Glow-worm Ultimate c User Manual

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Installation and Servicing

ULTIMATE 30c

G.C. No. 47-044-48

ULTIMATE 35c

G.C. No. 47-044-49

TABLE OF CONTENTS

INTRODUCTION

1 Instructions guidance ................................................................................................................... 3

1.1 Product documentation .......................................................................................3

1.2 Explanation of symbols .......................................................................................3

1.3 Guarantee registration ........................................................................................3

2 Appliance description ................................................................................................................... 3

2.1 Safety devices ....................................................................................................3

2.2 Data label ...........................................................................................................3

2.3 Regulation and statutory requirements .................................................................4

2.4 Hydraulic schematic ...........................................................................................4

3 Safety instructions and regulations ............................................................................................... 5

3.1 Safety instructions ..............................................................................................5

3.2 Regulations .......................................................................................................5

4 Recycling ..................................................................................................................................... 6

4.1 Appliance ...........................................................................................................6

4.2 Packaging ..........................................................................................................6

TECHNICAL DATA

5 ULTIMATE c ................................................................................................................................... 7

INSTALLATION

6 Appliance location ....................................................................................................................... 8

6.1 Location .............................................................................................................8

6.2 Clearances .........................................................................................................8

6.3 Ventilation .........................................................................................................8

7 Appliance installation .................................................................................................................. 9

7.1 Scope of delivery ................................................................................................9

7.2 Recommendations before installing .....................................................................9

7.3 Dimensions ......................................................................................................10

7.4 Mounting .........................................................................................................11

8 Hydraulic connection .................................................................................................................. 12

8.1 Gas and water connections ................................................................................12

8.2 Safety Discharge Valve ......................................................................................13

8.3 Connection to the condensate trap .....................................................................13

9 Evacuation of combustion gas ..................................................................................................... 15

9.1 Regulation ........................................................................................................15

9.2 Flue conﬁ guration description ...........................................................................16

10 Electrical connections ................................................................................................................. 17

10.1 Access to main board ........................................................................................17

10.2 Main board .......................................................................................................18

10.3 Electrical wiring ................................................................................................18

10.4 External accessories ..........................................................................................19

10.5 Testing the electrical connections ......................................................................19

10.6 Wiring diagram .................................................................................................20

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TABLE OF CONTENTS

11 Commissioning ......................................................................................................................... 21

11.1 Reading the ﬁ lling pressure ...............................................................................21

11.2 Switching on ....................................................................................................21

11.3 Filling the CH system (Central heating) ...............................................................21

11.4 Filling DHW Circuit ............................................................................................22

11.5 Filling the Condensate Trap ................................................................................22

11.6 Initial lighting ...................................................................................................22

11.7 Gas rates ..........................................................................................................23

11.8 Testing heating system ......................................................................................23

11.9 Testing domestic hot water system .....................................................................24

11.10 Completion .......................................................................................................24

12 Speciﬁ ed Adjustment .................................................................................................................24

12.1 Heating circuit adjustment .................................................................................24

12.2 Installation settings ..........................................................................................25

12.3 After Sales Service settings ...............................................................................25

12.4 Status of the appliance ......................................................................................26

12.5 Test modes .......................................................................................................27

12.6 CO2 measurement .............................................................................................27

12.7 Re-check and restart .........................................................................................27

13 User information ........................................................................................................................ 27

MAINTENANCE

14 Trouble-shooting ........................................................................................................................ 28

14.1 Fault diagnosis .................................................................................................28

14.2 Fault memory ....................................................................................................29

14.3 Fault codes .......................................................................................................29

14.4 Functional ﬂ ow diagram ....................................................................................31

15 Gas conversion adjustments ....................................................................................................... 32

15.1 Settings ...........................................................................................................32

15.2 Restart - re-check commissioning .......................................................................33

16 Draining ................................................................................................................................... 33

16.1 Heating circuit .................................................................................................33

16.2 Domestic Hot water circuit ................................................................................33

17 Servicing ................................................................................................................................... 33

17.1 Annual Maintenance .........................................................................................34

17.2 Casing removing ...............................................................................................34

17.3 Combustion check and setting the air/gas ratio valve ..........................................35

17.4 Servicing ..........................................................................................................36

17.5 Silencer ...........................................................................................................36

17.6 Expansion vessel ..............................................................................................37

17.7 Condensate trap ...............................................................................................37

17.8 Combustion block .............................................................................................38

17.9 Service completion ...........................................................................................39

18 Replacement of Parts .................................................................................................................. 39

18.1 General ............................................................................................................39

18.2 Boiler Access ....................................................................................................40

18.3 Viewing window ................................................................................................40

18.4 Hydraulic block .................................................................................................41

18.5 Combustion block .............................................................................................43

18.6 Condensate trap ...............................................................................................45

18.7 PCB ..................................................................................................................45

19 Spare parts ................................................................................................................................ 46

20 Manual Handling ........................................................................................................................ 48

21 Declaration of Conformity ........................................................................................................... 49

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INTRODUCTION

1 Instructions guidance

1.1 Product documentation

The instructions are an integral part of the appliance and must be handed to the user on completion of the installation in order to comply with the current regulation.

