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12-38hxi Range Installation & Service Manual Boilers - Glow-worm

1. 11 3 Burner Refer to diagrams 11 2 11 3 11 4 and 11 5 Isolate the gas supply at the gas service cock Disconnect the gas supply at the gas service cock NOTE DO NOT DISCONNECT AT THE GAS VALVE Remove the two gas pipe bracket securing screws from underside of inner case see diagram 11 1 Drop down the control panel into the service position Remove the four screws from the chassis front see diagram 11 3 Remove the chassis front by pulling it out at the top from its retaining slots NOTE When replacing chassis front panel ensure the bottom fits behind lip Disconnect the gas valve electrical plug at the gas valve see diagram 11 4 Disconnect the electrical leads from the fan Remove the five combustion chamber front securing nuts see diagram 11 5 Gently remove the fan gas valve andburner assembly from the combustion chamber complete with the gas pipe bracket and seal 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 Removal of the burner is not necessary during anormal service NOTE IF THE BURNER HAS TO BE REMOVED IT WILL REQUIRE A NEW GASKET WHEN REFITTED When replacing the assembly ensure the sealing grommet is correctly fitted CHASSIS FRONT pem SECURING SCREW P G 9247 CONTROL PANEL SERVICE POSITION Diagram
2. Make good the final connections 21 WALL TEMPLATE WALL PLUG 4 OFF SCREW N 12 x 50mm 4 OFF Diagram 6 1 12047 HANGING BRACKET 00200081 53 05 7 Gas Water and Condensate Connections GAS SERVICE COCK SHOWN IN 9 OPEN POSITION UNION CONNECTOR Ar GAS SERVICE N COCK LINER y GAS ae SERVICE SPIGOT ae gt COCK COUPLING set S GAS SUPPLY CONDENSATE PIPE IN DRAIN PIPE ee 7 1 Gas Connection Before connection check the supply of local gas The gas supply can be connected from below see diagram 7 1 or through the wall at the rear of the boiler Refer also to section 1 2 and 1 3 The whole of the gas installation including the meter should be inspected tested for soundness and purged in accordance with the current issue of BS6891 and in IE the current edition of I S 813 Domestic Gas Installations 7 2 Water Connections Provision is made for the water connections to be made from above the boiler see diagram 7 2 The position is shown on the wall template Flush out the domestic hot water and the heating systems before connecting to the boiler 7 3 Condensate Drain Connection The condensate drain see diagram 7 1 is suitable for use with standard Push fit overflow pipe and couplings DO NOT use adhesive when connecting to the spigot The drain pipe should be non corros
3. 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 balance 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 Donottwist reposition feetinstead 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 0020008153 05 Positioning of Appliance for Final Installation above worktop foreseeable obstructions etc Recommend 2 persons lift appliance to position into place Fit bracket securely onto wall before lifting appliance into position Obtain firm grip on front and sides of appliance lift upwards onto worktop if practicable Ensure stable balance achieved and lift upwards to position in place on bracket If 2 persons positioning onto bracket obtain firm grip at front and sides base of boiler Ensure co ordinated movements during 2 person lifts to ensure equal spread of weight of load Ensure safe lifting techniques are used keep back straight bend using legs when lifting load
4. This is an adaptive feature to cope with small system requirements 29 INNER CASING A casing PANEL PANEL a SS all wl SECURING ze REWS 2 OFF SECURING us 220 SCREWS Diagram 10 1 OVERHEAT FLOW THERMOSTAT 2 THERMISTOR RESET SWITCH J RETURN m RETURN THERMISTOR PIPE Diagram 10 2 7 iA THROTTLE GAS OFFSET ADJUSTMENT 12412 VALVE ELECTRICAL PLUG PRESSURE TEST POINT Diagram 10 3 0020008153 05 10 Commissioning 10 5 Testing Gas Natural Gas only Case Off Case On Burner CO G20 9 1 0 2 0 5 9 3 0 3 0 5 Burner CO Propane G31 10 5 0 3 0 7 10 7 0 3 0 8 Should any doubt exist about the gas rate check it using the gas meter test dial and stop watch at least 10 minutes after the burner has lit making sure that all other gas burning appliances and pilot lights are off The approximate gas rates 12hxi 1 29m h 45 6ft h 15hxi 1 61m h 57ft h 18hxi 2 0m h 70 6ft h 24hxi 2 57m h 90 8ft h 30hxi 3 02m h 107ft3 h 38hxi 4 06m h 143ft9 h The gas valve is factory set for natural gas G20 and should need no adjustment LPG G31 should be adjusted as described on page 27 LPG CONVERSION It should be checked that the supply pressure is 20mb when the boiler is firing at full rate This can be achieved
5. burner assembly Remove securing screw and washer in the centre of the insulation and withdraw insulation see diagram 13 3 0020008153 05 40 GAS YG MANIFOLD LPO mc Ef SCREW NS J 2 x FAN NN lt lt 11485 VENTURI PLATE SECURING SCREW 3 18hxi Illustrated Diagram 13 2 WASHER a x SECURING SCREW EXCHANGER w c ue NES gt Y Diagram 13 3 IT STEEL WASHER Diagram 13 4 13 Replacement of Parts 13 10 Viewing Window For access refer to section 13 1 Refer to diagram 13 4 Remove circlip Remove steel washer Remove glass Remove fibre washer Replace in reverse order 13 11 Heat Exchanger Refer to Manual Handling section on page 5 For access refer to section 13 1 Refer to section 11 3 for removal of the fan gas valve and burner assembly Drain the boiler Remove the clip securing the clear condense pipe to heat exchanger Pullto remove the clear condense pipe out of the bottom of the heat exchanger Undo the two nuts of the flow and return pipes from the heat exchanger see diagram 13 5 Move the pipes away from the heat exchanger Loosen the three heat exchanger securing screws and clamps two at the top and one at the bottom to remove the heat exchanger see diagram 13 5 CAUTION There will be water in the heat exchanger Remove clear condense pipe connector fr
6. 11 3 o o 12453 e ELECTRODE CONNECTOR IGNITION LEAD x FAN a ELECTRICAL LEAD GAS PIPE BRACKET EARTH SPADE e CONNECTOR HEAT EXCHANGER COMBUSTION CHAMBER FRONT SECURING NUTS b OFF IGNITER UNIT GAS VALVE Jee RETAINING SLOTS CHASSIS FRONT ELECTRICAL PLUG GAS VALVE Diagram 11 4 0020008153 05 32 11 Servicing 11 4 Combustion Chamber and Heat Exchanger Refer to diagram 13 3 Remove loose debris from combustion chamber using a soft brush and vacuum cleaner Carefully flush by spraying water any remaining debris through the condensate trap Ensure the water is kept away from electrical components 11 5 Condensate Drain The condense drain does not normally need removing during servicing To flush the condense drain carefully pour water into the heat exchanger and check that water flows freely to drain If the condense drain is blocked refer to section 13 16 for removal 11 6 Combustion Check Once the appliance has been reassembled apart from the front and inner casing panels connect a CO combustion analyser to the test point on the flue elbow see diagram 11 6 Turn on the gas service cock see diagram 11 1 With the power off and the appliance cold unclip the controls fascia and hinge it down to reveal the potentiometers on the rear of the User interface see diagram 11 7 Take care not
7. 2 persons performing lift ensure co ordinated movements during lift Avoid upper body top heavy bending do not lean forward sideways Recommend wear suitable cut resistant gloves with good grip to protect against sharp edges and ensure good grip Always use assistance if required Removal of carton from delivery van Recommend 2 person lift or 1 person with use of sack truck If 1 person is performing lift straddle the load tilt and place carton into position on truck Recommend secure appliance onto truck with suitable straps Ensure safe lifting techniques are used keep back straight bend using legs Keep load as close to body as possible If 2 persons performing lift ensure co ordinated movements during lift Always use assistance if required Carriage of carton from point of delivery to point of installation ground floor Recommend 2 person lift or 1 person with use of sack truck If 1 person is performing lift straddle the load tilt and place carton into position on truck Recommend secure appliance onto truck with suitable straps Ensure safe lifting techniques are used keep back straight 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 b
8. 230V ac 50Hz PERMANENT SUPPLY Diagram 9 2 00200081 53 05 9 Electrical Connections 9 2 Electrical connections testing Carry out preliminary electrical system checks as below 1 Testinsulation resistance to earth of mains cable 2 Testthe earth continuity and short circuit of cables 3 Testthe polarity of the mains 9 3 Pump Connection Ensure that a seperate pump supply cable is fed to the boiler see diagram 9 2 Remove connection box see diagram 9 1 Route the pump supply cable through the strain relief cable gland connect to the connection box as shown in diagram 9 2 Refer to diagram 12 1 for wiring colour code Refitthe connection box to the underside of the boiler using the two retaining screws 10 Commissioning Please ensure the Benchmark logbook is completed and left with the user and the magnetic lighting instruction label is placed on the surface of the boiler casing LPG CONVERSION 30hxi only NOTE Steps 10 1 to 10 3 will needto be completed before the appliance can be converted The 30hxi can be converted to run on LPG Propane G31 This conversion should only be carried out by a competent person During the conversion to Propane use of a suitable flue gas analyser is necessary 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
9. 3 0 7 Note that with the inner case front panel fitted the combustion readings will increase slightly Natural gas should read 9 3 0 3 0 5 Propane gas should read 10 7 0 3 0 8 33 Refer to diagram 11 6 For adjustment of Propane appliance refer to section 10 LPG conversion If adjustment proves necessary then proceed as follows Adjustment of the CO at minimum rate is very coarse so carefully adjust the CO with the offset adjustment to 9 1 see diagram 10 3 Rotate the service potentiometer fully clockwise see diagram 11 7 and recheck the maximum rate combustion which should be 9 1 0 2 0 5 After checking combustion rotate the service potentiometer fully anti clockwise so that the digital display indicates the water temperature Replace the cap onthe sampling point and refit the control cover rear panel 11475 COMBUSTION CHAMBER OFF ED ar ENG S Diagram 11 5 0020008153 05 11 Servicing i co LO co E COMBUSTION ANALYSER TEST POINT FLUE DUCT EXTENSION ded Diagram 11 6 RETAINING 5 LATCHES CONTROLS FASCIA SER INTERFACE a J lt MIN SERVICE POTENTIOMETER n i ATON MAX pee POTENTIOMETERS Diagram 11 7 0020008153 05 34 FRONT 2 CASING D gt r j LM Diagram 11 8 11 7 Inner Casing P
