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Xtrafast 96-120 Installation & Service Manual Boilers - Glow-worm

1. storage vessel thermistor 5 250 SENTI T 0 238 Opania Air pressure swifch 9 294 o CIN Domestic water flow sensor 57202 T ean Printed circuit board 5 248 Flip 57207 Q 3 woy valve 57206 TEE SYSTEM pressure sensor 9 205 iy gem Gas valve module 0 079 Central heating safety valve 0 228 o Domestic safety volve 5 229 Fe Overheat Thermostlo 5 212 o Ignition electrode 57194 en Flame sense electrode 57195 Clock limer n 5 245 Because of our constant endeavour for improvement details may vary slightly from those in the instructions 2000221595 40
2. HEATING replacement PCB 19 8 Central heating pump refer to diagram 19 7 Before starting refer to the front of Section 19 Important information Remove the front panel refer to Section 16 3 Lower the control panel refer to Section 16 4 Drain down central heating water circuit of the boiler only as follows Close isolating valves q and v on central heating isolating MET o cocks and C see diagram 7 1 AN p Diagram 19 7 2000221595 30 19 Replacement of Parts Note These valves are closed when slots are at right angles to direction of flow PLATE TO PLATE PIPE HEAT EXCHANGER CONNECTION Drain boiler by opening drain valves r and u see diagram 7 1 Note itis not necessary to drain down the entire heating system to carry out this work For ease of access if required remove the left hand side panel refer to Section 16 6 Undo two fixing screws and remove pump retaining bracket from front of pump e Pull out slotted metal clip securing pump outlet hose connection to pump e Remove pump from pump block by lifting up at front and pulling forward Gain access to the pump electrical connection box and remove cover Disconnect pump cable from pump avoid straining cables Transfer automatic air vent to replacement pump e Re connect electrical connection Open isolating valves on flow and return connections refill 3 7
3. see diagram 15 1 Turn the screw clockwise to close the bypass When using thermostatic radiator valves TRV s on all of the radiators it is essential that a separate adjustable bypass of 15 mm minimum diameter is fitted between the flow and return of the heating circuit see diagram 8 2 Any bypass must be fitted before system controls Diagram 15 1 2000221595 22 To ensure the continued efficient and safe operation of the 16 Routine Cleaning and Inspection boiler it is recommended that it is checked and serviced at regular intervals The frequency of servicing will depend upon the particular installation conditions 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 All parts are replaced in reverse order to removal 16 1 Products of combustion check refer to diagram 16 1 Note Toobtain a products of combustion reading unscrew the left hand sampling point cap on the flue elbow located on top of boiler Connect the analyser tube onto sampling point Switch on the electrical supply and gas supply then operate the boiler On completion of the test switch off the electrical supply andthe gas supply remove analyser tube and replace sampling point cap cO co O gt PRODUCTS SAMPLING POINT Diagram 16 1 16 2 Service Check and Preparation Operate boiler and check for any faults that need to be put right solate
4. STORAGE VESSEL Diagram 19 19 38 19 31 Storage vessel thermistor refer to diagram 19 20 For this operation the boiler must be removed from the wall Before starting refer to the front of Section 19 Important information Drain down central heating and domestic hot water circuit of boiler only referto relevant parts of Sections 16 13 and 19 8 Note It is not necessary to drain down entire heating system to carry out this work Disconnect flue system e Remove the base panel secured with four screws and hooked in at the rear Disconnect boiler pipes onto fixing jig e Remove the front panel refer to Section 16 3 Lower the control panel refer to Section 16 4 Gain access to rear of control panel e Unclip side clips and hinge up control panel cover see diagram 11 2 Disconnect mains cable and any external controls cables Remove the sealed chamber cover refer to Section 16 4 Remove the two side panels refer to Section 16 6 Using the two lifting handles positioned bottom left of the controls and to the center right of the combustion chamber lift the boiler off the hanging bracket and away from the wall e Remove the insulation from around the storage vessel Locate thermistor Disconnect the electrical connection to the thermistor Peel off the self adhesive thermistor Clean the surface prior to fitting the replacement thermistor in same position as old thermistor Refit v
5. 10 00pm to 07 00am 22 7 To override or advance the clock The clock has a manual On Off switch see diagram 3 which operates as follows 9 Upper position Heating On Off as set by the N tappets Middle position Heating Off continuously Lower position Heating On continuously Diagram 3 Draining Protection against freezing If the boiler is to be out of use for any long periods during severe weather conditions it is recommended that the whole system including the boiler be drained to avoid the risk of freezing If in doubt consult your servicing company Draining and filling Caution The boiler is installed as part of a sealed system which must only be drained and filled by a competent person Safety Devices Air flow rate safety device If an obstruction even partial of the flue occurs for any reason the built in safety system ofthe boiler will turn the boiler OFF and the fan will continue to run The boiler will be ready to operate when the fault has been cleared Overheat safety In case of boiler overheating the overheat thermostat will turn the boiler off The thermostat located on the heat exchanger flow pipe will need to be manually reset To have this done call a qualified service engineer or Heatcall Glow worm s own service organisation using the telephone number behind the controls cover door or on the front cover of this booklet In case of power supply fa
6. MAY ACTIVATE THE FLOW RATE IS DRAWN OFF DETECTOR WHEN THE TAPS ARE TURNED ON WATER NOT HOT ENOUGH OR UNEVEN FLOW FROM TAP NO DISPLAY OF TAP SYNBOL 27 2000221595 18 Wiring Diagram IGNITION SENSE IGNITION ELECTRODES ELECTRODE MODULE r mm 1 B C T JH E LS J bk 4 gt z AIR PRESSURE SWITCH PRESSURE SENSOR g YY lt w THERMISTOR OVERHEAT THERMISTOR T bk riir bk THERMISTOR u FLOW SENSOR W THREE WAY VALVE LL 1 9 bk CEEHBHH E CLOCK TIME bk 7 STORAGE VESSEL E THERMISTOR i V 230V 50Hz CHASSIS PERMANENT EARTH MAINS SUPPLY G ON OFF FUSED AT 3A d uuu E gy gly gly H ll 9683 USER INTERFACE 125mAT NOTE E VOLTAGE FREE room thermostat connection or link GREEN NOTE F Optional remote control unit with YELLOW programmable room stat connection Part No 86774 Diagram 18 1 2000221595 28 IMPORTANT INFORMATION WARNING Before commencing the replacement of any component isolate appliance from electrical supply and turn off gas at service cock Replacement of parts must be carried out by a competent person When replacing components it may be necessary to renew sealing washers gaskets and O rings If new ones are supplied with replacement components they must be used All parts are replaced in reverse order to removal
7. The thermostat will need to be manually reset To do this remove the front panel and sealed chamber cover locate the reset button on the heat exchanger flow pipe refer to Sections 16 3 16 4 16 5 and diagram 19 15 13 6 In case of power supply failure The boiler no longer operates As soon as power supply is restored the boiler will be automatically restarted 13 7 Frost protection The XTRAFAST has a built in frost protection device that protects the boiler from freezing If the boiler is to be left and there is a risk of frost ensure that the gas and electrical supplies are left connected The frost protection device will light the boiler when the temperature of the boiler water falls below 6 C When the temperature reaches 16 the boiler stops Note This device works irrespective of any room thermostat setting and will protect the complete heating system 2000221595 14 Changing Gas Type Should it become necessary to change the gas type a modification kit will be required This modification must only be carried out by a suitably qualified engineer Conversion natural Gas G20 to G30 G31 Part No 86216 15 Settings Bypass The XTRAFAST boiler has a built in bypass This must be adjusted according to the requirements of the system refer to the flow rate pressure curve diagram 4 The boiler is supplied with the built in bypass open a half a turn It is adjusted by turning the bypass screw a
8. any doubt exists contact the Glow worm Technical Helpline 01773 828100 The minimum acceptable spacings from the terminal to obstructions and ventilation openings are shown in diagram 6 1 The boiler must be installed so that the terminal is exposed to the external air Should any doubt exist as to the permissible position of the terminal contact the Glow worm Technical Helpline 01773 828100 MINIMUM SITING DIMENSIONS FOR THE POSITIONING OF FLUE TERMINALS MM A DIRECTLY BELOW ABOVE OR HORIZONTALLY TO AN OPENING AIR BRICK OPENING WINDOWS AIR VENT OR ANY OTHER VENTILATION OPENING 300 B BELOW GUTTER DRAIN SOIL PIPE C BELOW EAVES D BELOW A BALCONY OR CAR PORT E FROM VERTICAL DRAIN PIPES AND SOIL PIPES FROM INTERNAL CORNERS AND EXTERNAL CORNERS 300 ABOVE ADJACENT GROUND OR BALCONY LEVEL 300 FROM SURFACE FACING THE TERMINAL 600 FACING TERMINALS 1200 FROM OPENING DOOR WINDOW IN CAR PORT INTO DWELLING 1200 K VERTICAL FROM A TERMINAL 1500 HORIZONTALLY FROM A TERMINAL 600 6 2 Terminal guard A terminal guard is required if persons could come into contact with the terminal or the terminal could be sublject to damage If a terminal guard is required it must be positioned to provide aminimum of 50mm clearance from any part of the terminal and to be central over the terminal Teminal guard type supplied by Tower flue components Ltd Morley road Tonbridge Kent TN9 1HA 6 3 Flue options There are various flu