• Carefully read the manual, to understand all the information

to enable safe installation, use and servicing. No liability can be accepted in the event of damage for not complying with the guidance in this instruction manual.

These instructions consist of, Installation, Servicing, Fault Finding, Replacement of Parts and Spares. The instructions are an integral part of the appliance and must, to comply with the current issue of the Gas Safety (Installation and Use) Regulations, be handed to the user on completion of the installation.

1.2 Explanation of symbols

DANGER:

Risk of injuries.

2.1.2 Safety discharge valve

A safety discharge valve and discharge pipe are ﬁ tted to the boiler. This valve must not be touched.

- The heating safety valve opens when the pressure in the heating circuit exceeds 3 bars.

• Should there be any discharge from the pipe, isolate the boiler

electrical supply and call your installer or Glow-worm’s own service organisation.

2.1.3 Frost protection

The frost protection system operates the pump to start as soon as the temperature in the heating circuit falls below 12°C. The pump stops as soon as the temperature of the water contained in the heating circuit reaches 15°C. If the temperature in the heating system falls below 7°C, the burner ignites until it reaches 35°C. The frost-protection system is active when the appliance is switched on. The system alone cannot ensure that the installation is protected against frost. An separate frost thermostat is necessary to control the temperature of the system.

DANGER:

2.1.4 Condensate drain blockage

Your domestic water circuit (hot or cold) is not protected by the boiler.

DANGER:

e b i

Risk of electric shock.

ATTENTION:

Risk of damage to the appliance or to its surroundings.

IMPORTANT:

Important information.

1.3 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 oﬀ er our customers a Comprehensive 5 years Guarantee.

We recommend you complete and return as soon as possible your guarantee registration card. If your guarantee registration card is missing you can obtain a copy or record your registration by telephoning the Glow-worm Customer Service number 01773

828100.

2 Appliance description

2.1 Safety devices

2.1.1 Overheating safety

The appliance is designed to recognise the potential for an overheat lockout and will shutdown before this happens.

During freezing conditions this may be due to the forming of ice in the condense drain external to the house. In this case, a safety device shuts down the appliance.

2.2 Data label

The data label certiﬁ es the country where the appliance is intended to be installed.

Data label location:

Key 1 Data label

DANGER:

• Refer to chapter "Technical Data" in the technical data section

The appliance shall only be connected to the gas type(s) indicated on the data label.

to see the deﬁ nition of the abbreviations used on the data label.

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INTRODUCTION

2.3 Regulation and statutory requirements

2.3.1 CE Mark

This boiler meets the requirements of Statutory Instrument, No. 3083 The Boiler (Eﬃ ciency) Regulations, and therefore is deemed to meet the requirements of Directive 92/42/EEC on the eﬃ ciency requirements for new hot water boilers ﬁ red with liquid or gaseous fuels. Type test for purposes of Regulation 5 certiﬁ ed by: Notiﬁ ed body

1312. Product/production certiﬁ ed by: Notiﬁ ed body 0086.

The CE mark indicates that the appliances described in this manual are in compliance with the following directives:

- European directive n°2009-142 relative to gas appliances

- European directive n°2004-108 from the European Parliament and Council relative to electromagnetic compatibility

- European directive n°2006-95 from the European Parliament and Council relative to low voltage

- European directive n°92-42 relative to the yield of boilers

2.3.2 Local regulations

Benchmark places responsibilities on both manufacturers and installers. The purpose is to ensure that customers are provided with the correct equipment for their needs, that it is installed, commissioned and serviced in accordance with the manufacturer’s instructions by a competent person approved at the time by the Health and Safety Executive and that it meets the requirements of the appropriate Building Regulations. The Benchmark Checklist can be used to demonstrate compliance with Building Regulations and should be provided to the customer for future reference. Installers are required to carry out installation, commissioning and servicing work in accordance with the Benchmark Code of Practice which is available from the Heating and Hotwater Industry Council who manage and promote the Scheme.

