The CE mark on this appliance shows compliance with 1 Directive 90 396 EEC on the approximation of the laws of the Member States relating to appliances burning gaseous fuels 2 Directive 73 23 EEC on the harmonisation of the Laws of the Member States relating to electrical equipment designed for use within certain voltage limits 3 Directive 89 336 EEC on the approximation of the Laws of the Member States relating to electromagnetic compatibility IMPORTANT Where no British Standards exists materials and equipment should be fit for their purpose and of suitable quality and workmanship The installation of this boiler must be carried out by a competent person approved at the time by the Health and Safety Executive an
73. nds To avoid rain ingress to the air Inlet terminal it is good practice to aim the inlet downwards by approx 2 as rain can damage the boiler The Flue outlet pipe must always run at 44mm metre 2 5 back to the boiler IMPORTANT Long lengths of flues must be secured to the wall or ceiling it runs against Use at least one fixing bracket on each flue joint used or on straight flue runs every joint and for every metre flue run Provision must be made in concealed boxing or ductwork that the flue joints can be inspected during annual servicing The flue seals are sensitive to mineral oil based lubricants Do not grease the seals If the seals do need to be lubricated use only water Do not use the flue pipe to attach other pipes or equipment If visible advise the householder not to hang or clip items to flue pipes Do not stress the flue connections during the installation this can damage the flue seals Horizontal Terminal Installation NOTE The air inlet terminal and the flue outlet terminals must never be installed on the opposite sides of a property Termination must only be on the same wall or adjacent walls When installed close together separated vertically the air inlet must be fitted below the flue outlet terminal see diagram 10 25 The air terminal must not terminate less than 20mm from an adjacent wall or structure and the flue outlet terminal less than 100mm from any adjacent wall or structure With due
74. not applicable Diagram 12 2 12 3 Gas Supply The gas valve is factory set for natural gas G20 and should need no adjustment Turn on the gas supply at the isolation valve see diagram 12 1 Check the supply pressure at the pressure test point is 20mbar 12 4 Initial Lighting NOTE The combustion for this appliance has been checked adjusted and preset at the factory for operation on natural gas G20 as defined on the appliance data label Do not adjust the Gas Air ratio valve No measurement of the combustion is necessary having checked e the appliance has been installed in accordance with the instructions e the integrity of the flue system and flue seals e the integrity of the appliance combustion circuit and relevant seals e thatall internal external controls are calling for heat e the gas service isolation valve diagram 12 1 is open As an option a chargeable boiler only commissioning service can be provided by Glow worm Service by calling telephone No 01773 828100 LPG Conversion See section 12 9 NOTE If you have fitted a Glow worm Options Board Kit please refer to the instructions supplied with the kit for completion of commissioning Do not operate the boiler without water Refer to diagram 12 2 1 With no demand from any external controls switch on the electrical supply to the boiler Open the gas service isolation valve see diagram 12 1 2 Select your required function by p
75. of the boiler Reposition the wall template over the flue hole and mark the position of the fixing holes for the hanging bracket see diagram 7 1 Drill fixing holes and insert suitable wall plugs Preferred WALL fixing points TEMPLATE 067 WALL HANGING PLUG BRACKET SCREW N 12 x 50mm Diagram 7 1 7 2 Boiler Hanging IMPORTANT With regards to the Manual Handling Operations 1992 Regulations the following lift operation exceeds the recommended weight for a one man lift refer to section 17 Manual Handling Lifting the boiler into position lean the top of the boiler slightly to the wall and position just above the hanging bracket Lower the boiler slowly and engage onto the hanging bracket see diagram 7 2 6LVEL Diagram 7 2 15 8 Gas Water Connection 8 1 Systems Connection Remove the protective caps from the boiler connections NOTE The appliance may contain a small amount of water place a water container beneath the boiler connections Assemble and secure the pre formed copper tails to their respective isolation valves making sure of their correct orientation see diagram 8 1 Fit the isolation valves copper tails with seals to the appliance as shown in diagram 8 1 There are flats on the body of the valves for locating a spanner to aid tightening to copper tails NOTE Make sure that the test and drain points are accessible refer diag