9. carefully fit gasket to base of flue elbow Fit elbow onto boiler and secure with the four screws l Diagram 10 4 Concentric flue system The maximum permissible length L for the concentric flue system is 3 5 m For flue systems up to 1 5 m length the restrictor a supplied fitted to the boiler Inside the fan outlet must be left in place For longer flue systems the restrictor must be removed For each 90 flue elbow used or two 45 elbows the maximum permissible length L must be reduced by 1 metre Gasket Hab 249a Diagram 10 5 2000221595 16 11 Electrical Connection Warning This boiler must be earthed The boiler is supplied with a mains lead attached Standard colours are Brown Live Blue Neutral Green and Yellow Earth All system components must be of an approved type Electrical components have been tested to meet the equivalent requirements of the BEAB Connection of the whole electrical system and any heating P system controls to the electrical supply must be through a The boiler is supplird with a mains lead common isolator attached Connect this to the electrical supply Isolation should preferably be by a double pole switched fused spur box having a minimum contact separation of 3 mm 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 Diagram 11 1 A fused three pin
10. diagram 7 1 Connect the six copper connections and sealing washers to the isolating valves see diagram 7 1 Heating system connections Pipe diam 22mm Hot water system connections Pipe diam 15mm Gas connection Pipe diam 22mm Domestic safety valve connection Pipe diam 15mm Heating safety valve connection Pipe diam 15mm 8 2 Wall template e Remove the wall template follow the instructions given on the wall template Note It is important the hanging bracket and service cock 2000221595 bracket are fitted to a flat and true wall area for correct alignment with the boiler If this is cannot be achieved it is acceptable to pack outthe service cock bracket to obtain the correct alignment Position the wall template see diagram 8 1 Mark the position of the holes for the hanging bracket and jig Drill plug and fix the hanging bracket to the wall using suitable SCrews Check that the hanging bracket is level Drill plug and fix the fixing jig to the wall For horizontal flue system mark the position for the flue hole as follows 8 3 Flue to rear of boiler Mark correct position of hole from template 8 4 Flue to side of boiler e Mark the horizontal centre line for the hole on the rear wall Extend the horizontal centre line to the side wall and mark the vertical centre line of flue hole as shown in diagram 8 1 8 Piping System Installation 8 5 Cutting the flue
11. earth lead from fan Unscrew and remove two fan retaining screws at front edge of mounting plate e Remove fan with mounting plate attached by pulling forwards out of the boiler e Remove fan from mounting plate Note When re fitting make sure that the two lugs on the fan mounting plate engage in the flue hood Reconnect electrical leads 29 19 Replacement of Parts DOMESTIC HOT WATER THERMISTOR Diagram 19 1 CENTRAL HEATING THERMISTOR Diagram 19 2 FAN RETAINING SLOTS Diagram 19 3 19 4 Fan sensor refer to diagram 19 3 Before starting refer to the front of Section 19 Important information Remove the front panel refer to Section 16 3 Lower the control panel refer to Section 16 4 Remove the sealed chamber cover refer to Section 16 5 e Remove the 2 fan sensor retaining screws e Remove the fan sensor and disconnect the electrical connection avoid straining the cables 2000221595 19 Replacement of Parts 19 5 Air pressure switch refer to diagram 19 4 Before starting refer to the front of Section 19 Important WES IC information f Uu 1 AIR PRESSURE Remove the front panel refer to Section 16 3 SWITCH Lower the control panel refer to Section 16 4 Remove the sealed chamber cover refer to Section 16 5 Locate air pressure switch situated inside combustion chamber on top right hand side e Remove air pressure switch tube s Diagra
12. hole Making allowance for the slope of the flue cut hole in external wall preferably using a core drill For installations with internal and external access use a 105 mm diameter core drill For installations with internal access only use a 125 mm diameter core drill 8 6 Important When cutting the flue hole and when extending the flue centre line to a side wall remember that the flue system must have a fall of about 35 mm per metre of flue DOWNWARD towards the terminal There must NEVER be a downward incline towards the boiler 8 6 Terminal position The minimum acceptable spacings from the terminal to obstructions and ventilation openings are shown in diagram 6 1 The boiler must be installed so that the terminal is exposed to the external air Should any doubt exist as to the permissible position of the terminal contact the Glow worm Technical Helpline 01773 828100 8 7 Water connection Connect the system pipework to the copper connections on the fixing jig observing the correct flow and return format as shown in diagram 8 2 Do not subject the isolating valves to heat 8 8 Heating safety valve and domestic safety valve discharge refer to diagram 8 3 552 120 Diagram 8 1 Tee the domestic safety valve outlet pipe to the heating safety valve outlet pipe and extend horizontally to the outside wall WARNING It must not discharge above an entrance or window Additional D t or any type of public access area expans
13. on each injector is the same as that given in Section 1 Technical Data for the type of gas being used e Fit injector bar into burner secure with retaining rods Fit replacement burner 19 24 Burner injectors refer to diagram 19 16 Before starting refer to the front of Section 19 Important information e Remove the front panel refer to Section 16 3 Lower the control panel refer to Section 16 4 Remove the sealed chamber cover refer to Section 16 5 e Remove the combustion chamber cover refer to Section 16 7 Remove burner refer to Section 16 8 e Remove injector bar retaining nuts and separate the injector bar from the burner e Remove and renew injectors as required from injector bar Note Make sure that injector size marked on each injector is the same as that given in Section 1 Technical Data for the type of gas being used e Assemble the burner in reverse order to removal taking care to engage all parts correctly 19 25 Ignition electrode assembly refer to diagram 16 4 Before starting refer to the front of Section 19 Important information e Remove the front panel refer to Section 16 3 Lower the control panel refer to Section 16 4 Remove the sealed chamber cover refer to Section 16 5 e Remove the combustion chamber cover refer to Section 16 7 Pull off ignition leads from gas control valve Ease ignition leads through the grommet Undo and remove screws s
14. on the fan mounting plate engage in the flue hood FAN RETAINING SLOTS w ias q HALLD E 9 il Te r Y M uth eu LU Wan 1 Diagram 16 5 16 Routine Cleaning and Inspection 16 10 Spark and Sense Gaps e Check that the spark and sense gaps as shown in diagram 16 6 16 11 Flue system Check externally to make sure that flue is not blocked Inspect flue system to make sure that all fittings are secure 16 12 Operation of fan Switch on electrical supply and turn on gas e Light burner by opening a hot water tap Check that fan operates when burner lights and stops when it goes out 16 13 Cold water inlet filter Drain down domestic hot water circuit of boiler only as follows Close isolating valve throttle m on cold water isolating cock SPARK GAP see diagram 7 1 Note This valve is closed when screwed fully clockwise Undo connecting nut from boiler cold water inlet connection Clean and inspect filter replace if necessary see diagram 16 7 With both filter and restrictor in place reconnect connecting pipe to inlet connection and tighten Fully open isolating valve throttle on cold water inlet and check for leaks FLOW RESTRICTOR AND COLD WATER INLET FILTER Diagram 16 7 25 2000221595 17 Fault Finding Fault finding must be carried out by a competent person WARNING Always isolate the boiler from the electrical supply be
15. safe and economical use of your boiler Electrical Supply WARNING This boiler must be earthed All system components shall be of an approved type and shall be connected in accordance with the current issue of BS7671 and any applicable local regulations All external wiring between the appliance and the electrical supply and earthing requirements shall comply with the current IEE Regulations Connection of the boiler and system controls to the mains supply must be through a common isolator and must be fused 3A maximum This method of connection must be by a fused double pole isolating switch with a minimum contact separation 1 On Off button 2 Summer Winter mode selector 3 Hot water temperature adjuster 4 Hot water set point display 5 Graphic display 6 Heating temperature adjuster 7 Heating set point display 8 Display backlight 9 Clock timer refer to clock timer instructions for use Diagram 1 2000221595 of 3mm on both poles The switch should be readily accessible and preferably adjacent to the appliance It should supply the appliance only and be easily identifiable as so doing Alternatively an unswitched shuttered socket outlet and 3A fused 3 pin plug both to the current issue of BS1363 may be used provided that they are not used in a room containing a bath or shower Wiring to the boiler must be PVC 85 insulated cable not less than 0 75mm 24 0 20mm Gas safety Installatio
16. to the front of Section 19 Important information Drain down central heating and domestic hot water circuit of boiler only refer to relevant parts of Sections 16 13 and 19 8 Note It is not necessary to drain down entire heating system to carry out this work Disconnect flue system e Remove the base panel secured with four screws and hooked in at the rear Disconnect boiler pipes onto fixing jig e Remove the front panel refer to Section 16 3 Lower the control panel refer to Section 16 4 Gain access to rear of control panel e Unclip side clips and hinge up control panel cover see diagram 11 2 Disconnect mains cable and any external controls cables Carefully pull off electrical connection at H4 from the PCB Unclip to release the cable back to the storage vessel e Remove the sealed chamber cover refer to Section 16 4 Remove the two side panels refer to Section 16 6 Using the two lifting handles positioned bottom left of the controls and to the center right of the combustion chamber lift the boiler off the hanging bracket and away from the wall Fromrear of boiler disconnect domestic pipes from the bottom of the storage vessel Disconnect electrical connections from vessel Unclip vessel from boiler frame and remove from boiler 2000221595 19 Replacement of Parts CLIP POSITIONS 2 DOMESTIC HOT WATER STORAGE VESSEL 9883 9884 DOMESTIC HOT WATER