10. 7 0020008153 05 13 Replacement of Parts 13 15 Overheat Thermostat For access refer to section 13 1 Refer to diagram 13 7 Remove the electrical connections from the overheatthermostat Remove the retaining clip from the flow pipe Remove the overheat stat from the retaining clip NOTE When fitting new thermostat please ensure that it is located correctly onto the flat area of the pipe and the retaining clip is secure 13 16 Condensate Drain Refer to diagram 13 8 Remove the clips securing the flexible tubes to the siphon adapter by twisting the clips slightly to disengage the clip jaws from each other Remove flexible tubes from siphon adapter Lift off the siphon adapter Remove the drain connection downstream of the condense trap Remove the two condense trap securing screws Lift up and carefully remove the condense trap taking care not to spill any water which may be left in the unit As the unit is lifted remove the flexible pipe on the outlet Remove any solids found Before removing the float note it s orientation Remove the float to clean it Flush water through the trap to remove any remaining solids Check for any debris in the outlet pipe of the condensate drain and clean as necessary Reassemble and refit the condense trap IMPORTANT Please remove spigot bung before fitting condensate drain connection Using a suitable container flush the heat exchanger until the water
11. 87 B0 41 INJECTOR N A DOES NOT APPLY 87 B0 41 HEAT OUTPUT CONDENSING MODE 16 2kW HEAT OUTPUT CONDENSING MODE 30 58kW MAXIMUM MINIMUM MAXIMUM MINIMUM HEAT INPUT NETT Q kW 15 26 5 00 HEAT INPUT NETT Q 28 6 53 HEAT OUTPUTP kW 15 00 4 95 HEAT OUTPUT P 28 17 5 25 SERIAL No SERIAL No Ei 2000460401 Ke 2000460651 o C Slow worm gt C Slow worm 9 HEPWORTH HEATING LTD BELPER DERBYS DE561JT HEPWORTH HEATING LTD BELPER DERBYS DE561JT o 18hxi HIGH EFFICIENCY CONDENSING BOILER 38hxi HIGH EFFICIENCY CONDENSING BOILER 230V 50Hz 60W Fused at 3A GC No 41 047 63 230V 50Hz 60W Fused at 3A GC No 41 047 71 Foruseon I G20 20 mbar TYPE Cs Css Css Ces Foruseon Ij G20 20 mbar TYPE Cis Css Css Cas This boiler is intended exclusively EN437 IP X4D This boiler is intended exclusively EN437 IP X4D to be installed on a gas supply NOx Class 5 to be installed on a gas supply NOx Class 4 with a governed meter C 0086 with a governed meter WATER CIRCUIT PMS 3 bar WATER CIRCUIT PMS ie GB IE INJECTOR N A DOES NOT APPLY INJECTOR N A DOES NOT APPLY 37 B0 41 87 B0 41 HEAT OUTPUT CONDENSING MODE 20 02kW HEAT OUTPUT CONDENSING MUDE 410kW MAXIMUM acu MAXIMUM MINIMUM HEATINPUTNETTO SS EN HEAT INPUT NETT Q kW 38 35 6 70 HEAT OUTPUT P kW i HEAT OUTPUT P kW 18 57 4 95 38 00 es SERIAL No SERIAL No af Diagram 1 2 0020008153 05 12 2 Boiler Location and Ventilation 2 1 Boiler Locatio
12. Check that the CO combustion remains between 9 8 and 10 8 CO If it does not carefully adjust the gas valve throttle see diagram 10 3 until this is achieved 11 Remove analyser probe from the test point and replace the cap Refit the control panel 12 Fitthe LPG conversion label supplied in the documentation pack to the inner front panel alongside the data label Refit the inner door and outer door 10 Commissioning 10 1 Preliminaries All Systems Remove inner casing panel see diagram 10 1 A competent person in accordance with the current issue of BS6798 should carry out commissioning Make sure that the system has been thoroughly flushed out with cold water Refill the system with water making sure that all the air is properly vented from the system and pump diagram 10 2 shows vent point Before operating the boiler check that all external controls are calling for heat 10 2 Sealed Systems Fill the system until the pressure gauge registers the recommended pressure Clear any air locks and check for leaks Release the cold water to the initial design pressure 10 3 Preparation for Lighting Isolate the boiler from the mains electrical supply Test for gas soundness and purge air from the gas supply Turn on the gas service cock slot in line with the length of the valve see diagram 7 1 10 4 Initial Lighting The lighting procedure of the boiler is fully automated Check that all ext
13. Reminder leave these instructions and the Benchmark logbook with the user 11 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 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 British Gas 11 1 General Measurement of the products of combustion can be achieved by connection of a probe to the combustion analyser test point on the flue elbow see diagram 11 6 and section 11 6 IMPORTANT NOTE Products of combustion will be discharged when the cap is removed It is important to replace the cap immediately Testing Flue Gases If any doubt exists that the flue products are not exhausting correctly investigate by use of a gas analyser FGA 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 service cock see diagram 11 1 All routine servicing requirements can be achieved by the removal of the front pan
14. a 2mm Allen key and an electricians screwdriver Ensure that the appliance supply pressure 37mbar NOTE Remove the inner casing panel see diagram 10 1 1 To access the gas valve If necessary remove chassis front for extra access See diagram 11 3 Refer to diagram 10 3 and turn the gas valve throttle fully clockwise Turn the throttle back anti clockwise by 5 z turns Ensure that the gas analyser is set to the correct fuel setting Propane Attach combustion analyser to the combustion test point See diagram 11 6 0020008153 05 28 6 Unclip the controls fascia to reveal the service potentiometer on the rear of the user interface See diagram 11 7 Turn on the mains electrical supply and turn on the gas service cock Switch the boiler on Ensure external controls are calling for heat The boiler should fire automatically Using an electrical screwdriver rotate the service potentiometer to the mid point or 3 o clock position See diagram 11 7 The fan speed should now reduce to minimum and 12 should be shown flashing on the digital display Check the CO value If necessary refer to diagram 10 3 and using a 2mm allen key carefully adjust the offset screw until a CO reading of 10 5 0 2 is achieved Turning the offset screw clockwise increases the CO reading 10 After setting combustion rotate the service potentiometer fully anti clockwise so that the display indicates the water temperature
15. by checking the inlet pressure at the pressure test point on the gas valve shown in diagram 10 3 Disconnect pressure gauge Note that the burner pressure cannot be measured at the gas valve as it is altered by the suction of the fan and modulated according to demand Replace inner casing panel and casing panel see diagram 10 1 10 6 Testing Heating System Check that all remote controls are calling for heat The boiler will fire automatically Fully open all radiator valves flow control valve A and bypass valve B see diagram 4 3 Balance the radiators as required and if fitted adjust valve A to give the required system differential Turn off all radiators that can be shut off by the user and check to see if less than the maximum differential allowed of 20 C can be achieved across flow and return Allow the system to reach maximum temperature then switch off the boiler by isolating from the electrical supply Drain the entire system rapidly whilst hot using the drain tap at the lowest part of the system Fill and vent the system as described previously in section 10 2 Lock or remove the handle from control valve A to prevent unauthorised adjustment 10 7 Completion Adjust the boiler temperature control and any system controls to their required settings In addition itis necessary to complete the Benchmark logbook For IE itis necessary to complete a Declaration of Conformity to indicate c
16. flue to your required length Y mark the securing hole position in 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 8 7 Standard Separate the flue duct from the terminal by twisting to release the terminal catch then pull out of the retaining seal refer to diagram 8 8 The duct cutting lengths are shown in diagram 8 8 The air duct should be cut at the opposite end to the terminal fixing The terminal plastic duct MUST be cut at the opposite end to the catch The plastic flue duct extensions MUST be cut at the opposite end to seal The cut ducts must be de burred and all filings and debris removed NOTE If you require to lubricate the seals to ease installation please do not use a mineral oil based grease we would recommend the use of water 8 3 Flue Assembly The flue assembly is a push fit design with securing collars Having adjusted the telescopic or cut the air and flue ducts as described in section 8 2 Assemble the flue elbow to the air duct ensuring the correct alignment of the terminal Fit the collar into position mark through two of the pre drilled holes in the collar Remove collar and drill two 3mm diameter holes in the elbow take care not to pierce the inner flue duct Insert the terminal flue duct remembering to engage the catch within the terminal check for alignment Fit the rubber
17. from floor level Do not twist reposition feet instead Keep boiler as close as possible to body throughout lift to minimise strain on back Avoid upper body top heavy bending do not lean forward sideways 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 compartment etc restricting installation Recommend 2 persons lift appliance to position into place space permitting Fit bracket securely onto wall before lifting appliance into position Obtain firm grip on front and sides of appliance lift upwards onto worktop if practicable Ensure stable balance achieved and lift upwards to drop into place onto bracket If 2 persons positioning onto bracket obtain firm grip at frontand sides base of boiler Ensure co ordinated movements during 2 person lifts to ensure equal spread of weight of load If 1 person positioning onto bracket recommend obtain firm grip supporting base of boiler Ensure safe lifting techniques are used keep back straight bend using legs when lifting load from floor level Do not twist reposition feet instead Keep boiler as close as possible to body throughout lift to minimise strain on back Always use assistance if required Recommend wear suitable cut resistant gloves with good grip to protect against sharp edges and ensure goo