76. on 7 Switch the boiler on The boiler should fire automatically NOTE If the appliance does not light and goes to lockout F1 turn the throttle anti clockwise a further turn and press the reset button The appliance will after a short delay again attempt to fire Repeat this procedure up to a total of 2 extra turns on the throttle screw until the appliance lights Several ignition attempts may be needed to purge gas through the appliance before a successful ignition is achieved 8 Check and adjust the burner CO2 at maximum rate Press the reset button on the controls fascia release and immediately press and hold in the button After approximately 5 seconds will be displayed Pressing the mode button when Hi is selected will force the boiler to maximum rate the display will flash between Hi and the default display this will indicate the boiler has been forced to maximum 40 9 If necessary adjust the burner CO2 to the value shown in the SETTING column of the table by turning the throttle screw anti clockwise to increase see diagram 12 5 no more than 1 8 of a turn waiting a minute to allow for the appliance to stabilise before checking or making further adjustments 10 Exit the check sequences press the mode and buttons simultaneously this will reset the boiler to the default display 11 Check the burner CO2 at minimum rate to the value shown in the
77. pass Remove the retaining clips and three securing screws to remove the automatic bypass housing Fit new O rings before replacing the assembly Refill vent and pressurise the boiler MAINTENANCE m RETAINING AUTOMATIC CLIP AIR VENT EN Diagram 15 14 LOW WATER PRESSURE SENSOR NS 51165 E ELECTRICAL LEADS 5 RETAINING CLIP H HYDROBLOCK Diagram 15 15 SECURING SCREW 3 RETAINING CLIP 929 RETAINING one Diagram 15 16 57 15 Replacement of Parts 15 22 Hydroblock and Bypass Tube For access refer to section 15 1 IMPORTANT To replace the bypass tube the LH and RH hydroblocks will need to be removed The following procedure must also be used for the replacement of either the LH or RH hydroblock Drain the boiler heating circuit as described in the appropriate section of 15 1 Isolate the gas supply at the gas service isolation valve see diagram 12 1 Remove the low water pressure sensor from the LH hydroblock refer to section 15 20 Remove the blanking plate see diagram 15 17 Remove clips from the plastic LH hydroblock retaining the primary flow pipes and CH outlet pipe see diagram 15 17 Remove the primary flow pipe from the LH hydroblock Remove the CH filter from the primary flow pipe port in the LH hydroblock The filter is a push fit in the hydroblock port Undo the union nuts on the CH
78. peed incorrect Fan connector loose unconnected faulty or wires trapped Faulty fan Flame goes out whilst lit during a demand Gas tap is closed Gas valve connector is loose unconnected faulty or wires are trapped Ignitor connectors are loose unconnected faulty trapped Faulty Ignitor Low gas inlet pressure Incorrect gas valve adjustment Electrode Ignition leads loose unconnected faulty trapped Electrode broken defective or position incorrect Air inlet blocked flue inlet blocked flue duct leaking Earthing connection loose disconnected Condensate blocked Overheat Boiler has overheated allow to cool then press reset button Central Heating Flow Thermistor connection fault Thermistor wires unconnected faulty trapped Pressure Water pressure connector loose unconnected faulty or wires trapped Water Pressure Sensor faulty Pump ceased faulty Central Heating Return Thermistor connection fault Thermistor wires unconnected faulty trapped Flow and or return NTC faulty Thermistor wires unconnected faulty trapped PCB Memory or sensing fault Gas Valve control defective Loose connections on Main PCB or display PCB Central Heating Flow or Return Thermistor wires unconnected faulty trapped Electrode Ignition leads loose unconnected faulty trapped Earthing connection loose disconnected Gas valve connector loose wires unconnected faulty or tra
79. pped Faulty main board Faulty gas valve eBus Voltage failure Short circuit on eBus overload on eBus If 99C is displayed check that the thermistor wires are unconnected faulty or trapped Diagram 14 6 48 09861 14 Fault Finding Fault Codes continued Low Water pressure or Ignition temperature rise too slow Not enough water in the system Central Heating Flow or Return Thermistor wires loose faulty trapped Central Heating Flow or Return Thermistor not connected to pipe correctly Air in the system Faulty pump or pump speed too fast Central Heating Flow temperature rise too high during operation Central Heating Return temperature rise or temperature difference too high during operation Central Heating Temperature difference between Flow and Return too high during operation Check thermistors are connected to pipes correctly Air in the system System is too restrictive Generic error Check all electrical connections internal amp external Software incompatible Condensate pump error Option Telephone Group Service Trapped faulty wiring blockage in condensate pump NO DISPLAY or Er displayed Check connection from display PCB to main PCB connector X51 Diagnostic Menu The Diagnostic Menu provides the ability to view and change certain parameters See Diagram 14 7 for available parameters To enter the diagnostic menu a Press and hold t