• Visit www.centralheating.co.uk for more information.

2.4 Hydraulic schematic

Key 1 Gas isolating valve 2 Heating ﬂ ow isolating valve 3 Heating safety valve 4 Filter on cold water inlet 5 DHW ﬂ ow sensor 6 Water pressure sensor 7 Domestic plate to plate heat exchanger 8 Three way valve 9 By-pass 10 Heating return thermistor 11 Condensate trap 12 Ignition and control electrode 13 Burner 14 Main heat exchanger 15 Thermal fuse 16 Flue outlet 17 Silencer 18 Heating expansion vessel 19 Fan 20 Gas control valve 21 Ignition module 22 Heating ﬂ ow thermistor 23 Air vent 24 Pump 25 Manometer 26 Heating return isolating valve 27 Domestic cold water isolating valve A Heating ﬂ ow B Pipe for heating safety valve C Domestic hot water outlet D Gas E Cold water inlet F Heating return G Condensate drain

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INTRODUCTION

3 Safety instructions and regulations

3.1 Safety instructions

If the gas pressure at the input of the appliance is outside the range speciﬁ ed, the appliance must not be put into operation.

DANGER:

• Never disable security devices and do not try to adjust them.

With regards to the “Manual Handling Operations, 1992 Regulations”, the appliance exceeds the recommended weight for a one person lift. The handling of the boiler may involve lifting, pushing and pulling, the use of a sack truck may be required.

• Be sure to consider the following handling techniques and

- Grip the appliance at its base

- Use safety clothing where appropriate, e.g. gloves, safety

• Ensure safe lifting techniques are used:

- Keep back straight.

- Avoid twisting at the waist.

- Avoid upper body/top heavy bending.

- Always grip using the palm of the hand.

- Use designated hand holds.

- Keep load as close to body as possible.

- Always use assistance if required.

• Under no circumstances must the user interfere with or adjust

• When assembling the connections, correctly position the seals

• This appliance contains metal parts (components) and care

The basic safety instructions must be followed before attempting to maintain or replace spare parts:

• Stop the appliance.

• Electrically isolate the appliance from the power supply.

• Turn oﬀ the appliance gas isolation valve.

• Hydraulically isolate the appliance using the isolation valves if

• Should you need to replace hydraulic components, drain the

• Protect all the electrical components from water while working

Incorrect installation can cause electric shock or appliance damage.

precautions:

footwear.

sealed parts.

to avoid any leakage of gas or water.

should be taken when handling and cleaning, with particular regard to edges.

provided.

appliance.

on the appliance.

• Use only original spare parts.

• Use only new O-rings and gaskets.

• After having completed work on gas or water carrying

components, check for their tightness.

• When work on the appliance is completed, perform an

operational test and check for safety.

3.2 Regulations

3.2.1 Statutory requirements

IMPORTANT

Where no British Standards exists, materials and equipment should be ﬁ t for their purpose and of suitable quality and workmanship.

The installation of this boiler must be carried out by a competent person approved at the time by the Health and Safety Executive and in accordance with the rules in force in the countries of destination.

Manufacturer’s instructions must not be taken as overriding statutory requirements.

Statutory Requirements

In GB, the installation of the boiler must comply with the requirements of the current issue of BS6798 and be carried out by a competent person approved at the time by the Health and Safety Executive and as described in the following regulations:

- The manufacturer’s instructions supplied.

- The Gas Safety (Installation and Use) Regulations.

- The appropriate Buildings Regulations either The Building Regulations, The Building Regulations (Scotland), The Building Regulations (Northern Ireland).

- The Water Supply (water ﬁ ttings) Regulations 1999 and water byelaws 2000, Scotland.

- The Health and Safety at Work Act, Control of Substances Hazardous to Health (COSHH).

- Any electrical work must conform to BS7671 and part P of the building regulations where applicable.

Where no speciﬁ c instructions are given, reference should be made to the relevant British Standard Code of Practice.

In IE, the installation must be carried out by a competent person approved at the time by the Health and Safety Executive and installed in accordance with the current edition of I.S.813 “Domestic Gas Installations”, the current Building Regulations and reference should be made to the current ETCI rules for Electrical Installation.

GB: the following Codes of Practice apply: BS4814, BS6798, BS5440 Part 1 and 2, BS5546 Part 1, BS5449, BS6891, BS6700, BS7074 Part 1 and 2, BS7593, BS7671. IE: I.S.813, BS5546, BS 5449, BS 7074, BS 7593.