17. If any gas carrying components are disturbed removed or replaced it will be necessary on completion to check for gas soundness with leak detection fluid 19 1 Domestic hot water thermistor refer to diagram 19 1 Before starting refer to the front of Section 19 Important information e Remove the front panel refer to Section 16 3 Lower the control panel refer to Section 16 4 Locate domestic hot water thermistor on hot water flow pipe on right hand side of boiler adjacent to gas control valve Unclip thermistor from pipe Disconnect leads from thermistor Fit leads to replacement thermistor and fit thermistor to pipe The polarity is not important 19 2 Central heating thermistor refer to diagram 19 2 Before starting refer to the front of Section 19 Important information Remove the front panel refer to Section 16 3 Lower the control panel refer to Section 16 4 Locate central heating thermistor on heating flow pipe on centre of boiler Unclip thermistor from pipe Disconnect leads from thermistor Fit leads to replacement thermistor and fit thermistor to pipe The polarity is not important 19 3 Fan refer to diagram 19 3 Before starting refer to the front of Section 19 Important information e Remove the front panel refer to Section 16 3 Lower the control panel refer to Section 16 4 Remove the sealed chamber cover refer to Section 16 5 Disconnect power supply leads and
18. K THE AIR PRESSURE SWITCH e CHECK THE ELECTRICAL CONNECTIONS IF THE BURNER LIGHTS WITH ATRAIN OF SPARKS AND GOES OUT AFTER 7 SECONDS e REVERSE LIVE AND NEUTRAL TO THE ELECTRICAL PLUG e CHECK THE ELECTRODE AND ITS CORRECT CONNECTION NO IGNITION e CHECK IGNITION BOX Note MAX IGNITION TIME e CHECK THERE IS MORE THAN 40V BETWEEN LIVE AND EARTH 7 SECONDS IF THE TRAIN OF SPARKS DOES NOT LIGHT THE BURNER CHECK THE GAS TAP ON THE INSTALLATION IS OPEN THE GAS CONTROL VALVE e CHECK THE IGNITON BOX FF e PUMP BLOCKED OR ITS CONDENSER OUT OF SERVICE FF 7 ISOLATING COCKS CLOSED ON JIG OVERHEATING e DEFECTIVE OVERHEAT THERMOSTAT Raa BLEED OUT AIR e CHECK THE ELECTRICAL CONNECTIONS THIS FAULT MAY BE INTERMITTENT MAIN ein BOARD SWITCH OFF WAIT APPROXIMATLEY 5 SECONDS SWITCH ON x IF FAULT PERSISTS REPLACE MAIN CONTROL BOARD PCB TEMPERATURE LIMITER CHECK HEATING THERMISTOR MAY BE UNCLIPPED OR CONTROLLED BY THE THREE WAY VALVE FAULTY HEATING THERMISTOR FAULTY PUMP ON FLOW PIPE LOW HEATING FLOW RATE THIS FAULT MAY BE OCCASIONAL AND CAUSED BY ELECTROMAGNETIC INTERFERENCE OTHERWISE Oe COS OPI n F F CHECK THE MAIN CONTROL BOARD PCB OTHER FAULTS NOT DISPLAYED BY FAULT CODE THERE IS DEMAND BY THE ROOM TEMPERATURE THERMOSTAT e CHECK THE CONNECTIONS IF FAULT PERSISTS REPLACE MAIN CONTROL BOARD PCB CHECK THAT CONTACT 1 IS ON 1 OR MEASURE A RESIS
19. TANCE lt 10 ohms BETWEEN B5 1 AND B5 2 e CHECK ROOM THERMOSTAT CONNECTIONS OR MEASURE A RESISTANCE 50 ohms BETWEEN B3 1 AND B3 2 CHECK THREE WAY VALVE WATER NOT HOT ENOUGH CHECK THREE WAY VALVE MOTOR SWITCHING OR UNEVEN FLOW FROM e CHECK THE DIRECTION OF TAP THERE IS A CLIP ON THREE WAY VALVE READABILITY OF SYMBOL Ul HOT WATER DEMAND LOSS OF WATER Ll F e SENSOR IN SHORT CIRCUIT OR HAS ISOLATION FAULT PRESSURE SENSOR oni e CHECK THE ELECTRICAL CONNECTIONS USER INTERFACE INTERFACE MAY BE DAMP DRY IT OUT OR REPLACE 06 HEATING THERMISTOR ON FLOW e CIRCUITS OPEN OR SHORT CIRCUIT o e CHECK RESISTANCE OF THE THERMISTOR 12500 ohms AT 07 DOMESTIC THERMISTOR 20 1750 ohms AT 70 DHW PIPE UNCLIP THE THERMISTOR FROM THE PIPE IF THE BOILER RE LIGHTS WHEN THE THERMISTOR IS OPEN CIRCUIT 08 TEMPERATURE ON REPLACE THE THERMISTOR STORAGE VESSEL NO HEATING NO HEATING NO DISPLAY OF RADIATOR SYMBOL Il e MEASURE THE MICROFAST RESISTANCE 1000 ohms BETWEEN 4 1 AND H4 3 e READ THE VALUE OF FLOW RATE DETECTOR ON CODE 07 OF INFO MENU IT WILL READ HOT WATER OUTPUT L MIN x10 VALID RANGE 00 199 NOTE DIVIDE THE VALUE BY 10 IF 0 THE DETECTOR IS BLOCKED OR FAILED IF 0 THE DETECOR IS BLOCKED OR THE MAIN CONTROL BOARD PCB HAS FAILED THE BURNER COMES ON e CHECK THAT THE HOT WATER CIRCUIT HAS BEEN BLED WHEN COLD WATER PROPERLY ANY AIR BUFFER
20. allation 9 1 Statutory requirements The installation of this boiler must be carried out by a qualified registered person in accordance with the relevant requirements of the current issue of The Gas Safety Installation and Use Regulations The Building Regulations The local water company Byelaws The Building Standards Regulations Scotland The Health and Safety at Work Act 9 2 Sheet metal parts WARNING When installing or servicing this boiler care should be taken when handling the edges of sheet metal parts to avoid the possibility of personal injury 9 3 Installing the boiler Prior to starting work the system must be thoroughly flushed using a propriety cleanser such as Sentinel X300 to eliminate any foreign matter and contamination e g metal filings solder particles oil grease etc Note Solvent products could cause damage to the system The boiler pack consists of the boiler base panel literature sealing washers and securing screws Lay boiler on its back Remove all packaging from around the boiler e Remove front panel put in a safe place to avoid damaging it Ensure the plastic plugs are removed from water and gas pipes NOTE There will be some spillage of water e Remove transportation timber support bar from bottom rear of boiler e If required the boiler can be stood upright supported by extending the legs at the front bottom of the boiler Engage boiler upper part onto the han
21. be piped directly to an underfloor heating system without the need for a mixing bottle The maximum central heating flow temperature can be set to 53 C on the boiler printed circuit board during commissioning Pipe sectional areas shall be determined in accordance with normal practices using the output pressure curve diagram 4 The distribution system shall be calculated in accordance with the output requirements of the actual system not the maximum output of the boiler However provision shall be made to ensure sufficient flow so that the temperature difference between the flow and return pipes be less than or equal to 20 C The minimum flow is 400 l h The piping system shall be routed so as to avoid any air pockets and facilitate permanent venting of the installation Bleed fittings must be provided at every high point of the system and on all radiators The total volume of water permitted for the heating system depends amongst other things on the static head in the cold condition The expansion vessel on the boiler is pressurised at 0 5 bar corresponding to a static head of 5 m w g and allows a maximum system volume of 160 litres for an average temperature of 75 C and a maximum service pressure of 3 bar This pressure setting can be modified at commissioning stage if the static head differs An additional expansion vessel can be fitted to the system if required see diagram 8 2 Provision shall be made for a drain valv
22. boiler from the gas and electrical supplies e On completion check all gas carrying parts for soundness with leak detection fluid e Remove boiler casing as follows 16 3 Front panel Unscrew and remove the two front panel retaining brackets from the top of the boiler e Remove panel by lifting up and forward 16 4 Control panel e Lift control panel up and lower forwards to gain access to lower part of boiler 16 5 Sealed chamber cover Unclip the two toggle clips holding the sealed chamber cover see diagram 16 2 Lift cover up and off boiler 23 Diagram 16 3 16 6 Side panels For ease of access if required e Unscrew and remove the four screws securing lower grille onto boiler Unhook grille from rear of boiler and remove e Remove three screws from front of each side panel Unclip the toggle clip at the top of each side panel e Lift each panel up and then forward to remove 16 7 Combustion chamber cover Unscrew the two screws securing combustion chamber cover to combustion chamber then unclip the two toggle clips see diagram 16 3 Remove combustion chamber cover from boiler 2000221595 16 8 Burner refer to diagram 16 4 Undo main gas supply nut from under the sealed chamber Note The washer between main burner and main burner gas supply must be kept for use on reassembly Pull off ignition leads from gas control valve e Slacken but do not remove two burner suppor
23. bring rubber sealing collar hard up against external wall see diagram 10 4 e Fitinternal plastic flange G onto air duct pipe Push along the pipe until engaged against internal wall From inside insert flue duct pipe B into air duct pipe 5 Fit both O rings J into the flue elbow one at the inlet dies one atthe outlet By necessity they are aloosefit apply a small Us amount of silicone grease to each O ring when fitting D e Fixing collar D over air duct pipe A and elbow C ensuring it is the correct way round Note the fixing collar can only be The flue kit 86285 is 1000 mm long and comprises fitted one way due to different diameters of the flue elbow and Air duct pipe air duct Flue duct pipe Flue elbow e Take hold of the flue duct pipe and push gently onto the elbow Fixing collar outlet taking care not to tear the O ring Locking clips External rubber sealing collar Open fixing collar D and locate between elbow and air duct Internal flange pipe A Close fixing jig Engage the two fixing clips E onto the collar D and press down to lock into position Secure clips with screws provided Important If the flue has been cut ensure that there are no burrs that could damage the O ring e For flue systems less than 1 5 m long leave the restrictor a fitted in the fan outlet see diagram 10 5 e Remove the backing from the self adhesive gasket H and