80. ppliances 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 may be susceptible to irritation High dust levels are usual only if the material is broken Normal handling should not cause discomfort but follow normal good hygiene and wash your hands before eating drinking or going to the lavatory If you do suffer irritation to the eyes or severe irritation to the skin seek medical attention Manual Handling With regards to the Manual Handling Operations 1992 Regulations the appliance exceeds the recommended weight for a one man lift refer to section 17 for more information The handling of the boiler may involve lifting pushing and pulling the use of a sack truck may be required The following handling techniques and precautions should be considered Grip the boiler at its base Be physically capable Use safety clothing where appropriate e g gloves safety footwear Ensure safe lifting techniques are
81. r access refer to section 15 1 Refer to section 13 3 for removal of the burner module Remove securing screw and washer in the centre of the insulation and withdraw insulation see diagram 15 4 KY NY A 1 SUP Qu YO 55 VENTURI PLATE 3 SECURING lt i SCREW 3 Diagram 15 2 5 S MANIFOLD SECURING SCREW 2 Diagram 15 3 REAR 2 WASHER INSULATION S HEAT EXCHANGER SECURING SCREW Diagram 15 4 53 15 Replacement of Parts 15 10 Viewing Window For access refer to section 15 1 Refer to diagram 15 5 Remove circlip Remove steel washer Remove glass Remove fibre washer Replace in reverse order 15 11 Expansion Vessel For access refer to section 15 1 Refer to section 15 1 and drain the boiler heating circuit Undo the coupling at the base of the vessel see diagram 15 6 While holding the vessel remove the securing bolt on the top panel of the boiler Remove upper support bracket Fit a new gasket between the expansion vessel and coupling Refill vent and pressurise the boiler Check for leaks 15 12 Heat Exchanger Refer to Manual Handling section For access refer to section 15 1 Refer to section 13 3 for removal of the fan gas valve and burner assembly Refer to section 15 1 and drain the boiler heating circuit Remove the securing clip from the heat exchanger adapter then disconnect the adapter and flexib
82. ram 8 1 Plumb the system pipe work to the copper tails NOTE Do not subject the isolation valves to heat Flush out the heating system before connecting to the boiler refer to section 5 9 The whole of the gas installation including the meter should be inspected tested for tightness and purged in accordance with the current issue of BS6891 and in IE the current edition of 1 5 813 Domestic Gas Installations 16 e A WATER ISOLATION VALVE 2 OFF lt 3 WASHER ISOLATION VALVE Diagram 8 1 9 Safety Discharge Valve and Condensate Connections 9 1 Safety Discharge Valve Take the safety discharge pipe supplied in the pipe pack and the union nut and seal supplied in the loose items pack and fit as shown in diagram 9 1 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 The pipe must have a continuous fall and be routed to a position so that any discharge of water possibly boiling or steam cannot create any danger to persons damage to property or external electrical components and wiring To ease future servicing it is advisable to use a compression type fitting to extend the safety discharge valve tube 9 2 Condensate Trap and Siphonic Drain Connection The condensate drain connection is behind the pump at the rear of the boiler see diagram 9
83. 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 13 1 Servicing NOTE If the Combustion CO2 2 ratio 8 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 see diagram 13 2 Position the control box into the service position see diagram 13 3 Before commencing with a service or replacement of parts The boiler should be isolated from the electrical and gas supplies INNER CASING PANEL FRONT CASING 5 QQ 1 SECURING SCREWS SECURING 7 2 OFF SCREWS Diagram 13 2 IN 8cS L RETAINING STRAP CONTROL PANEL Diagram 13 3 13 Servicing 13 2 Spark Electrode Disconnect the spark electrode plug and earth lead see diagram 13 5 Remove the two securing screws and withdraw the spark electrode carefully from the combustion chamber see diagram 13 4 Inspect the tips for damage Clean away any debris and check the spark gap