NOTE: For further information, see the current issue of the Building Regulations, approved document L1 ( in the UK) and the following current issues of:

1) Central heating system speciﬁ cation (CheSS) and

2) Controls for domestic central heating system and hot water. BRECSU.

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INTRODUCTION

Gas Supply

The gas installation must be in accordance with the relevant standards.

In GB, this is BS6891. In IE, this is the current edition of I.S.813 “Domestic Gas Installations”.

The supply from the governed meter must be of adequate size to provide a steady inlet working pressure of 20mbar (8in wg) at the boiler. On completion, test the gas installation for tightness using the pressure drop method and suitable leak detection ﬂ uid, purge in accordance with the above standard.

Domestic Hot Water

All domestic hot water circuits, connections, ﬁ ttings must be in accordance with the relevant standards and water supply regulations.

Heating System

In GB, it is necessary to comply with the Water Supply (Water Fittings) Regulations 1999 (for Scotland, the Water Byelaws 2000, Scotland). To comply with the Water regulations your attention is drawn to: The Water Regulations guide published by the Water Regulations Advisory Service (WRAS) gives full details of the requirements.

4 Recycling

IMPORTANT:

4.1 Appliance

Most of the appliance is made of recyclable materials.

• Take the appliance to an appropriate collection point.

4.2 Packaging

We recommend that you recycle the packaging of the appliance in a responsible fashion.

The recycling of the packaging must be carried out by the qualiﬁ ed professional who installed the appliance.

This symbol indicates that this appliance must not be disposed of with household waste, that it should be selectively collected for energy recovery, reuse or recycling.

IMPORTANT:

By complying with this directive, you will contribute to the preservation of natural resources and the protection of human health.

In IE, the requirements given in the current edition of I.S.813 “Domestic Gas Installations” and the current Building Regulations must be followed.

Electrical Supply

The boiler MUST be earthed. All system components shall be of an approved type and all wiring to current I.E.E. wiring regulations. External wiring must be correctly earthed, polarised and in accordance with the relevant standards.

In GB, this is BS 7671. In IE, this is the current edition of ETCI rules.

The boiler MUST be connected to a permanent 230V ac, 50Hz 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.

3.2.2 Other regulations

Control of Substances Hazardous to Health

Under Section 6 of The Health and Safety at Work Act 1974, we are required to provide information on substances hazardous to health. The adhesives and sealants used in this appliance are cured and give no known hazard in this state.

• Sort the waste in order to separate those elements which can

be recycled (cardboard, plastics ...) and those which cannot be recycled.

• Eliminate the waste in accordance with existing regulations.

Insulation Pads: These can cause irritation to skin, eyes and the respiratory tract. If you have a history of skin complaint you may be susceptible to irritation. High dust levels are usual only if the material is broken. Normal handling should not cause discomfort, but follow normal good hygiene and wash your hands before eating, drinking or going to the lavatory.

• If you do suﬀ er irritation to the eyes or severe irritation to the

skin seek medical attention.

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TECHNICAL DATA

5 ULTIMATE c

Boiler, type C13, C33, C43

TECHNICAL DATA

Description Unit 30 35

Gas category ll

2H3P

SEDBUK rating 2009 % 88.8% 88.9%

Heating

Maximum heating input power kW 25 30.6 Minimum heating output power at

80/60°C (P min.) Maximum heating output power at

80/60°C (P max.) Minimum heating output power at

50/30°C (P min.) Maximum heating output power at

50/30°C (P max.)

kW 5.9 8.5

kW 24.5 30

kW 6.5 9.2

kW 26.4 32.5

Minimum heating temperature °C 10 10 Maximum heating temperature °C 80 80 Minimum heating ﬂ ow rate l/h 400 400

Content of heating expansion vessel

Heating expansion vessel preset pressure

Maximum heating system volume (approx)

Heating safety valve preset pressure (PMS)

l8 8

gallons 1.76 1.76

bar 0.75 0.75 psi 10.9 10.9

l 160 160

bar 3 3

lbf/in² 36/3 36/3

Domestic Hot Water

Minimum DHW output power (P min.)

Maximum DHW output power (P max.)

kW 6.1 8.7

kW 30.6 35.7

Maximum DHW temperature °C 60 60 Speciﬁ c ﬂ ow rate (∆T of 35 K) l/min 12.5 14.6

Minimum inlet water pressure

Maximum inlet water pressure

bar 0.3 0.3 psi 4.3 4.3 bar 10 10 psi 145 145

Combustion

Appliance NOx class 5 5

Electrical

Electrical supply V/Hz

230V /

50Hz

230V /

50Hz Standby mode electrical power W 6 6 Operational mode electrical power

(Max)

W 151 151

Internal fuse rating on main PCB A 2 2 Index of electrical protection (EN

60529)

IPX4D IPX4D

Description Unit 30 35

Gas connection Ø O.D. mm 15 (copper) 15 (copper) Heating flow and return connection

Ø O.D. Domestic Hot Water connection

Ø O.D.