24. control PCB 15 Domestic water flow sensor 16 Bypass 17 Domestic heat exchanger 18 Pump 19 Expansion vessel 20 Heating thermistor 21 Overheat safety thermostat 22 Flame sense electrode 23 Fan 24 Domestic safety valve 10 bar 25 Loss of water sensor A Heating return B Cold water inlet C Heating flow D Domestic hot water outlet E Gas A 2000221595 oU Vo B D Ye Diagram 5 1 6 Boiler Location Flue and Ventilation If the appliance has to be stored for any length of time before installation it should be kept in a safe place where it will not be a hazard to persons or obstruct any access Care should be taken when handling or moving the appliance taking note of the trucking points on the sides of the carton 6 1 Clearances The position of the boiler must be such that there is adequate space for servicing The recommended clearances are 20 mm either side of the boiler 600 mm at the front of the boiler 300 mm below the boiler 25 mm above the flue elbow Note The boiler must be mounted on a flat wall which is sufficiently robust to take its weight when full that is kg If in doubt expert advice should be obtained In the event of the wall being found not suitable Note Itis permissible to install the boiler with smaller clearances than those quoted above PROVIDING that adequate consideration is given for Servicing Repairs at a later date If
25. e B measure dimensions a and e see diagram 10 1 Cutboth the flue duct and air duct pipes to the dimensions given in Table C Important All cutting lengths should be measured from the push fit joint end of the extension pipe Do not leave any burrs or sharp edges on the cut ends of the pipes Note maximum horizontal flue length without bends is 3 5m Table A Flue cutting lengths mm Hear flue Air Duct pipe e 160 Flue duct pipe e 244 Note maximum distance x without extension 756 mm Side flue right or left Air Duct pipe e a 145 Flue duct pipe e a 229 Note maximum distance x without extension 990 mm Table B Number of extension kits required LIII e a X j X Diagram 10 1 D AIR DUCT PIPE Cutting length FLUE DUCT PIPE Flue option Dimension X No of extension kits Side flue 991 to 1991 mm 1 left or right 1991 to 2991 mm 2 Note Maximum flue length for 120 model is 2 metres Table C Flue extention cutting lengths mm Rear flue option Air Duct pipe e a 755 Flue duct pipe e a 755 Note maximum distance x without extension 990 mm Diagram 10 2 2000221595 10 Flue Installation 10 4 Installation of flue assembly Fit rubber sealing collar F see diagram 10 3 into groove at the outer end of pipe A Fit air duct pipe A into wall with groove to the outside Pull pipe inwards to
26. e at the lowest point of the system Where thermostatic radiator valves are fitted not all radiators must be fitted with this type of valve and in particular where the room thermostat is installed In the case of an existing installation itis ESSENTIAL that the system is thoroughly flushed prior to installing the new boiler Filling the system A filling device must be provided to fill the system see diagram 8 2 2000221595 4 Domestic Hot Water System Design Copper tubing or plastic hep o may be used for the domestic hot water system Unnecessary pressure losses should be avoided A flow restrictor limiting the flow through the boiler to a maximum of 12 l min is fitted to the boiler he boiler will operate with a minimum supply pressure of 0 7 bar but under reduced flow rate Best operating comfort will be obtained from a supply pressure of 1 bar Hard Water Areas In areas where the water is hard more than 200mg litre it is recommended that a proprietary scale reducer is fitted in the cold water supply to the boiler 5 Boiler Schematic 1 Domestic thermistor 2 Three way valve 3 Gas valve 4 Ignition module 5 Heating element 6 Micro accumulation vessel 7 Burner 8 Ignition electrode 9 Combustion chamber 10 Micro accumulation vessel thermistor 11 Main heat exchanger 12 Air pressure switch 13 Heating safety valve 3 bar 14 Electronic
27. e systems to choose from as follows Standard horizontal flue pack Standard horizontal extended flue pack Vertical flue pack Twin flue pack Extentions 90 and 45 bends Flue options and accessories For detailed information refer to flue guide Part No 223278 6 4 Cupboard or compartment ventilation The boiler can be fitted in a cupboard or compartment without the need for permanent ventilation Diagram 6 1 2000221595 The fixing jig is made up from left to right as follows A Heating return fitting with isolating valve v and drain knob u B Cold water inlet fitting with isolating valve m and factory fitted flow regulator and filter not shown C Heating flow fitting with isolating valve q drain knob r and safety valve s1 D Domestic hot water outlet fitting with safety valve s2 E Gas fitting ISOLATING 7 Fixing Jig Pack Other components within the fixing jig pack F Hanging bracket G wall template H copper connections J sealing washers K sealant putty 9959 VALVE PLATE LEFT COPPER HAND i SUPPORT BRACKET THE FIXING JIG SHOWN ASSEMBLED 7 OFF CONNECTIONS AND WASHERS RIGHT HAND SUPPORT BRACKET Diagram 7 1 8 Piping System Installation 8 1 Fixing jig e Remove the contents of the fixing jig pack e Secure the left and right hand support brackets to the isolating valve plate with the securing screws 4 OFF supplied see
28. ecuring electrode assembly onto burner Fit replacement electrode assembly onto burner in reverse order to removal e When refitting ensure that the grommet locates and seals correctly 2000221595 36 RETAINING NUT 2 OFF T INJECTORS Diagram 19 16 19 26 Flame sense electrode refer to diagram 16 4 Before starting refer to the front of Section 19 Important information e Remove the front panel refer to Section 16 3 Lower the control panel refer to Section 16 4 Remove the sealed chamber cover refer to Section 16 5 e Remove the combustion chamber cover refer to Section 16 7 Pull off flame sense lead from flame sense electrode e Undo and remove screws securing flame sense electrode onto burner Fit replacement flame sense electrode onto burner 19 27 User interface board assembly refer to diagram 19 17 Before starting refer to the front of Section 19 Important information e Remove the front panel refer to Section 16 3 Lower the control panel refer to Section 16 4 Gain access to rear of control panel e Unclip side clips and hinge up control panel cover see diagram 11 2 Carefully pull off electrical connection from the user interface board to PCB at B4 e Remove the two securing screws to release the control panel fascia Remove the two user interface board assembly securing screws to remove the user interface board assembly Fit replacement us
29. efore starting refer to the front of Section 19 Important information Remove the front panel refer to Section 16 3 Lower the control panel refer to Section 16 4 If safety valve seating is damaged it will be necessary to replace safety valve as a complete unit repair is not possible Drain down central heating water circuit and drain the boiler refer to relevant part of Section 19 8 e Remove the base panel secured with four screws and hooked in at the rear e If It is not possible to remove the safety valve securing pin without straining the pipe work to remove the safety valve Continue following the removal instructions below e Remove the heating flow isolating valve by disconnecting the two union nuts and removing the securing clip Disconnect the heating flow union nut at the safety valve housing Disconnect safety valve discharge pipe from safety valve e Remove the safety valve and housing e Remove safety valve securing pin e Remove safety valve Fit replacement safety valve 2000221595 Note Apply a small quantity of silicon grease to the safety valve O ring prior to fitting Open isolating valves on flow and return connections refill vent and pressurise boiler e Check for leaks 19 19 Domestic safety valve 10 bar refer to diagram 19 14 Before starting refer to the front of Section 19 Important information If safety valve seating is damaged it will be necessary to r
30. eplace safety valve as a complete unit repair is not possible e Remove the base panel secured with four screws and hooked in at the rear see diagram 19 14 Drain down the boiler refer to relevant part of Section 19 8 Disconnect safety valve discharge pipe from safety valve e Remove wire clip securing safety valve to domestic hot water outlet fitting and remove safety valve Fit replacement safety valve Note Apply a small quantity of silicon grease to the safety valve O ring prior to fitting Open isolating valves on flow and return connections refill vent and pressurise boiler e Check for leaks 19 20 Main heat exchanger refer to diagram 16 5 and 19 15 Before starting refer to the front of Section 19 Important information Remove the front panel refer to Section 16 3 Lower the control panel refer to Section 16 4 e Remove the sealed chamber cover refer to Section 16 5 e Remove the combustion chamber cover refer to Section 16 7 Drain down central heating water circuit and drain the boiler refer to relevant part of Section 19 8 Disconnect power supply leads and earth lead from fan Unscrew and remove two fan retaining screws from the right hand side edge of fan mounting plate e Remove fan with mounting plate attached by pulling forward and out of boiler e Remove air pressure switch sensing tube from sensing probe on flue hood e Remove screws securing flue hood to rear pa
31. er e Reconnect gas pipes Refit electrical connections in reverse order to removal GAS SAFETY VALVE Diagram 19 13 33 2000221595 19 16 Gas safety valve refer to diagram 19 13 Before starting refer to the front of Section 19 Important information e Remove the front panel refer to Section 16 3 Lower the control panel refer to Section 16 4 Remove gas control valve assembly refer to Section 19 15 Locate gas safety valve on the rear of the gas valve e Unscrew and remove the 2 screws securing the gas safety valve to the gas control valve Fit replacement gas safety valve in reverse order to removal taking care not to damage the O ring Refit electrical connections the polarity of the wires to the modulating coil is not important e Refit electrical connector to the gas safety valve Fit replacement gas control valve assembly into boiler e Reconnect gas pipes e Refit electrical connections in reverse order to removal 19 17 Spark ignition unit refer to diagram 19 13 Before starting refer to the front of Section 19 Important information Remove the front panel refer to Section 16 3 Lower the control panel refer to Section 16 4 Disconnect electrical connections from spark ignition unit e Remove screw securing spark ignition unit to gas valve mounting bracket Replace spark ignition unit 19 18 Heating safety valve 3 bar refer to diagram 19 14 B