84. 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 car ried out before moving the appliance into the area to take into account access stability of flooring lighting and other factors and appropriate measures taken 05 Vaillant Vaillant EC declaration of conformity Name and Address of the Vaillant Industrial UK Ltd manufacturer Nottingham Road Belper Derbyshire DE56 1JT Identification of product Glow worm Ultracom Series Condensing Wall Hung System Boilers Appliance type 18sxi amp 30sxi The appliance types satisfy the essential requirements of the relevant directives and Standards 90 396 EEC including amendments Designed and built to CE type examination certifi Directive on the approximation of the law of the cate member states relating to appliances burning gaseous fuels PIN no 87BO41 92 42 EEC including amendments Directive of efficiency relating to boiler burning Designed and built according to European Stan gaseous fuels dards 73 23 EEC including amendments EN 483 Directive on the harmonization of the laws of EN 677 Member States relating to electrical equip EN 60335 1 ment designed for use within certain voltage limits EN 60529 EN 50165 89 336 EEC including amendments EN 55014 Directive on the approximation of the law of the EN 61000 3 2 member states relating to electrom
85. ressing Mode scroll through your options and select one of the following Central heating Boiler functions ALL switched off OFF 3 Turn ON your external controls and select the room temperature required The boiler will operate automatically NOTE The display will indicate the Heating system water temperature or a fault code if in a fault condition 12 5 Check the Gas Inlet Pressure and Gas Rate The supply from the governed meter must be of adequate size to provide a steady inlet working pressure of 20mbar 8in wg at the boiler On completion test the gas installation for tightness using the pressure drop method and suitable leak detection fluid purge as necessary NOTE Due to the modulating operation of the boiler and the need to check the gas inlet pressure and measure the gas rate at maximum rate it will be necessary to force it to maximum Press the reset button on the controls fascia release and immediately press and hold in the button After approximately 5 seconds Hi will be displayed Pressing the mode button when Hi is selected will force the boiler to maximum rate the display will flash between Hi and the default display this will indicate the boiler has been forced to maximum Operational Gas Inlet Pressure With ALL other gas appliances operating check the operational supply pressure at the gas service isolation valve test point see diagram 12 1 The nomi
86. rews supplied making sure the nib fits into the locating slot in the boiler casing to ensure correct orientation Secure the first extension pipe to the flue adapter with the securing collar supplied by positioning the collar centrally over the joint then tighten the two screws on the securing collar see diagram 10 22 Fit more extension pipes as required using the collar and screws supplied with each extension pipe To fit position the collar centrally over the joint tighten the two screws on the securing collar Using the holes provided in the securing collar drill and insert the two self tapping screws supplied see diagram 10 23 Project the rise of the flue pipe to roof level and cut a 150mm hole in the roof Flue Terminal Installation a Pitched Roof Fit the required pitched roof weather collar over the 150mm hole in the roof Make good the tiling or slating around the collar incorporating the flashing of the weather collar Position the angle cap over the weather collar in the correct orientation to attain the correct angle for your roof b Flat Roof Fit the aluminium weather collar over the 150mm hole in the roof ensuring a weather tight seal From above carefully place the flue terminal through the weather collar Flue Terminal to Boiler Connection Should the clearances above the boiler to roof not allow for extensions it is permitted to cut the flue terminal ensuring the relationship of flue and air duct leng
87. rols heat demand 0 no heat request open 1 heat request closed d 9 Flow target temperature from external In 9C minimum from ext eBUS target value and target value terminal 7 intelligent control d 10 Status central heating pump 12 on 0 off 411 Status additional heating pump 1 to 100 on 0 off d 13 Hot water circulation pump via accessory module 1 to 100 on 0 off d 23 Summer Winter function 1 Winter 0 Summer d 25 Hot water activation via eBUS Control yes 0 no 4 27 Option Relay 1 Reserved for future use 4 28 Option Relay 2 Reserved for future use d 33 Fan speed target value in rpm 10 d 34 Fan speed actual value in rpm 10 d 35 Position of diverter valve 0 Heating 100 Hot water 40 Centre position d 40 Flow temperature Actual value in 9C d 41 Return temperature Actual value in 9C d 44 lonisation current Actual value in 10nA gt 80 no flame 40 good flame d 47 Outside temperature in C d 60 Number of safety temperature limiter cut offs Quantity d 61 Number of lock outs Number of unsuccessful ignitions in the last attempt d 64 Average ignition time In seconds d 65 Maximum ignition time In seconds d 67 Remaining burner anti cycling time block time Minutes d 68 Unsuccessful ignitions in the first attempt Quantity d 69 Unsuccessful ignitions in the second attempt Quantity d 76 Appliance variant device specific number 00 to 99 d 80 Heating operating hours inh d 81 DHW operating hours inh d 82 Cycles i