Condensate connection Ø I.D. mm

Safety valve discharge connection Ø O.D.

Lift weight

mm 22 (copper) 22 (copper)

mm 15 (copper) 15 (copper)

Pushﬁ t Plastic

mm 15 (copper) 15 (copper)

kg 37,7 38,3

lb 82 84.8

Total weight (installed) kg 41 43

Number of CE certiﬁ cate

1312 BU

5335

1312 BV

5336

Description Unit 30 35

Natural Gas G 20 (15 °C, 1013.25 mbar)

Maximum DHW gas ﬂ ow rate

Maximum heating gas ﬂ ow rate

Minimum gas ﬂ ow rate

at Qmax DHW + "tolerance

case ON"

CO2 at Qmax DHW + "tolerance case OFF"

CO2 at Qmin + "tolerance case ON"

CO2 at Qmin + "tolerance case OFF"

m3/h

3,24 3,77

2,65 3,24

0,65 0,92

% 9.2 ± 0.3% 9.2 ± 0.3%

% 9.0 ± 0.2% 9.0 ± 0.2%

% 8.9 ± 0.3% 8.9 ± 0.3%

% 8.7 ± 0.2% 8.7 ± 0.2%

Inlet pressure mbar 20 20

Propane Gas G 31 (15 °C, 1013.25 mbar)

Maximum DHW gas ﬂ ow rate kg/h 2,38 2,77

Maximum heating gas ﬂ ow rate kg/h 1,94 2,37

Minimum gas ﬂ ow rate kg/h 0.47 0.67

at Qmax DHW + "tolerance

case ON"

at Qmax DHW + "tolerance

case OFF"

CO2 at Qmin + "tolerance case ON"

CO2 at Qmin + "tolerance case OFF"

% 9.8 ± 0.3% 9.8 ± 0.3%

% 9.6 ± 0.2% 9.6 ± 0.2%

10.3 ±

0.3%

10.1 ±

0.3%

10.3 ±

0.3%

10.1 ±

0.3%

Inlet pressure mbar 37 37

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INSTALLATION

IMPORTANT:

6 Appliance location

6.1 Location

All the drawings dimensions are shown in mm.

ØA + 5 min.

ØA

6.1.1 Instructions

Before choosing a site for the appliance, carefully read the safety warnings and installation manual.

• Ensure that wall to which the appliance will be mounted on is

structurally safe in order to support the weight of the appliance.

• Ensure that the space that the appliance is to be installed

within allows the appliance to be installed and the clearances maintained. This will ensure that the connections to the water, gas and ﬂ ue can be accessed and inspected (see chapter Clearances).

• Explain these requirements to the appliance user.

• Do not install the appliance above another appliance that

could damage it (for example, above a cooker that might emit steam or grease) or in a room, which has a lot of dust in the atmosphere which is corrosive.

• The boiler must be ﬁ tted inside the property and exposed pipe

work may need to be protected from frost by ﬁ tting a frost thermostat.

6.1.2 Regulations

Location

This boiler is not suitable for outdoor installation. This boiler is suitable for installation in bathroom zones 2 and 3.

Timber Frame Buildings

If the boiler is to be installed in a timber frame building it should be ﬁ tted in accordance with the Institute of Gas Engineers document IGE/UP/7/1998. If in doubt seek advice from local gas undertaking or Glow-worm.

6.2 Clearances

• To allow periodic maintenance, ensure the distances indicated

on the diagram.

150

min.

600* min.

200

min.

Key * A removable compartment door can be placed a minimum 5 mm in

front of appliance. A clearance of 600 mm is required from a ﬁ xed surface.

The boiler and ﬂ ue are suitable for installation onto and through combustible materials provided that:

- Minimum 5mm clearance is maintained around the circumference of the ﬂ ue (air intake).

- The combustible surface and ﬁ xings are suitable for supporting the load.

- The minimum clearances from the boiler case are maintained.

6.3 Ventilation

6.3.1 Room Ventilation

The boiler is room sealed so a permanent air vent is not required.

6.3.2 Cupboard or Compartment Ventilation

Additional clearances may be beneﬁ cial around the boiler for installation and servicing. For ﬂ ue installations where external access is not practicable, consideration should be given for the space required to insert the ﬂ ue from inside the property, which may necessitate clearance larger than those speciﬁ ed in diagram.