32. er interface board 19 28 Clock timer refer to diagrams 19 17 and 19 18 Before starting refer to the front of Section 19 Important information e Remove the front panel refer to Section 16 3 Lower the control panel refer to Section 16 4 Gain access to rear of control panel e Unclip side clips and hinge up control panel cover see diagram 11 2 Carefully pull off electrical connection from the clock timer to PCB at B5 e Remove the two securing screws to release the control panel fascia e Remove the two clock timer securing screws to remove clock timer e Fit replacement clock timer 19 29 Mains power switch refer to diagram 19 17 Before starting refer to the front of Section 19 Important information e Remove the front panel refer to Section 16 3 Lower the control panel refer to Section 16 4 Gain access to rear of control panel e Unclip side clips and hinge up control panel cover see diagram 11 2 e Slide back and up to remove the mains power switch Carefully pull off electrical connections from the mains power switch Fit replacement mains power switch 37 19 Replacement of Parts MAINS POWER SWITCH USER INTERFACE BOARD Diagram 19 17 m z Bm RIS SEA CLOCK TIMER Diagram 19 18 2000221595 19 30 Domestic Hot water storage vessel refer to diagram 19 19 For this operation the boiler must be removed from the wall Before starting refer
33. ervicing and Maintenance To ensure the continued efficient and safe operation of the appliance 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 but in general once a year should be enough 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 in accordance with the rules in force in the countries of destination To obtain service please call your installer or Heatcall Glow worm s own service organisation using the telephone number behind the controls cover door Please be advised that the Benchmark logbook should be completed by the installation engineer on completion of commissioning and servicing All CORGI Registered Installers carry a CORGI ID card and have a registration number Both should be recorded in your boiler Logbook You can check your installer is CORGI registered by calling CORGI direct on 01256 372300 Cleaning WARNING This appliance contains metal parts components and care should be taken when handling and cleaning with particular regard to edges of sheet metal parts to avoid any possiblity of personal injury The boiler casing can be cleaned using a mild l
34. essel e Refit boiler onto fixing jig tighten all connections ensuring that all sealing washers are fitted before tightening e Reconnect flue making sure that all joints are properly connected 19 32 Storage vessel heating element refer to diagram 19 21 For this operation the boiler must be removed from the wall and the storage vessel removed refer to Section 19 30 e Remove the insulation from around the storage vessel Locate heating element Peel off the heating element secured with self adhesive tape Clean the surface prior to fitting the replacement heating element in same position as old heating element Refit vessel in reverse order to removal Refit boiler onto fixing jig tighten all connections ensuring that all sealing washers are fitted before tightening e Reconnect flue making sure that all joints are properly connected 39 DOMESTIC HOT WATER STORAGE VESSEL DOMESTIC HOT WATER STORAGE VESSEL 19 Replacement of Parts Diagram 19 21 2000221595 19 Replacement of Parts 19 33 Expansion vessel refer to diagram 19 22 UNION NUT NU For this operation the boiler must be removed from the wall JOE D RETAINING Before starting refer to the front of Section 19 Important E L 4 NUT information Drain down central heating and domestic hot water circuit of boiler only refer to relevant parts of Sections 16 13 and 19 8 Note It is not necessary to d
35. etent person Hab 264 To stop the boiler Press button 1 Setting to the SUMMER position Setting to the WINTER position Hot water only Heating hot water Press the mode button to select the summer symbol Press the mode button to select the winter symbol The flame symbol appears The actual temperature Illuminates when when the boiler is running of the heating system the boiler lights Press or to adjust the maximum temperature Press or to adjust the maximum temperature of the hot water 38 C to 60 C of the heating 38 C to 87 C Visual indication of set temperature Visual indication of set temperature To obtain domestic hot water open a hot water tap Hot water always has priority over central heating 5 2000221595 Clock timer instructions for use The boiler must be conected to the electrical supply and switched on Setting the time Rotate the clock actuater mechanism clockwise by hand until the current time is indicated by the arrow see diagram 2 Note The time is set in 24 hour format for example 1300 for 1pm Diagram 2 Setting the programme On and Off times e Select the On times by pushing the white tappets to the outside see diagram 2 Selectthe Off times by pushing the white tappets to the inside see diagram 2 The clock shown in diagram 2 is set as follows ON 07 00am to 09 00am 7 9 OFF 09 00am to 4 00pm 9 16 ON 4 00pm to 10 00pm 16 22 OFF
36. fore carrying out any electrical replacement work On completion of a fault finding task that has required the disconnection and making of electrical connections then check for earth continuity polarity and resistance to earth must be carried out If any gas carrying components are disturbed removed or replaced it will be necessary on completion to check for gas soundness with leak detection fluid Before trying to operate the boiler make sure that All gas supply cocks are open and that the gas supply has been purged of air Table 2 here is a permanent mains supply to the boiler he heating system pressure is at least 1 bar The fuse on the PCB is intact Preliminary electrical system checks as outlined in a multimeter instruction book are the first checks to be carried out during a fault finding procedure Should there be any doubt about the voltage supply to any of the components it is possible to carry out a simple electrical test to ensure all is operational in that area To carry out the electrical test gain access to the main Printed Circuit Board PCB and measure the voltages according to table 2 Voltage Measured value Measuring point 230 Volt 230 V AC Between terminals H8 1 and H8 2 24 Volt maximum 33V DC minimum 20V DC 15 Volt 15V 0 5V Between terminals B2 4 and B2 7 Between terminals B2 4 and B2 2 Display 5V 4 0 5V Between terminals B2 4 and B4 2 The In board fault diag
37. ging bracket Fit the washers between the boiler pipes and the inlet and outlet fittings on the fixing jig and connect the various couplings between the boiler and jig Fit the base panel hook in at the rear secure with the four self tapping securing screws at the front 2000221595 14 10 Flue Installation 10 1 Top outlet flue kit 86285 The boiler is only suitable for top outlet flue connection 10 2 Rear flue systems Refer to diagram 10 1 To calculate the length when flueing to the rear measure wall thickness e plus 160 mm for the outer air duct and e plus 244 mm for the inner flue duct measurement 10 3 Flue systems Right or Left Refer to diagram 10 1 To calculate the length when flueing to the side measure wall thickness e plus inside of wall to side of boiler a add 145 mm for the outer air duct and wall thickness e plus inside of wall to side of boiler a add 229 mm for the inner flue duct measurement Refer to diagram 10 2 Table A for cutting lengths of both flue duct and air duct pipes for each of the various flue options available Important All flue cutting lengths must be measured from the terminal end of the flue pipes see diagram 10 2 D When the dimension X measured on site is greater than that given in diagram 10 2 Table B extensions will be required as necessary Calculation of flue cutting lengths for extended flue Usingthe correct number of extension kits as Tabl
38. h Heating Ltd HE T Customer Services Tel 01773 828100 Nottingham Road Belper Derbyshire DE56 1JT General Sales enquiries Fax 01773 820569 One Contact Local Service Fax 01773 828070 Tel 01773 824141 Important Information Testing and Certification This boiler is tested and certificated for safety and performance It is therefore important that no alteration is made to the boiler without permission in writing from Hepworth Heating Ltd Any alteration not approved by Hepworth Heating Ltd could invalidate the certification boiler warranty and may also infringe the current issue of the Statutory Requirements The requirements are The installation of this boiler must be carried out by a competent person in accordance with the current rules in force in the countries of destination at the time of installation Manufacture s instructions supplied Manufacture s instructions must not be taken as overriding statutory requirements Note The boiler serial number is marked on the label attached to the inside of the drop down door Refer to the Introduction section for a description of the basic functions of the boiler The Users section describes how to safely operate the boiler Mandatory warning for CEE countries Warning This appliance is designed approved and inspected to meet the requirements of the market The identification plate located on the inside of the appliance certifies the origi