18. panel and discard Carefully place front panel and screws to one side 5 2 Wall Template Remove the wall template from the documentation pack and place in the desired position on a flat wall giving due consideration to boiler clearances see Section 2 2 and the flue you are fitting 5 3 Flue Hole Cutting The standard horizontal flues are designed with an internal fall of 44mm metre towards the boiler for disposal of condensate If the standard flue length alone is being used then the flue hole of diameter 105mm can be cut in the position marked on the wall template For standard side flues the horizontal flue centre line on the wall template should be extended to the side wall and the vertical centre of the flue hole marked at 176mm from the back wall For installations with external access a 105mm diameter core drill can be used For installations with internal access only a 125mm diameter core drill should be used When using extension pipes with the horizontal rear flue a core drill size of 125mm should be usedto allow the extension pieces to slope at 44mm metre 2 5 towards the boiler 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 ma
19. to run back into the boiler and out via the drain The flue can be installed from inside the building when access to the outside wall face is not practicable The diagrams 3 1 to 3 4 describe the lengths achievable without the use of extensions or elbows 75 min to 540 max a 12839 WALL THICKNESS OUTSIDE WALL FACE BOILER MOUNTING WALL NOTE If necessary it is permitted to increase this dimension to 600mm max TOP REAR FLUE STANDARD Diagram 3 1 NOTE If necessary it is permitted to increase this dimension to 600mm max 87min 12855 Max flue length 717mm 20mm min clearance OUTSIDE INTERNAL WALLFACE SURFACE Max distance from outside Min distance from outside wall face to min clearance wall face to min clearance LH 458mm RH 561mm TOP SIDE FLUE STANDARD LH RH 75mm Diagram 3 2 12837 208 min to 413 max WALL THICKNESS OUTSIDE WALL FACE BOILER MOUNTING WALL NOTE If necessary it is permitted to increase this dimension to 600mm max TOP REAR FLUE TELESCOPIC Diagram 3 3 NOTE If necessary it is permitted to increase this dimension to 600mm max N 20mm min clearance OUTSIDE INTERNAL WALLFACE SURFACE Max distance from out
20. 70 and Rhd is167 to suit a minimum wall thickness of 75mm Y 112 12658 j WALL THICKNESS T DRILL AND COLLAR OUTSIDE BOILER WALL FACE MOUNTING WALL TOP REAR FLUE STANDARD Diagram 8 3 x i A WALL THICKNESS 112 DRILL AND SCREW TOP REAR FLUE TELESCOPIC COLLAR BOILER OUTSIDE WALL FACE MOUNTING WALL DRILL AND SCREW Diagram 8 4 Top Side flue Telescopic with the flue elbow temporarily fitted measure the distance from the outside wall to the butt joint see diagram 8 6 If the measurement Y exceeds 525mm then the appropriate length of extension pipe is required if the dimension is less than 320mm DO NOT cut the flue it can project to a maximum of 600mm if this is not desirable then a Standard flue MUST be used and cut to length lt 12843 FLUE DUCT OUTER RUBBER COLLAR AIR COLLAR DRILL AND OUTSIDE WALL FACE INNER PLASTIC COLLAR TOP SIDE FLUE STANDARD Diagram 8 5 a y io co OUTER FLUE RUBBER DUCT AIR COLLAR DUCT COLLAR DRILL AND OUTSIDE WALL FACE INNER PLASTIC COLLAR TOP SIDE FLUE TELESCOPIC Diagram 8 6 25 0020008153 05 8 Flue Preparation Telescopic and Standard Flue 8 2 cont d Flue and Air Ducts Telescopic The Telescopic Flue system MUST NOT be cut Adjust the
21. ATE m h 0 67 4 06 GAS RATE after 10 mins ft h 23 8 143 from cold 1 4 Technical Data All dimensions are given in millimetres except as noted See diagram 1 1 and Tables 1 and 2 The data label is positioned on the inner door refer to diagram 1 2 The Seasonal Efficiency Domestic Boilers UK SEDBUK is All hxi boilers Class A The value is used inthe UK Government s Standard Assessment Procedure SAP for energy rating of dwellings The test data from which it has been calculated has been certified by B S I 1 5 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 7 3 for more details 11 0020008153 05 1 Technical Information x e 2000460684 M 2000460456 e CEGlow worm C Slow worm BELPER DERBYSHIRE DE56 1JT BELPER DERBYSHIRE DE56 1JT 12hxi HIGH EFFICIENCY CONDENSING BOILER 24hxi HIGH EFFICIENCY CONDENSING BOILER 230V 50Hz 60W Fused at 3A GC No 41 047 73 230V 50Hz 60W Fused at 3A G
22. C No 41 047 69 Foruse on Ij G20 20 mbar TYPE C s Css Css Cas Foruseon Ij G20 20 mbar TYPE CisC33 Css Cas This boiler is intended exclusively EN437 IP X4D This boiler is intended exclusively EN437 IP X4D to be installed on a gas supply NOx Class 5 to be installed on a gas supply NOx Class 5 with a governed meter with a governed meter WATER CIRCUIT PMS 3bar WATER CIRCUIT PMS 3bar INJECTOR N A DOES NOT APPLY INJECTOR N A DOES NOT APPLY 87 B0 41 87 B0 41 HEAT OUTPUT CONDENSING MODE 12 9kW HEAT OUTPUT CONDENSING MODE 25kW MAXIMUM MINIMUM MAXIMUM MINIMUM HEAT INPUT NETTQ kW 12 20 5 00 HEAT INPUT NETT Q kW 24 39 5 30 HEAT OUTPUTP kW 12 00 4 95 HEATOUTPUTP kW 24 00 5 25 SERIAL No SERIAL No Lo N 2000460685 e 2000460453 g C Slow worm x C Glow worm BELPER DERBYSHIRE DE56 1JT ka HEPWORTH HEATING LTD BELPER DERBYS DE561JT Y 15hxi HIGH EFFICIENCY CONDENSING BOILER 30hxi HIGH EFFICIENCY CONDENSING BOILER 230V 50Hz 60W Fused at 3A GC No 41 047 74 230V 50Hz 60W Fused at 3A GC No 41 047 64 Foruse on Ij G20 20 mbar TYPE C s Cs CssCo For use on ILusp Nip Adjusted for use on This boiler is intended exclusively EN437 IP X4D NOx Class5 natural gas G20 20 mbar to be installed on a gas supply x Class This boiler is intended exclusively with a governed meter to be installed on a gas supply WATER CIRCUIT PMS 3bar with a governed meter INJECTOR N A D0ES NOT APPLY WATER CIRCUIT PMS 3bar
23. ERFACE BOARD Diagram 13 12 0020008153 05 14 Spare Parts When ordering spare parts contact Glow worm s own service organisation using the telephone number on the inside front cover of this booklet Please quote the name of the appliance and serial number to be found on the data label see diagram 1 2 If ordering from British Gas also quote the G C number of the part Key No Part No Description GC No 1 801645 Fan assembly E84024 2 801637 Spark electrode E83999 3 801655 Igniter unit E84015 4 801649 Gas valve E84004 4 2000802452 Gas valve 38hxi only H20596 5 801722 Heating flow amp return thermistor 2 E84003 6 801724 Overheat stat E83996 7 4000124180 Main P C B E84019 8 801809 Mains Reset Switch E84794 9 2000802640 User interface 18 hxi kakak 9 2000802641 User interface 30 hxi ane 9 2000802658 User interface 12 hxi IUE 9 2000802659 User interface 15 hxi H17 407 9 2000802660 User interface 24 hxi H17 409 9 2000802801 User interface 38hxi H17 411 10 801632 Burner 12 hxi 15 hxi 18 hxi E84021 10 2000801702 Burner 24 hxi 30 hxi E84249 10 2000801702 Burner 38 hxi E84249 11 2000801923 230V Controls Interface E84018 3 Diagram 14 1 Because of our constant endeavour for improvement details may vary slightly from those shown in these instructions 00200081 53 05 44
24. EW x 2 GASKET SEALING fitted COLLAR Y SCREW x 1 TELESCOPIC TERMINAL ASSEMBLY SEALING COLLAR STANDARD TERMINAL ASSEMBLY Diagram 8 1 e xt 45 Bend 2 e 2000460485 lt T 2off 90 Bend 2000460484 o 0 5m EXTENSION 2000460481 im EXTENSION 2000460482 L3 VERTICAL FLUE ADAPTOR 2m A2024600 EXTENSION 2000460483 Diagram 8 2 0020008153 05 24 8 Flue Preparation Telescopic and Standard Flue 8 2 Flue Length Top Rear flue Standard with the flue elbow temporarily fitted measure the distance from the outside wall to the butt joint see diagram 8 3 If the measurement Y exceeds 652mm then the appropriate length of extension pipe is required The minimum dimension is187mm to suita 75mm min wall thickness Top Rear flue Telescopic with the flue elbow temporarily fitted measure the distance from the outside wall to the butt joint see diagram 8 4 If the measurement Y exceeds 525mm then the appropriate length of extension pipe is required if the dimension is less than 320mm DO NOT cut the flue it can project to a maximum of 600mm if this is not desirable then a Standard flue MUST be used and cut to length Top Side flue Standard with the flue elbow temporarily fitted measure the distance from the outside wall to the butt joint see diagram 8 5 If the measurement Y exceeds 652mm then the appropriate length of extension pipe is required The minimum dimension for Lhd is 2
25. 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 lt a 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 DEPT 400mm MIN ROWS OF 3 x 12mm HOLES AT 25mm CENTRES 50mm FROM BOTTOM OF TUBE HOLES T Internal Termination Downstream of ree AWAY FROM POUSE j Sink Waste External Termination into Soakaway Diagram 7 3 23 0020008153 05 8 Flue Preparation Telescopic and Standard Flue 8 1 Flue Components Additional flue accessories are available to suit your site s nm conditions see diagram 8 2 The components supplied in the Standard and Telescopic kit are shown in diagram 8 1 The Glow worm Flue Options Guide available on request or through the web site describes in detail the necessary accessories Top Outlet Horizontal Concentric Flue Packs FLUE A2043600 Horizontal telescopic flue pack ELBOW a A2043400 Standard horizontal flue pack SECURING SCREW x 4 COLLAR SEALING SCREW x 2 TAPE telescopic only SCR
26. Instructions for Use Installation and Servicing Tobeleftwiththe user 12041 12hxi 15hx1 G C No 41 047 73 G C No 41 047 74 18hxi 24hx1 G C No 41 047 63 G C No 41 047 69 30hxi 38hx G C No 41 047 64 G C No 41 047 71 High Efficiency Condensing Boilers low worm High Efficiency First Glow worm Nottingham Road Belper Derbyshire DE56 1JT 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 In addition this product is guaranteed for 12 months from the date of installation or 18 months from the date of manufacture whichever is the shorter for 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 CORGI registered gas installer 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 ma