88. ruction 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 it is necessary to complete a Declaration of Conformity to indicate compliance to 1 5 813 An example of this is given in the current edition of 1 S 813 12 Commissioning 12 8 Instruct the User e Demonstrate then instruct the User about the lighting procedure and heating system controls operation e Advise the user on the use and maintenance of any scale reducer and pass on any relevant instructional documents e Advise that to ensure the continued efficient and safe operation of the boiler it is recommended that it is checked and serviced at regular intervals The frequency of servicing will depend upon the installation conditions and usage but in general once a year should be enough e Draw attention if applicable to the current issue of the Gas Safety Installation and Use Regulations Section 35 which imposes a duty of care on all persons who let out any property containing a gas appliance in the UK e The user shall not interfere with or adjust sealed components e t is the Law that any servicing is carried out by a competent person approved at the time by the Health and Safety Executive e Advise the user that like all condensing boilers this appliance will produce a plume of condensation from the flue term
89. s that can be shut off by the user and check to see if less than the maximum differential allowed of 20 C can be achieved across flow and return NOTE Should the system require that the appliance has to be adjusted the front will need to be removed as described in the servicing section 13 and the control box lowered into its service position The appliance pump has two speeds and can be adjusted depending on the requirements of the system The appliance has an inbuilt automatic adjustable bypass valve The pressure can be adjusted between approx 1 5 and 3 5mH20 but is factory pre set to approx 2 5mH20 The pressure changes by approx 0 1mH 0 for each full turn of the bypass screw see diagram 12 3 Turning clockwise increases the pressure and turning anti clockwise decreases the pressure 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 Lock or remove the handle from control valve if fitted Adjust the boiler temperature controls and any system controls to their required settings 38 9986 55 AUTOMATIC SCREW BYPASS VALVE RETAINING aS C Diagram 12 3 12 7 Completion Fit the base coverplate see diagram 12 4 Ensure that the magnetic lighting inst
90. setpoint Check external controls Antifreeze active fan speed variation too high waiting during blocking function Check fan connection frost protection active Priority 4 Temperature below 89 C check thermistor connection if this is not true No Heating demand from external controls 24V Check wiring in external controller Check wiring at Installer Interface Accesory Module is blocking burner operation Check accessory module waiting time temperature difference flow return sensor too high Check thermistor fit Check flow amp return thermistor connections to pipes Check harness connection to thermistor Check harness wires are not trapped between any internal components waiting time no water in system temperature gradient error rise flow return sensor too high Check flow amp return thermistor connections to pipes Check harness connection to thermistor Check harness wires are not trapped between any internal components Waiting period pressure sensor Check system pressure default display Return Sensor check is running demand DHW or heating is blocked Check return thermistor connection to pipe Check harness connection to thermistor Water pressure sensor check is running demand DHW or heating is blocked Check connection to pressure sensor Check pump has not seized Flow Return sensor check is running demand DHW or heating
91. shower e The boiler is suitable for installation in bathroom zones 2 and 3 11 1 Electrical Wiring If you are fitting the Glow worm Options Board Kit please refer to the instructions supplied with the kit for the system wiring Remove the electrical cartridge from the fittings pack Remove the securing screw to open the cartridge NOTE There are two screws supplied loose in the electrical cartridge these will be required to secure the cartridge into the electrical interface housing Slacken the screws of the cable strain relief in the electrical cartridge see diagram 11 1 Route the mains supply and system cables through the strain relief and connect to the relevant plug refer to the appropriate sections 11 2 or 11 3 ELECTRICAL CARTRIDGE 20661 CABLE STRAIN Diagram 11 1 KEY DESCRIPTION 24V N MAINS NEUTRAL ROOM THERMOSTAT L MAINS LIVE MAINS EARTH R SWITCH LIVE 230v O F FROST STAT 230v switchable Ov LOW VOLTAGE 0v DEMAND EBUS 24v LOW VOLTAGE DEMAND 24v INSTALLER INTERFACE Ebus 1 CONNECTION 1 eoleoeoo tat NOTE This appliance 3 AMP FUSE will not operate without DOUBLE a link or system 24V SYSTEM POLE controls fitted CONTROLS ISOLATOR NOTE ALL CABLES CONNECT