39. ilure The boiler no longer operates As soon as power supply is restored the boiler will be automatically restarted Frost protection The XTRAFAST has a built in frost protection device that protects the boiler from freezing If the boiler is to be left and there is arisk of frost ensure that the gas and electrical supplies 2000221595 are left connected The frost protection device will light the boiler when the temperature of the boiler water falls below 6 C When the temperature reaches 16 C the boiler stops Note This device works irrespective of any room thermostat setting and will protect the complete heating system Heating safety valve CAUTION A heating safety valve with a discharge pipe is fitted to this boiler The valve MUST NOT BE TOUCHED except by a qualified registered person If the valve discharges at any time switch the boiler off and isolate it from the electrical supply Contact your installation service company Pressure relief valve CAUTION A domestic hot water pressure relief valve with a discharge pipe is fitted to this boiler The valve MUST NOT BE TOUCHED except by a qualified registered person If the valve discharges at any time switch the boiler off and isolate it from the electrical supply Contact a qualified service engineer or Heatcall Glow worm s own service organisation using the telephone number behind the controls cover door or on the front cover of this booklet S
40. ion Boiler nie Connect the safety valve discharge pipe to the outlets of both vessel the heating safety valve and the domestic water safety valve if required the discharge must be extended using not less than 15mm pipe to discharge in a visible position outside the building facing downward preferably over a drain The pipe must have a continuous fall and be routed to a position sothatany discharge of water possibly boiling or steam cannot create any danger to persons damage to property or external electrical components and wiring Tighten all pipe connection joints Cold supply 8 9 Gas connection G The supply from the governed gas meter must be of adequate Filing device size to provide a constant inlet working pressure of 20 mbar 8 Heating n in Ww g circuit avoid low gas pressure problems itis recommended that the gas supply is connected using 22 mm pipe control valve Drain point Diagram 8 2 On completion the gas installation must be tested using the pressure drop method and purged in accordance with the HEATING SAFETY DOMESTIC current issue of BS6891 VALVE 3 bar masz SAFETY 8 10 Gas Safety Installation and use y 5 VALVE Regulations 21 wa l A 10bar In your interests and that of gas safety itis the law that ALL gas appliances are installed and serviced by a competent person in accordance with the above regulations Diagram 8 3 13 2000221595 9 Boiler inst
41. iquid detergent with a damp cloth followed by a dry cloth to polish Do not use any form of abrasive or solvent cleaner as you may damage the paint work Boiler casing CAUTION Do not remove or adjust the casing in any way as incorrect fitting may result in faulty operation If in doubt consult your installation service company 1 Technical Data o 5 x e o lt x lt lt lt x e X gt Heating Heating output ajustable from kW to kW from BTU H to BTU H Efficiency Maximum heating temperature C Expansion vessel effective capacity 1 Expansion vessel charge pressure bar Maximum system capacity at 75 D 160 275 safety valve O Qo maximum service pressure bar Products outlet diameter mm 60 Fresh air inlet diameter mm 100 100 Hot water Hot water output automatically variable from kW to kW from BTU H CBTU H Maximum hot water temperature C Specific flow rate for 30 C temp rise I min Threshold flow rate I min Nominal water flow rate I min Maximum supply pressure bar Minimum operating pressure bar Natural Gas G20 Es XTRAFAST 96 Es XTRAFAST 120 Burner injector mm Inlet pressure mbar Burner pressure mbar Gas rate maximum m h 3 20 3 98 Gas rate minimum m h 1 32 Electrical supply V 230 Maximum absorbed power W Level of protecti
42. ken 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 The insulation is composed of non combustible material Spare Parts REMEMBER 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 Hepworth Heating Ltd 2000221595 2 Contents CONTENTS INSTRUCTION FOR USE INSTALLATION INSTRUCTIONS SERVICING INSTRUCTIONS DESCRIPTION Introduction Controls and Lighting Clock timer instructions for use Draining Safety Devices Servicing and Maintenance Technical Data Dimensions Heating System Design Domestic Hot Water System Design Boiler Schematic Boiler Location Flue and Ventilation Fixing Jig Pack Piping System Installation Boiler Installation Flue Installation Electrical Connection Commissioning Safety Devices Changing Gas Type Settings Routine Cleaning and Inspection Fault Finding Wiring Diagram Replacement of Parts Spare Parts SECTION gt PAGE O O O O 2000221595 Introduction The XTRAFAST 96 and 120boiler is a wall mounted modulating c
43. low worm 2000221595 11 01 Quality through design Instructions for Use Installation and Servicing Tobeleftwiththe user Hab 255a rafast 96 120 G C No 47 047 25 G C No 47 047 26 Fanned Flue Combination Boiler C benchmark gt The mark of quality for domestic heating This is a Cat IL Appliance The instructions consist of three parts User Installation and Servicing Instructions which include the Guarantee Registration Card 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 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 First Year Guarantee In the centre pages are to be found your Guarantee Registration Card which we recommend you complete and return as soon as possible If this card is missing you can obtain a copy or record your registration by telephoning the Heatcall Customer Service number 01773 828100 Our Guarantee gives you peace of mind plus valuable protection against breakdown by covering the cost of HY All replacement parts REGISTER YOUR GLOW WORM APPLIANCE W All labour charges FOR 1ST YEAR GUARANTEE PROTECTION L All call out charges CALL 0208 247 9857 Hepwort
44. m 19 4 Disconnect air pressure switch electrical connections Undo screws on top of boiler securing air pressure switch to boiler and remove switch 19 6 Domestic water flow sensor refer to diagram 19 5 Before starting refer to the front of Section 19 Important information 1 WATER Remove the front panel refer to Section 16 3 FLOW Lower the control panel refer to Section 16 4 t SENSOR e Drain down domestic hot water circuit of boiler only refer to relevant part of Section 16 13 Locate flow sensor on cold water inlet pipe to boiler inside controls area Carefully pull off electrical connector from flow sensor Pull out slotted metal clip securing cold water inlet pipe to flow Diagram 19 5 sensor disconnect union nut securing cold water inlet pipe to isolating valve and remove Pull out slotted metal clip securing flow sensor to pump mounting remove sensor 19 7 Printed circuit board PCB refer to diagram 19 6 Before starting refer to the front of Section 19 Important information Remove the front panel refer to Section 16 3 Lower the control panel refer to Section 16 4 Gain access to rear of control panel Unclip side clips and hinge up control panel cover to gain access to PCB see diagram 11 2 Carefully pull off electrical connections to PCB Unclip and lift out PCB pP a CENTRAL Note Make sure that PCB connections are fully pushed onto Ab
45. n and use Regulations In your interests and that of gas safety itis the law that ALL gas appliances are installed and serviced by a qualified registered person in accordance with the above regulations Gas leak or fault If agas leak or fault exists or is suspected turn the boiler off and consult the local gas supply company or your installation service company Air in the heating system Persistent air in the heating system may indicate leaks in the system or corrosion taking place Call your Installation Servicing company Overheating safety In the event of a problem the overheating safety devices cause safety shutdown of the boiler If this happens call your Installation Servicing company Boiler controls The control panel located at the lower front of the boiler casing see diagram 1 allows the boiler to be started shut down controlled and monitored during use Flue Do not obstruct the outside terminal of the boiler Ancillary equipment A range of flue accessories are available including vertical flues twin pipe flues bends etc For further information contact your supplier Controls and Lighting Bis M ere Make sure that e The boiler is connected to the electrical supply e he gas service cock is open Then follow the instructions below Press the On Off button 1 The pressure must be between 1 and 2 bar If not the system must be filled by a comp
46. n where the product was manufactured and the country for which it is intended If you see any exception to this rule please contact your nearest Glow worm dealer Thank you in advance for your assistance 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 Product production certified by Notified body 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 harmonization of the Laws of the Member States relating to the 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 Substances Hazardous to Health The adhesives and sealants used in this appliance are cured and give no known hazard in this state INSULATION PADS CERAMIC FIBRE GLASSYARN MINERAL WOOL 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 bro
47. nel e Lift flue hood clear of heat exchanger Unclip overheat thermostat from heating flow pipe e Pull out slotted metal clips securing pipes from heat exchanger e Lift heat exchanger up and forwards to remove from boiler taking care not to damage insulation DO NOT DAMAGE PAINTED FINISH OF HEAT EXCHANGER Fit replacement heat exchanger Note When re fitting fan make sure that the two lugs on the fan mounting plate engage in the flue hood 19 Replacement of Parts Open isolating valves on flow and return connections refill qu LL vent and pressurise boiler e Check for leaks 19 21 Overheat thermostat refer to diagram 19 15 Before starting refer to the front of Section 19 Important information e Remove the front panel refer to Section 16 3 Lower the control panel refer to Section 16 4 Remove the sealed chamber cover refer to Section 16 5 Locate high limit thermostat on heating flow pipe on left hand side of boiler e Disconnect electrical connection from thermostat Unclip thermostat from heating flow pipe Fit replacement thermostat in reverse order to removal Use heat sink compound supplied e Refit connection to thermostat 19 22 Combustion chamber insulation Before starting refer to the front of Section 19 Important information Remove the front panel refer to Section 16 3 Lower the control panel refer to Section 16 4 Remove the sealed chamber cove