27. Main PCB Central heating return temperature is greater than 90 C System fault Possible pump failure Check Thermistor on return Maximum temperature rise slope Possible pump failure Air in system Maximum delta temperature 0020008153 05 38 Check Thermistor on return System too restrictive Diagram 12 4 12188 13 Replacement of Parts 13 1 Important Notes 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 Replacement of parts must be carried out by a competent person Before replacing any parts the boiler must be isolated from the mains electric supply and the gas must be turned off at the service cock on the boiler see diagram 11 1 Unless stated otherwise parts are replaced in the reverse order to removal After replacing any parts always test for gas soundness and if necessary carry out functional test of the controls For replacement of parts the casing panel the inner casing panel and chassis front panel of the boiler will need to be removed see diagrams 10 1 and 11 3 to remove undo the two screws on the underside of the front casing Undo the two screws on the front of the inner front panel and lift off Remove the four screws from the chassis front and remove it by pulling it ou
28. ack 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 00200081 53 05 Manual Handling 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 personis performing lift straddle the load tilt and place carton into position on truck Recommend secure appliance onto truck with suitable straps Ensure safe lifting techniques are used keep back straight bend using legs Keep load as close to body as possible If 2 persons performing lift ensure co ordinated movements during lift 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 be
29. anel Seal Check Refer to diagram 11 8 Check the condition of the seal replace as required To replace remove the old seal thoroughly clean the casing surfaces Fit the new seal it is supplied to the correct length 12 Fault Finding NOTE 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 There is a permanent mains supply to the boiler There is a heating demand from the external controls WARNING Always isolate the boiler from the electrical supply before carrying out any electrical replacement work Always check for gas soundness after any service work Electrical Testing Shouldthere be any doubt aboutthe voltage supply to any ofthe components it is possible to carry out a simple electrical test Important On completion of the Service Fault Finding tasks which have required the breaking and remaking ofthe electrical connections the earth continuity polarity short circuit and resistance to earth checks must be repeated using a suitable multimeter To carry out the electrical test gain access as follows Hinge down the control box and remove Torx screws and unhook the rear panel refer diagram 12 1 Refer to the Wiring diagram 12 2 and fault finding charts diagrams 12 3 and 12 4 35 RETAINING STRAP RETAINING SLOT 9247 CONTROL PANEL Diagram 12 1 00200081 53 05 12 Fault F
30. appears clear in the container Reassemble siphon adapter 13 17 Inner Casing Sealing Panel Refer to section 11 7 13 18 Access to Switches User Interface and 230v controls Interface For access refer to section 13 1 Release the front of the controls fascia by carefully prising up the two retaining latches see diagram 11 7 Do not allow the front of the fascia to swing down and be loosely held by the electrical connections to the mains reset switch and user interface Either remove the connections or support the fascia 13 19 Mains Reset Switch Refer to section 13 18 for access Remove the switch retaining screw Remove switch from housing see diagram 13 9 Remove electrical leads 0020008153 05 42 a SIPHON ADAPTER CONDENSE TRAP SCREW ROM ee SPIGOT O BUNG remove and discard Diagram 13 8 MAINS RESET N ELECTRICAL SWITCH CONNECTIONS HOUSING sssi ee a KNOB RETAINING CLIPS 1 MAINS RESET SWITCH 2 MAINS RESET KNOB Diagram 13 9 13 Replacement of Parts 13 20 Mains Reset Knob Refer to section 13 18 for access Remove actuator by springing back retaining clips Spring back knob retaining clips and push knob out from the back see diagram 13 9 13 21 User Interface Refer to section 13 18 for access and diagram 13 10 Remove electrical plug Remove the three securing screws Withdraw the board When replacing the
31. are made To gain access to the connection box remove the two retaining screws indicated in diagram 9 1 and carefully lower and pull forward the box to reveal the terminal strip inside Remove the test cable from the terminal strip and discard Connect both the mains supply and switched live from the external controls room thermostat and if applicable frost thermostat into the marked terminals as shown in diagram 9 2 If aroom thermostat is not fitted then the connecting link must be fitted between terminals 1 and 2 see diagrams 9 2 and 12 2 Connect the pump supply into the marked pump terminals as shown in diagram 9 2 Observe all terminal markings and colour codes as shown in diagram 12 2 NOTE The boiler incorporates a pump overun thermostat Only feed the pump from the marked terminals in the connection box on the boiler not from a separate supply Ensure that all flexible cords are routed through the strain relief cable glands on the inlet of the connection box Refit the connection box to the underside of the boiler using the two retaining screws 27 RETAINING SCREWS 2 c LO Q N CONNECTION BOX Diagram 9 1 CONNECTION BOX 13113 JO PUMP NEUTRAL FROSTSTAT INO ma m3 If there are no external controls available then a link can be fitted which will make the boiler run continuously JUNCTION BOX DOUBLE POLE ISOLATOR
32. board refer to instructions supplied with replacement PCB on setting it up 13 22 Main PCB For access refer to section 13 1 Hinge down the control box see diagram 13 11 Remove TORX screws and unhook the rear panel Remove the electrical connections to the PCB Prise back the two PCB retaining clips and withdraw the PCB When refitting the rear panel ensure the leads are not trapped see diagram 13 1 13 23 Control Box For access refer to section 13 22 Remove relevant plugs and connectors refer to wiring diagram 12 1 Withdraw grommets and leads so they are hanging loose Unthread the retaining strap and remove the control box by drawing it outwards away from its retaining slots see diagram 13 11 13 24 Fuse Main PCB Control Box For access refer to section 13 22 The fuse is located at bottom right hand side of the PCB see diagram 12 2 or 13 1 13 25 230V Controls Interface For access refer to section 13 18 Disconnect the electrical connection from the 230V controls interface board and the electrical connection from the main PCB see diagram 13 12 Remove the 230V controls interface retaining screw Remove the 230V controls interface board 43 SECURING SCREWS 11417 USER INTERFACE Diagram 13 10 9247 RETAINING STRAP RETAINING SLOT CONTROL PANEL Diagram 13 11 11419 j 230V CONTROLS T INTERFACE USER INT
33. connections fittings must be in accordance with the relevant standards and water supply regulations For GB Guidance G17 to G24 and recommendation R17 to R24 of the Water Regulations Guide For IE The currentedition of I S 813 Domestic Gas Installations Where a storage system will not have a vent to atmosphere the installation must comply with the building regulations and local Water Company bylaws see also the current issue of BS5546 and BS6700 If fitting to an existing system the local authority should be informed 4 Water System 4 11 Sealed water Systems The installation must comply with the appropriate requirements ofthe current issue of BS4814 BS5449 BS6759 BS6798 and BS7074 Part 1 and 2 See diagram 4 3 for a suggested layout 4 12 Safety Valve A safety valve must be fitted to a sealed system It shall be preset non adjustable with a lift pressure of 3 bar incorporating seating of a resilient material a test device and a connection for drain The drain from the safety valve must be routed outside the building must not discharge above an entrance or window or any type of public access area be clear of any electrical fittings and positioned so that any discharge can be seen 4 13 Expansion Vessel A diaphragm type expansion vessel conforming to the current issue of BS4814 see also BS7074 Part 1 and 2 must be connected at a point close to the inlet side of the circulating pump see th
34. current issue of the 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 Typetestforpurposes 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 0020008153 05 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 Ceramic Fibre 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 handli
35. d grip when handling appliance Positioning of Appliance for Final Installation in roof space restricting installation Recommend 2 persons lift appliance to position into place space permitting Fit bracket securely onto wall before lifting appliance into position Obtain firm grip on front and sides of appliance lift upwards ensure stable balance achieved and lift upwards to position into place onto bracket If 2 persons positioning onto bracket obtain firm grip at front and sides base of boiler Ensure co ordinated movements during 2 person lifts to ensure equal spread of weight of load If 1 person positioning onto bracket recommend obtain firm grip supporting base of boiler Ensure safe lifting techniques are used keep back straight bend using legs when lifting load from floor level Do not twist reposition feet instead Keep boiler as close as possible to body throughout lift to minimise strain on back Always use assistance if required Recommend wear suitable cut resistant gloves with good grip to protect against sharp edges and ensure good grip when handling appliance It is recommended a risk assessment of the roof space area be carried out before moving the appliance into the area to take into account access stability of flooring lighting and other factors and appropriate measures taken Appliance Safety Devices User Instructions Electrical Supply Failure Reset Switch The boiler will not work wit
36. dance with these instructions Any fault arising from incorrect wiring cannot be put right under the terms of the Glow worm guarantee All system components must be of an approved type Electrical components have been testedto meetthe equivalent requirements of the BEAB Connection of the whole electrical system and any heating system controls to the electrical supply must be through a common isolator Isolation should preferably be by a double pole switched fused spur box having a minimum contact separation of 3mm on each pole The fused spur box should be readily accessible and preferably adjacent to the boiler It should be identified as to its use A fused three pin plug and shuttered socket outlet may be used instead of a fused spur box provided that a They are not used 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 Do not interrupt the mains supply with a time switch or programmer 9 1 External controls Mains Voltage Important If a replacement supply cable is required it must be purchased Part No S1008600 Ensure that a seperate external controls cable and pump supply cable are fed to the boiler Refer to wiring diagram in section 12 All hxi boilers are fitted with a connection box located at the base of the boiler into which all connections