92. th of extension pipe is required The minimum dimension is 187mm to suit a 75mm min wall thickness The flue can project to a maximum of 600mm if this is desirable refer to diagram 10 14 10 9 SIDE Flue With the flue elbow temporarily fitted measure the distance from the outside wall to the butt joint see diagram 10 15 If the measurement Y exceeds 665mm then the appropriate length of extension pipe is required The minimum dimension for Lhd is 254 and Rhd 226 to suit a minimum wall thickness of 75mm The flue can project to a maximum of 600mm if this is desirable refer to diagram 10 14 EZZEL WALL THICKNESS BUTT JOINT OUTSIDE INSIDE WALL FACE WALL FACE Diagram 10 13 MAXIMUM 6 66 SEALING COLLAR OUTSIDE WALL FACE Diagram 10 14 Yt 8 E BUTT JOINT 7 OUTSIDE WALL FACE m t Left Hand illustrated Diagram 10 15 25 10 Standard Flue Length Preparation and Installation AIR DUCT 2786 ae COLLAR SECURING 13mm TERMINAL CATCH im FLUE DUCT L 11mm Diagram 10 16 5 A SEALING CPP Diagram 10 17 26 10 10 Flue Fitting IMPORTANT The flue seals are sensitive to mineral oil based lubricants Do not grease the seals If the seals do need to be lubricated use only water During the installation of the flue system ensure that debris su
93. 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 62 SE Positioning of Appliance for Final Installation no obstructions Recommend 2 persons lift appliance to position into place Fit bracket securely onto wall before lifting appliance into position Obtain firm grip on front and sides of appliance lift upwards ensure stable bal ance achieved and lift upwards to position in place on bracket Ensure safe lifting techniques are used keep back straight bend using legs when lifting load from floor level Do not twist reposition feet instead Keep boiler as close as possible to body throughout lift to minimise strain on back Ensure co ordinated movements to ensure equal spread of weight of load Always use assistance if required Recommend wear suitable cut resistant gloves with good grip to protect against sharp edges and ensure good grip when handling appliance Positioning of Appliance for Final Installation above worktop foreseeable obstructions etc Recommend 2 persons lift appliance to position into place Fit bracket securely onto wall before lifting appliance into position Obtain
94. ths are retained 10 Vertical Flue Length Preparation and Installation Ridge Tile Terminal A ridge tile terminal is available part no A2043800 see diagram 10 20 The installation of a ridge tile will be required A suitable ridge tile is manufactured by Aspect East Anglia Limited The Old Mill East Harling NORWICH NR16 2QW Website www aspectroofing co uk Contact Chris Haythorpe General Manager Tile Division Tel 01953 717777 Fax 01953 717164 S8r max 125 Diagram 10 20 29 10 Vertical Flue Length Preparation and Installation Completion of Installation With the flue terminal positioned in the roof the length of the final pipe can be determined If a telescopic length cannot be used then a standard flue length can be cut to make the correct length Cut the flue to the desired length measuring from the O ring end and discard the plain end of the tube The cuts must be square and made free of burrs to allow correct assembly NOTE The flue pipe is 10mm longer than the air pipe see diagram 10 24 Carefully push the terminal assembly upwards to allow room for fitting the final flue piece Fit a fixing bracket to the terminal assembly Pull the terminal assembly down and join to the flue system Ensure that the terminal is making a weather tight seal on the weather collar Secure the fixing bracket fitted to the terminal to the roofing struts or a purpose made batton
95. umference of the flue air intake 2 The combustible surface and fixings are suitable for supporting the load 3 The minimum clearances from the boiler case are maintained 3 5 Room Ventilation The boiler is room sealed so a permanent air vent is not required 3 6 Cupboard or Compartment Ventilation Due to the high efficiency and hence low casing temperature of this boiler cupboard or compartment ventilation is not necessary Leave existing air vents 8066 CLEARANCES 5mm clearance to combustible material Zz 5 20 m A 5 20 200 A removable compartment door can be placed a minimum 5mm in front of the appliance A clearance of 600mm is required from a fixed surface A 5mm to a non permanent surface 20mm to a permanent surface Diagram 3 1 4 Flue Options and Terminal Clearances Ridge Tile Terminal Part No A2043800 Section 10 page 29 Top horizontal telescopic flue 260 100 Top horizontal standard flue 60 100 Part No A2043600 Section 10 page 19 Part No A2043400 Section 10 page 23 2 1 Plume Management Kit basic set white concentric flue 60 100 Part No A2044100 for use with Part No A2043400 and Part No A2043600 Section 10 page 34 Twin Flue Twin Flue Adapter concentric flue 080 Part No A2011000 Section 10 page 31 Multiple Boiler Chimney Flue Vertical con