48. ng resistor see diagram 11 3 ON NO ACCOUNT must any electrical voltage be applied to any of the terminals of the external controls plug Remote Control A remote control is available for the Xtrafast Part no xxxxxx If the remote control is fitted the wire link must be in place on connector E and the Switch SW3 must be adjusted see diagram 11 4 11 2 Electrical test Carry out preliminary electrical system checks as below 1 Test insulation resistance to earth of mains cables 2 Test earth continuity and short circuit of all cables 3 Test the polarity of the mains ON OFF Set 1 amp 2 OFF 1 Remote Control with without for normal 2 Parameters open locked Table 4b operation Diagram 11 4 Note For further information see the building regulations 1991 Conservation of Fuel and Power 1995 edition appendix G 17 2000221595 12 Commissioning Please ensure the Benchmark logbook is completed and left with the user The commissioning and first firing of the boiler must only be done by a qualified registered person Gas valve settings Refer to Section 15 Settings Gas installation It is recommended that any air is purged from the supply at the gas inlet test point on the gas valve see diagram 12 1 Filling th 1 g the system 1 to 8 GAS INLET TEST POINT Press the mains On Off button The warning light will illuminate The display will indicate 0 bar pressure in the sys
49. nostic system Should a fault occur on the boiler the warning LED at the top of the user display amp will illuminate and the LCD display will indicate the precise area where the fault has occurred A fault code is displayed on the left hand side of the LCD display whilst at the same time the letters appear with a telephone symbol Thermistor values The following table applies to the central heating domestic hot water and storage vessel thermistors Temperature C Resistance 2 m U 32565 25345 gt 19875 15700 i us 12500 UT q 10000 Kk P 8060 S 6535 5330 7 Es NER ERE RE 4370 5 a 3605 o p T 2989 op P a 2490 2085 J MR 1755 y 1480 1 1260 S 1070 920 I MO 785 jj 680 2000221595 System pressure sensor The resistance of The sensor at various pressures is as follows 0 bar between 280 Q and 320 Q Bor between 195 Q and 220 Q 3 between 93 Q and 143 Q 26 17 Fault Finding TO AID FAULT FINDING REFER TO DIAGRAMS 5 1 AND 18 1 CODE TYPE OF FAULT DISPLAY SYMBOL CHECK THIS SYMBOL IS NOT INSTANTANEOUS BUT IF IT APPEARS AFTER 40 SECONDS CHECK AIR FLOW SAFETY THE FLUE SYSTEM FOR A BLOCKAGE EXCESS LENGTH c e CHEC
50. of pictograms and or letters and numbers exactly in which area the fault lies Should the boiler fail to operate during Commissioning the most likely fault is that the gas supply to the boiler has not been turned on or purged sufficiently or thatthere is no pressure in the heating system These are indicated as follows 13 1 No gas supply 4 This will be indicated on the g X display as a pictogram of a spark To rectify this proceed as follows e Switch off the boiler at the On Off push button Rectify the gas supply problem Restart the boiler by pressing the On Off button 13 2 Insufficient system pressure This will be indicated on the display as a flashing warning indicating the system pressure islow Torectify thisthe system must be re filled refer to Section 12 Commissioning EVES 13 3 Other faults These are indicated on the display by a fault code and a telephone symbol Further information on the fault codes can be found in the Section 17 Fault Finding 21 General safety devices 13 4 Air flow rate safety device If an obstruction even partial of the flue occurs for any reason whatsoever the built in safety system of the boiler will turn the boiler OFF and the fan will continue to run The boiler will be ready to operate when the fault has been cleared 13 5 Overheat safety In case of boiler overheating the overheat thermostat will turn the boiler off
51. of the heating 38 C to 87 C Visual indication of set temperature 2000221595 20 Adjust heating temperature to maximum 87 Check that any external controls if fitted are calling for heat set room thermostat to maximum Allow the temperature to rise to the maximum value with all radiator valves open The temperature rise will cause release of the gases contained in the water of the central heating system Gases driven towards the boiler will be automatically released through the automatic air vent he gases trapped at the highest point of the system must be released by bleeding the radiators Check the burner gas rate required ten minutes from lighting Refer to Data Label on electrical controls box Should there be any doubt about the gas rate it should be checked at the meter On reaching maximum temperature the boiler should be turned off and the system drained as rapidly as possible whilst still hot Refill system to a pressure of between 1 and 2 bar and vent as before Restart boiler and operate until a maximum temperature is reached Shutdownboiler and ventheating system If necessary top up heating system and make sure that a pressure of atleast 1 bar is indicated when system is COLD 13 Safety Devices The XTRAFAST incorporates a visual display that indicates fault conditions should they occur In the event of a fault the display will indicate by means
52. ombination boiler with electronic ignition providing central heating and instantaneous hot water The boiler is equipped with a 4 litre domestic hot water storage vessel that ensures maximum hot water temperature stability during domestic demand The boiler is of the Il category for use with Natural Gas G20 as distributed in the United Kingdom The boiler has a fan assisted balanced flue which both discharges the products of combustion to and draws the combustion air from the outside of the room The boiler is suitable for top outlet flue connection only Both the central heating and domestic hot water temperature are user adjustable from the boiler control panel Domestic hot water demand always has priority over heating demand The 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 The boiler can be installed against either an external wall or on an adjacent inside wall that is the flue system will pass directly to the rear or to either side to the terminal fitted on the outside wall face The installation must be carried out by a competent person in accordance with the relevant requirements of The Building Regulations The Water Byelaws The Building Standards Scotland Regulations and any applicable local regulations These instructions should be carefully followed for the
53. on Paa P44 Fuse rating Xtrafast 96 Xtrafast 120 Lift weight 51 2kg 112 9lb kg Ib Total weight Inclusive water kg D kg D The Seasonal Efficiency Domestic Boilers UK SEDBUK is ro The value is used in the UK Government s Standard Assesssment Procedure SAP for energy rating of dwellings The test data from which it has been calculated have been certified by B S I 2000221595 1 Technical Data PUMP 96 60 c 50 sL v 5 2 5 E 88g i5 9 zg 10 c a 200 400 600 800 1000 1200 10 kPa 1 m WG Flow rate through heating system l h PUMP 120 80 _ 70 it 60 25 50 9 40 HB 5 amp 30 22 20 9 c 0 a O 200 400 600 1000 1200 10 kPa 1 m WG Flow rate through I h Bypass fully shut open 1 4 turn amp open 1 2 turn Open 1 turn open 2 turns Diagram 4 2000221595 8 2 Dimensions The XTRAFAST is delivered in three separate packages the boiler the fixing jig the flue system Lifting Weight 51 2 kg X 470 96 552 120 Diagram 5 3 Heating System Design e The XTRAFAST is compatible with any type of installation Heating surfaces may consist of radiators convectors or fan assisted convectors The XTRAFAST can
54. on 16 4 Locate 3 way valve in centre of lower controls area e Remove electrical plug from valve head Pull out slotted metal clip from valve body and remove valve head from body e Fit replacement valve head Note 1 When refitting clip ensure that letters OK are as shown 2 It is not necessary to drain boiler to carry out this work 19 11 Three way valve actuator refer to diagram 19 10 Before starting refer to the front of Section 19 Important information Remove the front panel refer to Section 16 3 Lower the control panel refer to Section 16 4 Drain down central heating and domestic hot water circuit of boiler only refer to relevant parts of Sections 16 13 and 19 8 Note It is not necessary to drain down entire heating system to carry out this work Remove three way valve head refer to Section 19 10 Pull out slotted metal clips and remove bypass pipe e Remove three way valve actuator from three way bypass valve housing e Fit replacement three way valve actuator into three way bypass valve housing 19 12 Bypass refer to diagram 19 11 Before starting refer to the front of Section 19 Important information e Remove the front panel refer to Section 16 3 Lower the control panel refer to Section 16 4 Drain down central heating water circuit and drain the boiler refer to relevant part of Section 19 8 Note itis not necessary to drain down the entire heating system to carry o
55. plug and shuttered socket outlet may be used instead of a fused spur box provided that a They are notused in a room containing a fixed bath or shower b Both the plug and socket comply with the current issue of BS1363 The mains electrical supply must be maintained at all times in order to provide domestic hot water SIDE CLIPS Do not interrupt the mains supply with atime switch or programmer WARNING ON NO ACCOUNT MUST ANY EXTERNAL VOLTAGE BE APPLIED TO ANY OF THE TERMINALS ON THE HEATING CONTROLS CONNECTION PLUG Warning 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 p m puris XTRAFAST boiler is designed to operate at maximum E I 2 efficiency at all times but will be most efficient and economical when connected to a room thermostat 11 1 External controls To gain access to the external control connections unclip side Bee IMPORTANT clips and hinge up control panel cover see diagram 11 2 With VOLTAGE FREE The boiler will work for heating without a room thermostat being MES room thermostat connected provided that the wire link fitted between the two terminals of the connector E is left in place see diagram 11 3 Without room Alternatively a 230V room thermostat can be used but do not thermostat make any connection to the compensati