37. drain see section 7 3 must not be modified or blocked 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 It is normal and not a fault indication Cleaning The boiler casing can be cleaned using a mild liquid detergent with a damp cloth then a dry cloth to polish Do not use any form of abrasive or solvent cleaner as you may damage the paintwork Electrical Supply 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 Make sure that if fitted the immersion heater in the cylinder is switched off NOTE If you have a sealed water system contact your installation servicing company as draining refilling and pressurising MUST be carried out by a competent person 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
38. e diagrammatic layout diagram 4 3 unless laid down differently by the manufacturer The expansion vessel volume depends on the total water system volume and the initial system design pressure For any system an accurate calculation of vessel size is given in the current issue of BS5449 and BS7074 Part 1 Example For an initial design pressure of 0 7 bar the minimum total vessel volume required is 0 063 x Total System Volume NOTE Ahigher initial design pressure requires alarger volume expansion vessel Guidance on vessel sizing is also given in the current issue of BS5449 and BS7074 Part 1 for IE refer to the current edition of I S 813 Domestic Gas Installations The charge pressure must not be less than the static head of the system that is the height of the highest point of the system above the expansion vessel 4 14 Pressure Gauge A pressure gauge with a set pointer and covering at least 0 to 4 bar 0 to 60 Ib in shall be fitted permanently to the system in a position where it can be seen when filling the system 4 15 Domestic Hot Water Cylinder SINGLE FEED INDIRECT CYLINDERS ARE NOT SUITABLE The domestic hot water cylinder must be of the double feed fully indirect coil type It must be suitable for working at a gauge pressure of 0 35 bar above the safety valve setting 4 16 Water Makeup Provision should be made for replacing water loss from the system using a make up bottle mounted in a position higher than the
39. el inner panel and chassis front only Remove the two screws on the underside of the front panel and lift off Undo the two screws on the front of inner panel and lift off see diagram 10 1 and 11 3 For access inside the appliance a Torx T20 drive is required or alternatively a flat blade screwdriver can be used To remove chassis front refer to section 11 3 Unless stated otherwise any part removed during servicing should be replaced in the reverse order to removal Servicing should always include the removal of any debris from the condensate pipe and siphon After completing any servicing of gas carrying components ALWAYS test for gas soundness and carry out a functional test of the controls 11 2 Spark Electrode Disconnect the ignition lead and earth lead from the ignitor unit and two securing screws at the spark electrode Withdraw the spark electrode carefully from the combustion chamber see diagram 11 2 Inspect the tips for damage Clean away any debris and check the spark gap is 3 5mm to 4 5mm Check the electrode gasket for signs of damage and replace if necessary 31 SEALING GAS PIPE BRACKET y inc SECURING SCREW CONDENSE UNION NUT TRAP GAS SERVICE COCK OEY GAS m d SUPPLY PIPE IN Diagram 11 1 HEAT SPARK GAP EXCHANGER 3 5 to 4 5mm SPARK ELECTRODE NEL Diagram 11 2 SECURING SCREW 2 OFF EARTH LEAD 00200081 53 05 11 Servicing
40. ent edition of 1 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 Propane G31 37mbar at the boiler On completion test the gas installation for soundness using the pressure drop method and suitable leak detection fluid purge in accordance with the above standard 1 Technical Information TABLE 2 TABLE 2 cont d 12 hxi BURNER Case Off CO Case On 9 1 0 2 0 5 9 3 0 3 0 5 APPROXIMATE m h GAS RATE after 10 mins fE h from cold MIN MAX 0 53 1 29 18 7 45 6 15 hxi BURNER Case Off eCO Case On 9 1 0 2 0 5 9 3 0 3 0 5 APPROXIMATE m h GAS RATE after 10 mins ft h from cold MIN MAX 0 53 1 61 18 7 57 0 18 hxi BURNER Case Off CO Case On 9 1 0 2 0 5 9 3 0 3 0 5 APPROXIMATE m h GAS RATE after 10 mins ft h from cold MIN MAX 0 53 2 00 18 7 70 6 24 hxi BURNER Case Off CO Case On 9 1 0 2 0 5 9 3 0 3 0 5 APPROXIMATE m h GAS RATE after 10 mins fF h from cold MIN MAX 0 56 2 58 19 8 91 1 30 hxi BURNER Case Off CO Case On 9 1 0 2 0 5 9 3 0 3 0 5 MIN MAX APPROXIMATE m h 0 56 3 02 GAS RATE after 10 mins fF h 19 8 107 from cold 38 hxi BURNER Case Off CO Case On 8 8 0 2 0 5 9 0 0 3 0 5 MIN MAX APPROXIM
41. ernal controls are calling for heat If an integral programer is fitted check that it is correctly programmed and if necessary overridden to provide heat Ensure that the water temperature control knob is turned OFF Turn on the mains electrical supply and the mains reset switch to l on the controls fascia Turn the water temperature control knob to I MINIMUM The fan should start and after a few seconds the ignition will commence If the burner fails to light the fan will stop Initially this may be due to air in the gas supply line The boiler will automatically have three attempts at ignition If necessary turn the mains reset switch to the off position O then back to the on position I and the boiler will restart After the boiler has lit allow to warm at MINIMUM temperature setting to purge any air from the system NOTE If the appliance is operated above MINIMUM on initial lighting there is a possibility that the overheat stat will trip this is due to air in the system having not been purged See diagram 10 2 for overheat thermostat reset switch Once the system has been purged of air turn the central heating knob to the desired temperature The appliance will then continue to fire until the user controls are satisfied NOTE After first power up the firing sequence for central heating changes After one minute stabilisation time the boiler will ramp slowly to full rate rather than going immediately to full rate
42. fore attempting the lift Take care to avoid trip hazards slippery or wet surfaces and when climbing steps and stairs When transferring appliance into roofspace recommend 1 person to be in roofspace to receive the appliance and other person to be below to pass up and support appliance Ensure safe lifting techniques are used keep back straight bend using legs Keep load as close to body as possible Always use assistance if required It is assumed safe access flooring and adequate lighting are provided in the roof space Itis tecommendeda risk assessment of the roof space area be carried out before moving the appliance into the area to take into account access stability of flooring lighting and other factors and appropriate measures taken Unpacking of appliance from carton Recommend 2 persons unpack appliance from carton Always keep working area clear Recommend cut base end of carton and open carton flaps then tilt boiler forwards from its side onto its base and remove carton by sliding up overthe boiler 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 Dispose of packaging in a responsible manner Recommend wear suitable cut resistant gloves with good grip to protect against sharp edges and ensure good grip when handling appliance outside packaging Positioning of Appliance for Final Installation no obstructions
43. g Servicing Fault Finding Replacement of Parts Spare Parts SECTION 8 O Q G S 11 12 13 14 PAGE No O O ONN 13 14 16 20 21 22 24 27 28 31 35 44 0020008153 05 Important Information 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 Sheet 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 Gas Category This boiler is for use only on G20 natural gas but the 30hxi 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 appliances are installed by a competent person in accordance with the current issue of the above regulations Testing and Certification The boiler is tested and certificated for safety and performance It is therefore important that no alteration is made to the boiler unless approved in writing by Glow worm Any alteration not approved by Glow worm could invalidate the certification boiler warranty and may also infringe the
44. hout an electrical supply Normal operation ofthe boiler should resume when the electrical supply is restored Reset any external controls to resume normal operation of the central heating If the boiler does not resume normal operation turn the mains reset switch off and on If the boiler does not resume normal operation after this the overheat stat may have operated Overheating Safety In the event of the boiler overheating the safety devices will cause a safety shutdown If this happens call your Installation Servicing company Frost Protection The appliance has a built in frost protection programme as long as the electricity and gas are left switched on This device operates the burner and system pump when the temperature inside the boiler falls to 3 C Any other exposed areas of the system should be protected by a separate frost thermostat 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 Contact your installation servicing company if the fault persists Maintenance and Servicing User Instructions For the continued efficient and safe operation of the boiler it is recommended thatitis checked and serviced at regular intervals The f
45. inding OVERHEAT YN THERMOSTAT YA THERMISTOR bk CH FLOW THERMISTOR CH RETURN Ut BOX B bk BLACK w WHITE or ORANGE g y GREEN gn GREEN USER INTERFACE YELLOW g y YELLOW IGNITION ELECTRODE Zi aa br SWITCH LIVE Frost it 12933 230V SWITCHED LIVE INPUT THERMOSTAT CONNECTIONS 230V 50Hz PERMANENT MAINS SUPPLY FUSED AT 3A CHASSIS EARTH Diagram 12 2 0020008153 05 36 12 Fault Finding Is there temperature indicated on LCD Ensure external controls are calling for demand Wait 60 seconds YES Does F flash NO Does boiler modulate YES before desired set point is reached Differential is to high Current flow rate too low O Does boiler go off N YES before desired set point is reached COMPON 12191 Is a F displayed NO Check wires between main pcb and interface YES REFER TO DIAGRAM 12 4 ENT CH thermi Temperature rise too high Current flow rate too low NO stor 10K Q 25 C Fan 24V DC across blue and red at fan Correct operation Gas Valve 24V DC 55 Q Diagram 12 3 37 0020008153 05 12 Fault Finding DESCRIPTION POSSIBLE CAUSE Ignition fault lockout Boiler failed to light No gas Insufficient gas Incorrect gas valve adjustment Electrode Ignition lead defect E