96. used Keep back straight Avoid twisting at the waist Avoid upper body top heavy bending Always grip using the palm of the hand Use designated hand holds Keep load as close to body as possible Always use assistance if required Electrical Supply The boiler MUST be earthed All system components shall be of an approved type and all wiring to current I E E wiring regulations External wiring must be correctly earthed polarised and in accordance with the relevant standards In GB this is BS 7671 In IE this is the current edition of ETCI rules The boiler MUST be connected to a permanent 230V ac 50Hz supply Connection of the whole electrical system of the boiler including any heating controls to the electrical supply MUST be through one common isolator and must be fused 3 Amp maximum Isolation should be by a double pole switched fused spur box with a minimum gap of 3mm for both poles The fused spur box should be readily accessible and preferably adjacent to the appliance It should be identified as to its use Alternatively connection can be made through an unswitched shuttered socket and 3A fused 3 pin plug both to the current issue of BS 1363 provided they are not used in a room containing a bath or shower Wiring to the boiler must be PVC 859 insulated cable not less than 0 75mm2 24 0 20mm Testing and Certification This boiler is tested and certificated for safety and performa
97. ve During the conversion to Propane use of a suitable flue gas analyser is necessary e The person carrying out a combustion measurement should have been assessed as competent in the use of a flue gas analyser and the interpretation of the results e The flue gas analyser used should be one meeting the requirements of BS7927 or BS EN50379 3 and be calibrated in accordance with the analyser manufacturers requirements e Competence can be demonstrated by satisfactory completion of the CPA1 ACS assessment which covers the use of electronic portable combustion gas analysers in accordance with BS 7967 parts 1 to 4 As an option a chargeable boiler only commissioning service can be provided by Glow worm Service by calling telephone No 01773 828100 Tools required to make the conversion are a 2mm Allen key and an electricians screwdriver Ensure that the appliance supply pressure 37mbar 1 Access the gas valve 2 Refer to diagram 12 5 and turn the gas valve throttle fully clockwise 3 Turn the throttle anti clockwise by the number of turns shown in the table 4 Ensure that the gas analyser is set to the correct fuel setting Propane 5 Attach combustion analyserto the combustion test point refer diagram 13 1 IMPORTANT Remember to replace the cap on completion of the test 6 Make sure that the external controls are calling for heat then turn the mains electrical supply and gas service isolation valve
98. y external controls to resume normal operation of the central heating If the boiler does not resume normal operation press the reset button If the boiler does not resume normal operation after this call your Installation Servicing company or Glow worm service Overheating Safety The boiler software is designed to recognise the potential for an overheat lockout and will shutdown before this happens To restart the boiler press the reset button on the controls fascia If the boiler fails to resume normal operation and all external controls are calling for heat then call your Installation Servicing company or Glow worm service Safety Discharge Valve A safety discharge valve and discharge pipe are fitted to the boiler This valve must not be touched Should there be any discharge from the pipe isolate the boiler electrical supply and call your installer or Glow worm s own service organisation using the telephone number on the inside front cover of this booklet Frost protection The appliance has a built in frost protection device that protects the boiler from freezing With the gas and electric supplies ON and irrespective of any room thermostat setting the frost protection device will operate the pump when the temperature of the boiler water falls below 8 C A timer is used so that the temperature can be checked periodically After 10 minutes the pump will be stopped if the temperature is higher than 10 C or has already

Ultracom sxi Installation & Service Manual Boilers - Glow-worm

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Ultracom sxi Installation &amp; Service Manual Boilers - Glow-worm

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Ultracom sxi Installation & Service Manual Boilers - Glow-worm