- 8 -

Due to the high eﬃ ciency and low casing temperature of this boiler, cupboard or compartment ventilation is not necessary.

• Existing ventilation should be investigated for its purpose

before removing.

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INSTALLATION

7 Appliance installation

7.1 Scope of delivery

The appliance is delivered in a single carton with a document pack and ﬁ ttings.

IMPORTANT:

• Please check the contents.

2.2

2.1

The ﬂ ues package will be ordered according to the conﬁ guration of the installation.

2.3

2.4

2.5 3

4.1

7.2 Recommendations before installing

7.2.1 Domestic hot water circuit design

Water pressure

The minimum working pressure to obtain the maximum domestic ﬂ ow is 1,0 bar.

The maximum working pressure of the domestic hot water circuit is 10 bar. If the cold water supply pressure exceeds this, then a pressure-reducing valve must be ﬁ tted in the supply to the boiler.

‘Hard’ water areas

The temperatures within the heat exchanger are limited by the boiler control system to minimise scale formation within the hot water pipework. However, in areas where the water is ‘hard’ (i.e. more than 200 mg/L of calcium carbonate), it is recommended that the hot water setting is reduced and that a scale reducer is ﬁ tted, refer to the manufacturer’s instructions or consult the local water company for additional advice.

Domestic water ﬂ ow rate

The domestic hot water ﬂ ow has a restrictor, factory ﬁ tted, which reduces the ﬂ ow to a maximum of:

- 30 : 10/min,

- 35 : 12/min,

1 4.6

Key 1 Boiler (x1)

2 Accessories bag (x1)

2.1 Connection bag (x1)

- Heating return valve (x1)

- Cold water inlet valve (x1)

- Heating ﬂ ow valve (x1)

- Domestic hot water connection (x1)

- Gas isolation valve (x1)

2.2 Hanging bracket (x1)

2.3 Screws and wall plugs bag (x1)

2.4 Seals bag (x1)

- Flat seal ½" (x2)

- Flat seal ¾" (x5)

- Flat seal for cold water inlet ¾" (x4)

2.5 PRV pipe (x1) 3 Wall template (x1)

4 Documents pack (x1)

4.1 Installation and servicing manual (x1)

4.2 Flue book (x1)

4.3 Instructions for use (x1)

4.4 Guarantee envelope pack (x1)

4.5 Magnetic lighting instruction label (x1)

4.6 Gas conversion label (x1)

4.2

4.3

4.4

4.5

Central Heating water ﬂ ow rate

If it is necessary to alter the ﬂ ow rate, the system can be ﬁ tted with a lockable balancing valve in the main ﬂ ow or return pipes.

- Heating circuit design

Key 1 Drain point 2 External bypass (if required) 3 Domestic hot water out 4 Domestic cold water supply in 5 Boiler 6 Additional expansion vessel (if required) 7 Heating return circuit 8 Heating ﬂ ow circuit 9 Optional balancing valve

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INSTALLATION

General

This boiler is designed for use as part of a sealed water central heating system with fully pumped circulation. The pump, expansion vessel and associated safety devices are all ﬁ tted within the boiler.

Safety valve

The safety valve is an integral part of the boiler and it cannot be adjusted. The pipe from the safety discharge valve must discharge safely in accordance with standards.

Expansion vessel

The boiler has an integral expansion vessel with a capacity of 8 litres (1.76 gallons), with a charge pressure of 0.75bar.

IMPORTANT:

- In GB, Guidance on vessel sizing is also given in the current

- In IE, current edition of I.S.813 “Domestic Gas Installations”.

The boiler is ﬁ tted with an automatic bypass.

• Ensure that under no circumstances does the ﬂ ow rate drop

The heating system volume should be calculated to ensure that the expansion vessel is suitable, it may be necessary to add an additional vessel.

issue of BS5449 and BS7074 Part 1.

Bypass

below the ﬁ gure speciﬁ ed, refer to chapter "Technical data".

Drain points

Drain taps must be provided at all low points of the system, which will allow the entire system to be drained.

Drain taps shall be to the current issue of BS2879.

Water treatment

Existing system- It is essential that prior to installing the new boiler the system is thoroughly ﬂ ushed.

New system- For optimum performance after installation, the boiler and its associated central heating system should also be ﬂ ushed.

Flushing shall be carried out in accordance with BS 7593, a chemical cleanser can be used either Sentinel X300, X400 or Fernox F3 are suitable.

It is recommended to ﬂ ush existing systems ﬁ rst before ﬁ tting the new boiler.