46. ing lamp will illuminate green to indicate the boiler has lit the system temperature will now be displayed instead of system pressure The temperature of the central heating water can be adjusted by turning the central heating water temperature control to desired setting between 1 Min and ty Max Maximum setting is appoximately 82 C Set the control to 0 to switch off heating If the boiler fails to light reset the controls see paragraph below TO RESET If a fault occurs the running lamp will flash red and a fault code will appear on the digital display TO RESET 2 Turn the Mains Reset Switch to 0 wait for 5 seconds turn Mains Reset Switch to 1 the boiler is reset If the fault persists contact your installer service provider using the telephone number on the inside font cover of this booklet TO TURN THE BOILER OFF 3 Turn the Mains Reset Switch to the OFF 0 position Turn the gas supply OFF at the gas service cock if the boiler is to be out of use for some time 00200081 53 05 8 1 Technical Information 1 1 IMPORTANT NOTICE The boiler is supplied in one carton which includes a fittings and documentation pack This boiler is for use only on G20 natural gas but the 30hxi may be converted for use on G31 gas Propane L P G 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 car
47. is infomation 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 0020008153 05 Operating the Boiler User Instructions CONTROLS MAINS RESET FASCIA CONTROL LIGHT SWITCH 0 I A C Slow worm o lur CENTRAL HEATING WATER TEMPERATURE DIGITAL CONTROL DISPLAY Diagram 1 OPERATION OF THE BOILER 1 Check that all isolating valves on the boiler are open and that water flows from the hot water tap 2 Ifyou are in any doubt about the boiler being filled with water contact your installer or Glow worm s own service organisation using the telephone number on the inside front cover of this booklet Do not operate the boiler without water 3 Check that the electrical supply to the boiler is ON and set any remote controls as required With the Central Heating Water Temperature Control in its OFF 0 position turn the Mains Reset Switch to the ON 1 position the running lamp will initially illuminate green then go off the system pressure will be displayed and should read on the digital display at least 0 7bar recommended 1 Obar if less you MUST contact your installation servicing company USER CONTROLS CENTRAL HEATING CONTROL 1 Turn the central heating water temperature control ON the lighting sequence will begin the runn
48. ive plastic The condensate drain pipe should have a fall of at least 2 5 away from the boiler and if possible be discharged into the household internal drainage system If this is not practicable discharge can be allowed into the external household drains or a purpose designed soak away refer to diagram 7 3 It is recommended that any external condensate drain pipe is insulated 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 0020008153 05 22 22mm compression is the recommended fixing for servicing not supplied tow Diagram 7 2 RETURN 7 Gas Water and Condensate Connections e e eo 2 ME M EXTERNAL SOM AND VENT STACK EXTERNAL MAX 3M ig mm MIN 22mm MIN NO RESTRICTION NO RESTRICTION ON LENGTH ON LENGTH Internal Soil and Vent Pipe p External Soil and Vent Pipe or Rainwater Pipe SINK CONSTITUTES EXTERNAL LENGTH AIR BREAK OF PIPE 3M MAX 22mm MIN 22mm MIN NO RESTRICTION x ON LENGTH OPEN END OF PIPE NOTE FOR
49. king or Glow worm 2 4 Room Ventilation The boiler is room sealed so when it is installed in a room or space a permanent air vent is not required 2 5 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 13 Ad 200 T A removable compartment door can be placed at least 5mm in front of the appliance MINIMUM CLEARANCE FROM PERMANENT SURFACES Diagram 2 1 0020008153 05 3 Flue Location and Ventilation 3 1 Flue Options This boiler is suitable for concentric Horizontal and Vertical flues elevated horizontal and vertical twin all are fitted onto the top of the boiler The Glow worm Flue Options Guide available on request or through the web site describes in detail the necessary accessories These instructions describe the use of the standard and telescopic horizontal flues The instructions for all other flues will be contained in those packs 3 2 Flue Length The maximum permissable horizontal flue length is 10 metres plus the flue terminal this can be achieved by use of the accessories however should an additional 90 or 2 x 45 elbows be used then the length MUST be reduced by 1metre 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
50. lectronic igniter defective Check air inlet duct Check connections to igniter unit Ignition fault lockout Went out when lit As F1 possible cause Overheat fault Overheat stat operated Maximum temperature exceeded Check thermistor connections Air in system with thermistor at maximum setting Faulty overheat stat connection Check that pump is wired into appliance and not from programmer This would cause no pump overrun Central heating flow thermistor fault Thermistor cable defective broken thermistor faulty Check that thermistor attached correctly to pipe Central heating return thermistor fault Thermistor cable defective broken thermistor faulty Check that thermistor attached correctly to pipe Main board connection fault Check wiring between mainboard and user interface User interface connection fault Check wiring between mainboard and user interface Main PCB connection fault Check connections and wires Central heating flow temperature is greater than 95 C System fault Possible pump failure Check Thermistor on flow Flame detection fault flame presence for more than 5 seconds after burner stop Gas valve defective Power supply is less than 170V Check electrical supply polarity User interface fault Faulty User Interface Central heating thermistor unplugged Check Thermistor connection Software incompatibility Incorrect user interface or
51. ly pipe from the gas valve When refitting the gas valve take care as it can be fitted more than one way After assemblytestfor gas soundness and purge in accordance with the current issue of BS6891 or in IE the current edition of I S 813 Domestic Gas Installations 13 6 Fan For access refer to section 13 1 Remove electrical plug Refer to section 11 3 for removal of the fan gas valve and burner assembly Remove the gas valve as described in the relevant parts of section 13 5 Remove the venturi plate secured with three screws and remove the two screws securing the fan to the gas manifold see diagram 13 2 Check the gasket and replace if necessary NOTE The 30hxi and 38hxi fan is secured through an extension piece with two securing screws check and replace any seals or gaskets if necessary 13 7 Burner For access refer to section 13 1 Refer to section 11 3 for removal of the fan gas valve and burner assembly Remove the four screws that secure the burner NOTE THE BURNER WILL REQUIRE A NEW GASKET WHEN REFITTED 13 8 Front Insulation For access refer to section 13 1 Refer to section 11 3 for removal of the fan gas valve and burner assembly Remove burner as per section 13 7 Remove spark electrode see section 13 2 NOTE THE BURNER WILL REQUIRE A NEW GASKET WHEN REFITTED 13 9 Rear Insulation For access refer to section 13 1 Refer to section 11 3 for removal of the fan gas valve and
52. mum 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 2 6 A suitable guard is manufactured by Tower Flue Components Morley Rd Tonbridge Kent TN9 1RA Size 280mm x 280mm x 270mm TERMINAL GUARD 12325 N NW oo a a a a A a 42232323133 Sa PP REENE Sa S AK SE BF SZ SU SS SG SDN NI Sat hd FF a a 11111 1 1 LII Diagram 3 6 00200081 53 05 4 Water System 12 hxi Pressure Loss Graph 24 hxi Pressure Loss Graph 2 12342 a o o w Ds o 0 5 o Water Pressure Loss metres head of water Water Pressure Loss metres head of water 0 100 200 300 400 500 600 0 100 200 300 400 500 Flow Rate litres hour Flow Rate litres hour 520 I hr 20 diff 12kW 500 I hr 20 diff 12kW 15 hxi Pressure Loss Graph 30hxi Pressure Loss Graph 2 3 00 N a o N Water Pressure Loss metres head of water ol Water Pressure Loss metres head of water 1 00 0 50 0 L 0 00 d 9 rm 0 100 200 300 400 500 600 700 800 200 400 600 800 1000 1200 1400 Flow Rate litres hour Flow Rate litres hour 646 I hr 20 diff 12kW 1220 l hr 20 diff 30kW 18 hxi Pressure Loss Graph 38hxi Pressu
53. n This boiler is not suitable for outdoor installation This boiler may be installed in any room although particular attention is drawn to the installation of a boiler in a room containing a bath or shower where reference must be made to the relevant requirements This boiler is suitable for installation in bathroom zones 2 and 3 In GB this is the current I E E WIRING REGULATIONS and BUILDING REGULATIONS In IE reference should be made to the current edition of I S 813 Domestic Gas Installations and the current ETCI rules The boiler must be mounted on a flat wall which is sufficiently robust to take its total weight see Table 1 Section 1 2 2 Clearances The boiler should be positioned so that at least the minimum operationaland servicing clearances are provided see diagram 2 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 2 1 2 3 Timber Frame Buildings Ifthe 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 and BG Operational Procedures Part 19 Building and Kitchen Work Section 7 Timber Frame Constructions If in doubt seek advice from the local gas underta
54. n IE 1 5 8138 BS5546 BS 5449 BS 7074 BS 7593 Manufacturer s instructions must not be taken as overriding statutory requirements 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 Certification This boiler certificated to the current issue of EN 483 for performance and safety It is important that no alteration is made to the boiler without permission in writing from Glow worm Any alteration that is not approved by Glow worm could invalidate the warranty and could also infringe the current issue of the Statutory Requirements 00200081 53 05 1 Technical Information INSIDE WALL FIXING FACE CONDENSATE DRAIN tO RETURN EY CONDENSATE BOILER DRAIN 133 I Diagram 1 1 TABLE 1 TOTAL WEIGHT 12 hxi 30kg 15 hxi 30kg 18 hxi 30kg 24 hxi 33kg 30 hxi 33kg 38 hxi 33kg GAS CONNECTION Rc in BSPT WATER CONNECTION 22mm copper ELECTRICITY SUPPLY 230V 50Hz fused 3A ELECTRICAL RATING 60W INTERNAL FUSE RATE 0020008153 05 Main PCB 630mAT 10 1 3 Gas Supply The gas installation shall be in accordance with the relevant standards In GB this is BS6891 In IE this is the curr