56. q E L zh id and pressurise boiler Check for leaks X NV NONU S ARN i 19 9 Hot water plate to plate heat exchanger THREE WAY refer to diagram 19 8 VALVE Before starting refer to the front of Section 19 Important information u 2 ns 4 F e Remove the front panel refer to Section 16 3 3 PR Lower the control panel refer to Section 16 4 ls RA m Drain down central heating and domestic hot water circuits of boiler only referto relevant parts of Sections 16 13 and 19 8 Diagram 19 9 Togain access to the left hand securing screw Disconnectthe domestic water flow sensor at the plate to plate heat exchanger and cold water inlet Remove the domestic hot water flow sensor refer to Section 19 6 e Supporting domestic heat exchanger unscrew and remove two screws securing it onto pump mounting and 3 way valve bypass housing e Remove plate to plate heat exchanger from boiler Fitreplacement plate to plate heat exchanger using new seals supplied Note Plate to plate heat exchanger mounting screws are offset to ensure correct fitting of replacement THREE WAY VALVE BYPASS HOUSING THREE WAY VALVE ACTUATOR Diagram 19 10 31 2000221595 19 10 Three way valve head refer to diagram 19 9 Before starting refer to the front of Section 19 Important information e Remove the front panel refer to Section 16 3 Lower the control panel refer to Secti
57. r refer to Section 16 5 HEATING SAFETY VALVE 3 bar Diagram 19 14 e Remove the combustion chamber cover refer to Section 16 7 Remove main heat exchanger refer to Section 19 20 RESET e Remove fan and loosen flue hood refer to relevant parts of BUTTON Sections 19 3 and 16 9 Front panel insulation e Lift frontinsulation panel free from retaining lugs on combustion chamber cover Rear panel insulation Pull rear insulation panel free from retaining lug at rear of combustion chamber by tilting forward Fit replacement insulation panels in reverse order to removal e Refit combustion chamber cover Side Panels Note Rear panel must be removed first Pull out side panels free from retaining lugs at side of combustion chamber by tilting sideways e Fit replacement insulation panels in reverse order to removal e Refit combustion chamber cover 35 2000221595 19 Replacement of Parts 19 23 Burner Before starting refer to the front of Section 19 Important information e Remove the front panel refer to Section 16 3 Lower the control panel refer to Section 16 4 Remove the sealed chamber cover refer to Section 16 5 e Remove the combustion chamber cover refer to Section 16 7 Remove burner refer to Section 16 8 Assemble replacement burner supplied in parts as follows Fit burner injectors to burner injector bar and tighten Note Make sure that injector size marked
58. rain down entire heating system to carry out this work Disconnect flue system e Remove the base panel secured with four screws and hooked in at the rear Disconnect boiler pipes onto fixing jig e Remove the front panel refer to Section 16 3 Lower the control panel refer to Section 16 4 Gain access to rear of control panel e Unclip side clips and hinge up control panel cover see diagram 11 2 EXPANSION VESSEL Disconnect mains cable and any external controls cables Remove the sealed chamber cover refer to Section 16 4 Remove the two side panels refer to Section 16 6 Using the two lifting handles positioned bottom left of the controls and to the center right of the combustion chamber lift the boiler off the hanging bracket and away from the wall Supporting expansion vessel unscrew and remove expansion vessel retaining nut and screw e Remove expansion vessel e Fit replacement expansion vessel Note Check that expansion vessel pressure is correct see Section 1 Technical Data E Diagram 19 22 20 Spare Parts When ordering spare parts quote the part number and description stating the appliance model number and serial number from the data label Short parts list No Description Part No G C No HD Domestic hot water thermistor OFZ VO NEN Central heating thermistor DAZ TS
59. t screws at rear of burner chamber using a long blade screw driver Ease burner from boiler by lifting up from key hole slots threading the gas supply and ignition leads through the grommets and pulling forwards taking care notto damage the insulation Before you completly remove the burner pull off flame sense lead from flame sense electrode Clean burner by washing in soapy water Dry thoroughly before refitting e When refitting burner ensure that the burner locates and seals correctly through the grommets Note To gain access to injectors for removal refer to Section 19 24 in Replacement of Parts GROMMETS MAIN GAS SUPPLY NUT IGNITION LEADS SECURING SCREWS IGNITION ELECTRODE ASSEMBLY FLAME SENSE ELECTRODE Diagram 16 4 2000221595 16 Routine Cleaning and Inspection 16 9 Heat exchanger refer to diagram 16 5 Disconnect electrical leads from fan Unscrew and remove two fan retaining screws from the right hand side edge of fan mounting plate Remove fan with mounting plate attached by pulling forward and out of boiler e Remove air pressure switch sensing tube from sensing probe on flue hood e Remove screws securing flue hood to rear panel e Lift flue hood clear of heat exchanger and examine for debris Using a soft brush or vacuum clean as required DO NOT USE ANY TOOL LIKELY TO DAMAGE PAINTED FINISH OF HEAT EXCHANGER Note When re fitting fan make sure that the two lugs
60. tem Undo cap on automatic air vent on top of pump and leave undone Open the boiler isolating valves v and q the slot of the screw corresponds to flow direction Fully open valve m by turning anti clockwise Open the system filling loop and fill the The pressure must be between 1 and 2 bar system until the pressure indicated on the display is between 1 and 2 bar 2000221595 18 12 Commissioning Bleed each radiator to Leave the cap on the Open various hot water remove the air re tighten pump auto air vent open taps to bleed system bleed screws Make sure the display indicates a system pressure of between 1 and 2 bar Re fill system as necessary The warning light will extinguish at 1 bar The pressure must be between 1 and 2 bar 19 2000221595 12 Commissioning Lighting the boiler Make sure that e The boiler is connected to the electrical supply The gas service cock is open Then follow the instructions below Q Press the On Off button 1 The pressure must be between 1 and 2 bar If not the system must be filled by a competent person To stop the boiler Press button 1 Setting to the WINTER position Heating hot water Press the mode button to select the winter symbol The actual temperature of the heating system illuminates when the boiler lights Adjusting the heating temperature O Press or to adjust the maximum temperature
61. to damage the O ring 19 15 Gas Control valve assembly refer to diagram 19 13 Before starting refer to the front of Section 19 Important information Remove the front panel refer to Section 16 3 Lower the control panel refer to Section 16 4 Disconnect multi plug from stepper motor Disconnect electrical connections from spark ignition unit above gas control valve assembly Disconnect electrical connection from R H side of gas control valve assembly mounting bracket e Undo main gas supply nut from main burner see diagram 16 4 Note The washer must be kept for use on reassembly e Undo main gas union nut between gas control valve supply pipe and gas inlet valve Note The washer must be kept for use on reassembly Unscrew and remove screw securing gas control valve mounting bracket to boiler frame ear J GAS CONTROL VALVE ASSEMBLY e Withdraw gas control valve assembly pipes and bracket taking care not to strain the electrical connection at the rear of the gas control valve While supporting the gas control valve assembly disconnect the electrical connection atthe rear of the gas control valve see diagram 19 13 Using old gas control valve as a guide transfer gas pipes and bracket from old gas control valve to replacement gas control valve Refit electrical connector to the rear of the gas control valve assembly e Fit replacement gas control valve assembly into boil
62. ut this work Pull out slotted metal clips and remove bypass pipe Pull out slotted metal clip securing bypass into bypass housing ease up and out bypass valve using a screw driver 2000221595 32 19 Replacement of Parts Diagram 19 11 SYSTEM WATER PRESSURE SENSOR Diagram 19 12 19 13 System water pressure sensor refer to diagram 19 12 Before starting refer to the front of Section 19 Important information e Remove the front panel refer to Section 16 3 Lower the control panel refer to Section 16 4 Drain down central heating water circuit and drain the boiler refer to relevant part of Section 19 8 Locate system water pressure sensor at front left hand side of boiler Pull off slotted metal clip and remove sensor from boiler take care not to strain cables Remove electrical connection from sensor 19 Replacement of Parts 19 14 Gas control valve stepper motor refer to diagram 19 13 SPARK IGNITION UNIT Before starting refer to the front of Section 19 Important information e Remove the front panel refer to Section 16 3 Lower the control panel refer to Section 16 4 Locate gas control valve stepper motor attached to front of gas valve Disconnect multi plug from stepper motor e Remove screws securing stepper motor onto gas valve body Withdraw stepper motor from gas valve body e Fit replacement stepper motor in reverse order to removal taking care not

Xtrafast 96-120 Installation & Service Manual Boilers - Glow-worm

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Xtrafast 96-120 Installation &amp; Service Manual Boilers - Glow-worm

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Xtrafast 96-120 Installation & Service Manual Boilers - Glow-worm