• Ensure all cleanser is removed from the whole system before

adding an inhibitor.

For long-term corrosion protection after ﬂ ushing, an inhibitor suitable for stainless steel heat exchangers can be used. Either Sentinel X100 or Fernox F1 inhibitor can be used.

The boiler is suitable for use on systems using softened water.

7.3 Dimensions

Filling the sealed system

IMPORTANT:

Suitable external ﬁ lling systems are shown diagrammatically, see diagram below.

Key 1 Heating ﬂ ow circuit 2 Heating return circuit 3 Boiler 4 Double check valve assembly 5 Domestic cold water supply in 6 Temporary ﬁ lling loop (remove immediately after ﬁ lling) 7 Drain point

The boiler does not contain any ﬁ lling loop, an external one must be ﬁ tted.

7 6

130

740

418

338

The system should be pressurised to 0.8bar, indicated on the digital display with no heating demand.

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INSTALLATION

7.4 Mounting

• Make sure that the equipment used for implementing the

installation is compatible with that of the appliance.

• Determine the assembly location. See the "Appliance location"

chapter.

7.4.1 Fixing to the wall

Key 1 Wall template 2 Standard ﬂ ue length horizontal 3 2.5° 44mm/metre inclined extended ﬂ ue length 4 Wall plug 5 Hanging bracket 6 Screw

Flue hole cutting

• Mark the position of the ﬂ ue centre.

130

90°

117

* 80/125 ﬂ ue = Ø150mm ** 80/125 ﬂ ue = Ø130mm *** 80/125 ﬂ ue = 156mm

• Take the wall template and place in the desired position

on the wall, giving due consideration to the required boiler clearances, see chapter "Appliance location > Clearances", and the ﬂ ue you are ﬁ tting.

892

• Remove the wall template, then drilling the ﬂ ue hole.

IMPORTANT:

• Use a 105mm diameter core drill for external access ﬂ ue

• Use a 125mm diameter core drill for internal access only ﬂ ue

• If ﬁ tting a side ﬂ ue, extend the ﬂ ue centre line into the corner

• If ﬁ tting an extended side ﬂ ue, determine the ﬂ ue hole centre

Due to the varied site conditions the ﬁ xings supplied may not be suitable, please make sure that those used are.

The ﬂ ue is designed with an internal fall of 44mm/metre (2.5o), therefore the hole can be drilled horizontally.

installation (60/100 ﬂ ue) (80/125 ﬂ ue > Ø130mm).

installation (60/100 ﬂ ue) (80/125 ﬂ ue > Ø150mm).

IMPORTANT:

If ﬂ ue extension pipes are to be used then a core drill size of 125mm is required. This will allow the extension pieces to slope at 44mm/metre (2.5o) towards the boiler.

then 130mm along the adjacent wall.

by extending the dashed inclined line on the template to the side wall. This dashed line is drawn at 44mm/metre (2.5o) rise from the boiler. Where this line reaches the side wall, a horizontal line should be marked. The vertical centre line of the ﬂ ue should then be marked at 130mm from the back wall. To allow for the ﬂ ue passing through the wall at this angle a 125mm hole should be drilled irrespective of internal or external installation.

Hanging bracket ﬁ xing

0020167175_01 - 02/13 - Glow-worm

• Drill the holes for the ﬁ xing screws in accordance with the wall

template.

• Fix the hanging bracket on the wall.

- 11 -

INSTALLATION

7.4.2 Boiler hanging

DANGER:

Key 1 Boiler 2 Hanging bracket

• Lifting the boiler into position, lean the top of the boiler

• Lower the boiler slowly and engage onto the hanging bracket.

With regards to the Manual Handling Operations, 1992 Regulations, the following lift operation exceeds the recommended weight for a one person lift, refer to chapter "Manual Handling".

slightly to the wall and position just above the hanging bracket.

8 Hydraulic connection

DANGER:

• Only use original seals supplied with the appliance.

• Check that there are no leaks. Repair if necessary.

• Check the cold water inlet ﬁ lter is ﬁ tted ( located in the

Key 1 Heating return isolating valve + sealing washer ¾" 2 Cold water inlet isolating valve + sealing washer ½" 3 Gas service isolating valve with pressure test point + sealing washer

4 Domestic hot water outlet isolating valve + sealing washer ½" 5 Heating ﬂ ow isolating valve + sealing washer ¾" 6 Connection Ø O.D. 22 mm 7 Connection Ø O.D. 15 mm 8 Gas connection Ø O.D. 15 mm

Do not perform any 'hot work' directly under the appliance, this may cause damage to the appliance base. Heat may also damage the isolation valves. Always pre-assemble pipes before ﬁ tting them to the boiler.

appliance cold water inlet pipe).