55. ned to provide central heating from a fully pumped open vented or sealed water system with a fully indirect cylinder Once the controls are set the boiler operates automatically Please read these instructions and follow them carefully for the correct installation and economical use of your boiler Water Treatment Inthe case of an existing installation it is ESSENTIAL that prior to installing the new boiler the system is thoroughly flushed For optimum performance after installation of a new system the boiler and its associated central heating system should also be flushed Flushing should be carried out in accordance with BS7593 1992 using acleanser such as Sentinel X300 or X400 Fernox Superfloc or Salamander corrosion guard cleaner 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 or Salamander corrosion guard inhibitor Compartment or Cupboard Installations If the boiler is fitted into a compartment or cupboard it does not require ventilation openings Do not use the compartment or cupboard for storage Clearances If fixtures are positioned close to the boiler space must be left as shown in diagram 2 1 Enough space must also be left in front of the boiler to allow for servicing Condensate Drain The condensate
56. ng 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 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 1 S 813 Domestic Gas Installations 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 may be used provided they are not used ina room containing a bath or shower The colours of three core flexible cable are blue neutral brown live green and yellow earth General Information General Note This boiler is desig
57. ns CHeSS 4 6 Water Treatment Inthe case of an existing installation it is ESSENTIAL that prior to installing the new boiler the system is thoroughly flushed For optimum performance after installation of a new system the boiler and its associated central heating system should also be flushed Flushing should be carried out in accordance with BS7593 1992 using acleanser such as Sentinel X300 or X400 or Fernox Superfloc 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 and Fernox 4 7 Open Vented Water System The boiler must be supplied from an unrestricted water supply taken from a feed and expansion cistern situated ata maximum height of 27 metres 90ft above the boiler The cold feed must be 15mm minimum size The vent must rise continuously and be unrestricted It is important that the relative positions of the pump cold feed and open vent are as shown in diagram 4 2 0020008153 05 18 For combined feed and vent a 22mm pipe must be fitted in accordance with BS 5449 4 9 Domestic Hot Water Cylinder SINGLE FEED INDIRECT CYLINDERS ARE NOT SUITABLE The domestic hot water cylinder must be of the double feed fully indirect coil type 4 10 Domestic Hot Water System unvented General All domestic hot water circuits
58. nufacturer 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 For customer service call 01773 828100 Technical helpline 01773 828300 For General and Sales enquiries Tel 017793 824639 Fax 01773 820569 To register your Glow worm appliance call 0800 073 2142 C Chenchmark gt The code of practice for the installation commissioning amp servicing of gas central heating 0020008153 05 2 Contents The instructions consist of three parts User Installation and Servicing Instructions 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 INTRODUCTION INSTRUCTIONS FOR USE INSTALLATION INSTRUCTIONS SERVICING INSTRUCTIONS DESCRIPTION Important Information General Information Manual Handling Appliance Safety Devices Maintenance and Servicing Operating the Boiler Technical Information Boiler Location and Ventilation Flue Location and Ventilation Water System Installation Preparation Boiler Fixing Gas Water and Condensate Conns Flue Preparation Telescopic and Standard Flue Electrical Connections Commissionin
59. om bottom of heat exchanger 13 12 Flue Hood For access refer to section 13 1 Remove heat exchanger as per section 13 11 Remove the two securing screws and pull the flue hood down and away from the flue hood bracket and flue elbow see diagram 13 6 13 13 Heating Flow Thermistor For access refer to section 13 1 Refer to diagram 13 7 Remove the electrical connections from the thermistor Remove the retaining clip from the flow pipe Remove the thermistor from the retaining clip Note that the polarity of the wiring to thermistors is unimportant 13 14 Heating Return Thermistor For access refer to section 13 1 Refer to diagram 13 7 Remove the electrical connections from the thermistor Remove the retaining clip from the flow pipe Remove the thermistor from the retaining clip Note that the polarity of the wiring to thermistor is unimportant 41 FLOW AND 3 O RETURN D N PIPE nuts ur SECURIN SCREWS AND CLAMPS 8 OFF FLUE HOOD y FLUE HOOD BRACKET SECURING SCREWS Diagram 13 6 HEATING FLOW OVERHEAT THERMISTOR THERMOSTAT IN by N a FLOW _ NY R PIPE 7 ASCA WS27 A QN EAE SES NS TER 77 lI v De w E J amp l E r RETURN l PIPE HEATING RETURN THERMISTOR Diagram 13
60. ompliance to l S 813 An example of this is given in the current edition of I S 813 Testing Flue Gases If any doubt exists that the flue products are not exhausting correctly investigate by use of a gas analyser FGA 10 Commissioning Instructions to the User 10 8 User Controls and Options The mains reset switch is used to restart the boiler after a fault condition has occurred i e ignition failure The water temperature control knob allows the user to set the desired temperature Temperature Display The digtal display normally shows the operating temperature of the unit 10 9 Pump Exercise Program After a power cut or every 24 hour in frost setting summer mode the pump will run for one minute to prevent it from sticking This will also occur during normal operating if there is no demand for more than 24 hours 10 10 Frost Protection The boiler has a built in frost protection programme as long as the electricity and gas are left switched on This device operates the burner and system pump when the temperature inside the boiler falls to 3 C When the temperature inside the appliance reaches 10 C the burner will shut down and after a short period the pump will stop This device primarily protects the boiler Any other exposed areas of the system should be protected by a separate frost thermostat 00200081 53 05 10 11 Instruct the User Instruct and demonstrate the lighting procedure and advise the u
61. re Loss Graph 2 5 4 50 e e m N 0 54 Water Pressure Loss metres head of water 0 100 200 300 400 500 600 700 Flow Rate litres hour 0 00 C t 773 86 l hr 20 diff 18 kW 200 400 600 800 1000 1200 1400 1600 Flow Rate litres hour i 1633 l hr 20 diff 38kW Diagram 4 1 800 900 1000 Water Pressure Loss metres head of water 0020008153 05 16 4 Water System 4 1 Draining Tap A draining tap must be provided at the lowest point of the system which will allow the entire system and hot water system to be drained Draining taps shall be to the current issue of BS 2879 4 2 Safety Valve A safety valve need not be fitted to an open vented system 4 3 Pump The pump should be fitted on the flow pipe from the boiler and have isolating valves each side A variable duty pump should be set to give a temperature difference of no greater than 20 C between the flow and return with the thermostat set at MAX which is about 80 C to give a flow rate as shown in table 3 See chart for pressure loss of the boiler diagram 4 1 High resistance microbore systems may require a higher duty pump 4 4 Flow Rate If it is necessary to alter the flow rate the system can be fitted with a lockable balancing valve in the main flow or return pipe
62. requency of servicing will depend upon the installation conditions and usage but in general once a year should be enough If this appliance is installed in a rented property in the UK 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 Glow worm s own service organisation using the telephone number on the inside front cover of this booklet Please be advised that the installation engineer on completion of commissioning and servicing should complete the Benchmark logbook All CORGI Registered Installers carry a CORGI ID card and have a registration number Both should be recorded in your boiler Logbook Youcancheck your installer is CORGI registered by calling CORGI direct on 01256 372300 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 Glow worm If replacement parts are required contact Glow worm s own service organisation using the telephone number on the inside front cover of this booklet Please quote the name of the appliance th
63. ried out by a competent person in accordance the rules in force in the countries of destination Manufacturer s instructions must not be taken as overriding statutory requirements 1 2 Statutory Requirements The appliance is suitable only for installation in GB and IE and should be installed in accordance with the rules in force In GB the installation of the boiler must be carried out by a competent person 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 Fittings Regulations or Water byelaws in 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 and installed in accordance with the current edition of I S 813 Domestic Gas Installations the current Building Regulations and reference should be made to the current ETCI rules for Electrical Installation In GB the following Codes of Practice apply BS4814 BS6798 BS5440 Part 1 and 2 BS5546 Part 1 BS5449 BS6891 BS6700 BS7074 Part 1 and 2 BS7593 BS7671 I
64. rked at 176mm from the back wall see diagram 5 2 To allow for the flue passing through the wall at this angle a 125mm hole should be drilled irrespective of internal or external installation If necessary remove the wall template whilst drilling the flue hole 00200081 53 05 20 RETAINING LUG SECURING 2 OFF SCREW 2 OFF O QU SN lt b N gt FRONT CASING PANEL Diagram 5 1 Kel e 2 5 Inclined 44mm metre WALL Extended 176 TEMPLATE flue length Standard flue length 125 Horizontal EXTENDED SIDE FLUE Diagram 5 2 6 Boiler Fixing 6 1 Hanging Bracket Fixing If previously removed reposition the wall template over the flue hole and mark the position of the fixing holes for the hanging bracket see diagram 6 1 Mark and drill the fixing holes and secure the hanging bracket which is supplied in the polystyrene pack NOTE Due tothe varied site conditions we do not supply fixings and advise that the installer should supply those which are suitable 6 2 Boiler Fixing 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 Manual Handling section on page 5 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
65. s shown as valve A in diagram 4 3 The flow rate through the boiler must not be allowed to fall below that given in Table 3 9235 Open vented system Recommended relationship between 4 i pump cold feed and vent HEIGHT 22mm MIN VENT FEED AND EXPANSION CISTERN 15mm MIN COLD FEED PN MIN AUTOMATIC BY PASS z T z m O c z 1000mm MIN 4 CYLINDER HEATING BOILER 150mm MAX Diagram 4 2 17 Table 3 Flow Rate MODEL MINIMUM FLOW RATE 12 hxi 15 hxi 18 hxi 24 hxi 30 hxi 38 hxi 520 litres hr 646 litres hr 773 8 litres hr 500 litres hr 1220 litres hr 1633 litres hr This is equal to 20 C differential at maximum heat input 00200081 53 05 4 Water System O O 3 LITRES 0 66 gals a MAKE UP BOTTLE FLOW AIR r if d CONTROL Y RELEASE SEGUI VALVE A N POINT pose AUTO gt AIR i I 4 2 VENT NON RETURN posce A FILLING POINT VALVE i AUTOMATIC Sd E X BYPASS Rigen ie T VALVE B V x EET E ETE N FLOW MA S E FLOW SAFETY ae LATING ED CONTROL 1 VALVE u amp RETURN VALVE A EO L P 2 buscan i V PRESSURE GAUGE bad A Make up alternatives N DRAIN ue J EXPANSION N COCK E VESSEL Diagram 4 3 4 5 Bypass 4 8 Combined Feed and Vent A system bypass will be required fitted at least 1 5 metres away from the boiler refer to the current issue of the central heating system specificatio
66. sealing collar behind the locating lugs on the flue terminal see diagram 8 1 Push the flue assembly into the wall externally or internally initially 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 duct to be drawn back into the flue elbow after the boiler has been mounted 8 4 Flue Attachment To Boiler 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 the air duct then fit the collar and secure with screws provided see diagram 8 9 NOTE If the air and flue ducts have been correctly cut to the instructions given in section 8 2 the rubber sealing collar should fit flush with the outside wall check this Slide the internal trim ring back against the wall securing in place with a small amount of sealant if required 0020008153 05 26 N LO E ME um AIR DUCT TELESCOPIC TOP TELESCOPIC AIR DUCT SECURING Diagram 8 7 N st ex p AIR DUCT 3 gt 4 L 13mm TERMINAL CATCH FLUE DUCT L L 11mm DUCT CUTTING LENGTHS Diagram 8 8 e vt A Diagram 8 9 9 Electrical Connections Warning This boiler must be earthed This appliance must be wired in accor
67. ser on the safe and efficient operation of the boiler Instruct on and demonstrate the operation of any heating System controls Advise the user on the use and maintenance of any scale reducer and pass on any relevant instructional documents Advise thatto ensure the continued efficient and safe operation of the boiler it is recommended that it is checked and serviced atregular intervals The frequency of servicing will depend upon the installation conditions and usage but in general once a year should be enough 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 The user shall not interfere with or adjust sealed components It is the Law that any servicing is carried out by a competent person Advise the user that like all condensing boilers this appliance will produce a plume of condensation from the flue terminal in cool weather This is due to the high efficiency and hence low flue gas temperature of the boiler Advise the user of the precautions necessary to prevent damage tothe system boiler and the building in the event of the heating system being out of use during frost or freezing conditions Advise the user that the permanent mains electrical supply SHOULD NOT be switched off as the built in frost protection and pump saver program would not be operable
68. side Min distance from outside wall face to min clearance wall face to min clearance LH 330mm LH 125mm RH 433mm RH 228mm TOP SIDE FLUE TELESCOPIC Diagram 3 4 0020008153 05 14 3 Flue Location and Ventilation eo o UNDER CAR PORT etc ite MINIMUM SITING DIMENSIONS FOR FANNED FLUE TERMINALS POSITION MM 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 H FROM INTERNAL EXTERNAL CORNERS 25 H TO A BOUNDARY ALONGSIDE THE TERMINAL 300 I ABOVE ADJACENT GROUND OR BALCONY LEVEL 300 J FROM SURFACE OR A BOUNDARY FACING THE TERMINAL 600 K 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 3 5 15 3 3 Terminal Position The minimum acceptable siting dimensions for the terminal from obstructions other terminals and ventilation openings are shown in diagram 3 5 For Ireland the minimum dis
69. t at the top from its retaining slots NOTE When replacing chassis front panel ensure the bottom fits behind the lip The side panels can be hinged sideways to aid replacement of parts Undo and remove the three screws securing each side panel to the boiler two at the front and one at the top 13 2 Spark Electrode For access refer to section 13 1 Remove the spark plug lead earth lead and two securing screws Withdraw the spark electrode carefully from the combustion chamber see diagram 11 2 13 3 Igniter Unit For access refer to section 13 1 Remove ignition lead and electrical connections see diagram 11 4 Remove igniter unit by removing two securing screws 13 4 Ignition Lead For access refer to section 13 1 Refer to diagram 11 4 Pull the spark plug style connector off the spark electrode and the spade connector connected to the igniter unit MAIN PCB 12411 FUSE CLIPS RETAINING Diagram 13 1 39 0020008153 05 13 Replacement of Parts 13 5 Gas Valve For access refer to section 13 1 Remove the electrical plug from the gas valve see diagram 10 3 Refer to section 11 3 for removal of the fan gas valve and burner assembly Before removing the gas valve note its position on the fan Remove the three securing screws which fix the gas valve plastic swirl plate to the venturi on the fan Remove the gas valve Remove the gas supp
70. tances for flue terminal positioning must be those detailed in I S 813 Domestic Gas Installations The terminal must be exposed to the external air allowing free passage of air across it at all times Being a condensing boiler some pluming may occur from the flue outlet This should be taken into consideration when selecting the position for the terminal H andJ Seediagram 3 5 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 Increased siting flexibility can be achieved by using the Glow worm Plume Management Kit A2044000 black or A2044100 white NOTE If necessary it is permitted to increase the terminal protrusion through the outside wall to greaterthan the minimum dimension of 87mm but no more than 600mm see diagram 1 1 Carports or similar extensions of a roof only or a roof and one wall require special consideration with respectto 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 3 4 Terminal Guard A terminal guard is required if persons could come into contact with the terminal or the terminal could be subject to damage If a terminal guard is required it must be positioned to provide mini
71. to allow the fascia to drop down and damage the wiring Turn on the electrical supply Ensure external controls are calling for heat The boiler should fire automatically Allow the boiler to fire for a minimum of 60 seconds and then using an electrical screwdriver rotate the service potentiometer fully clockwise see diagram 11 7 This will allow the digital display to indicate the flashing fan speed on the appliance fascia In the fully clockwise position the display should be indicating the maximum fan speed of the appliance 27 1 for 12hxi 32 1 for 15hxi 41 1 for 18hxi 47 1 for 24hxi and 57 1 for 30hxi and 38hxi Check the CO value which should be 9 1 0 2 0 5 Note that with the inner casing panel fitted the combustion readings will increase slightly to 9 3 0 3 0 5 If adjustment proves necessary then proceed as follows Any adjustment to the gas valve should only be carried out by a competent person Refer to diagram 10 3 Adjust the maximum rate CO with the throttle to 9 1 Rotate anti clockwise to increase Rotate the service potentiometer fully anti clockwise Hold it in this position for about 5 seconds before rotating the service potentiometer clockwise to the mid point or 3 o clock position The fan should reduce to 1200 100 rpm which will flash 12 on the digital display Check the CO value which should be 9 1 0 2 0 5 For Propane the CO value should be 10 5 0
72. top point of the system connected through a non return valve to the return side of either the heating circuit or the hot water cylinder Alternatively provision for make up can be made using a filling loop 4 17 Filling a Sealed Water System Provision for filling the system at low level must be made see diagram 4 4 There must be no permanent connection to the mains water supply even through a non return valve We do not recommend filling using artificially softened water SUPPLY PIPE BOILER CONTROL VALVE DOUBLE CHECK VALVE FLOW RETURN HOSE UNION I I lt q ss Sa HEATING CONTRO vA TEMPORARY IRCUIT CONNECTION onou VALVE UNION DRAIN POINT Method 1 BOILER FLOW RETURN TYPE CA BACKFLOW PREVENTION DEVICE CONTROL CONTROL VALVE VALVE SUPPLY PIPE HEATING CIRCUIT AIR GAP TUNDISH Method 2 Diagram 4 4 0020008153 05 5 Installation Preparation 5 1 Appliance Pack IMPORTANT With regards to the Health and Safety Manual Handling requirements two persons shall be required to lift the appliance refer to manual handling on page 5 NOTE The fittings pack is located in the base polystyrene packing under the boiler base Remove the polystyrene end packing pieces then carefully lay the boiler on its back remove the two front casing panel securing screws and lift off the panel from two retaining lugs see diagram 5 1 Remove the transit packaging behind the front

12-38hxi Range Installation & Service Manual Boilers - Glow-worm

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12-38hxi Range Installation &amp; Service Manual Boilers - Glow-worm

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12-38hxi Range Installation & Service Manual Boilers - Glow-worm