6 7

½"

8.1 Gas and water connections

The whole of the gas installation, including the meter, should be inspected, tested for tightness and purged in accordance with the current issue of BS6891 and in IE the current edition of I.S.813 “Domestic Gas Installations”.

IMPORTANT:

• Take care to clean the pipes before assembly removing any

• Do not use any solvent products, due to the risk of damaging

The appliance may contain a small amount of water, place a water container beneath the boiler connections.

debris or burrs. Grease and oils may need to be removed they are not possible to remove by cleansing and ﬂ ushing. Foreign bodies in the system may enter the appliance and interrupt its operation.

the circuit.

• Use only the original gas cock GER/1 DN15, CE-0085 CL 0082.

• Use only the olive and ﬂ at seal washer supplied with the gas

cock.

• Remove the protective caps from the boiler connections.

• Flush out the domestic hot water and the heating systems.

IMPORTANT:

Before turning on the cold mains supply to the boiler turn oﬀ the cold water inlet to the boiler, lock the ﬁ lling loop in the closed position and close its ﬁ lling taps.

- 12 -

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8.2 Safety Discharge Valve

INSTALLATION

Key 1 Discharge pipe 15mm o.d. 2 Pressure relief valve PRV 3 Draining outlet A PRV outlet - to outside B Appliance drain

This must be extended, using not less than 15mm o.d. pipe, to discharge, in a visible position, outside the building, facing downwards, preferably over a drain.

To ease future servicing it is advisable to use a compression type ﬁ tting to extend the safety discharge valve tube.

The pipe must have a continuous fall and be routed to a position so that any discharge of water, possibly boiling, or steam cannot create any danger to persons, damage to property or external electrical components and wiring.

8.3 Connection to the condensate trap

DANGER:

Condensate produced by the appliance is mildly acidic (pH 3.5 - 5.0). Use protective gloves

Key 1 Condensate pipe 2 Condensate outlet pushﬁ t

• Make sure there is no protective plug ﬁ tted.

• Connect the condensate pipe (1) to the condensate outlet (2).

IMPORTANT:

Wherever possible, the condensate drainage pipe should be terminated into a suitable internal foul water discharge point such as an internal soil and vent stack, internal kitchen or bathroom waste pipe, washing machine waste pipe etc - ensuring that condensate drains away from the boiler under gravity.

Consideration must always be given to reducing the possibility of condensate pipes freezing and guidance must always be followed in the current BS 6798:2009. It is recommended to insulate external condensate pipes, any insulation must be vermin and peck-proof.

If it is unavoidable to run and terminate the condensate internally it is strongly advised to minimise the outside length of pipe and be of a minimum external diameter of 32 mm. Condensate pipes that pass through or from appliances installed in lofts, garages and basements should be treated as external pipes. Follow good installation practices and remove burrs from cut pipes and observe the recommended jointing method of the pipes and ﬁ ttings. Note some installations may require the use of a condensate pump on order to achieve internal discharge.

The pipe should have a fall of a least 2.5° 44mm/metre away from the boiler.

ATTENTION:

• Refer to BS5546 and BS6798 for advice on disposal of boiler

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Condensate must only be discharged in accordance with these instructions.

IMPORTANT:

The volume of condensates evacuated can reach about 15 litres per day for a detached house. This volume is negligible compared to the volume of waste water discharged by a house, because the condensates are diluted in this water.

condensate.

To be connected to the most appropriate discharge configuration

CONDENSATE PUMP

- 13 -

INSTALLATION

INCREASE PIPE SIZE

Washing machine trap / waste

- 14 -

100 mm min.

75 mm min.

2.5

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INSTALLATION

9 Evacuation of combustion gas

9.1 Regulation

ATTENTION:

Diﬀ erent ﬂ ue outlet conﬁ gurations can be carried out.

• Consult your supplier for more information about the other

• Standard ﬂ ue terminal kits have an in-built fall back to the

Only ﬂ ue accessories supplied by Glow-worm must be used.

possibilities and associated accessories.

44 mm/m

boiler to drain the condensate. These can be ﬁ tted level between the appliance and the termination position. All other extended ﬂ ues must have a fall of at least 44mm/m

1 2

ATTENTION:

If the ﬂ ue terminal is positioned near a light source insects may enter the ﬂ ue system. Where safe and practical to do so advise the homeowner to check the ﬂ ue outlet and clear visible insects from the terminal end.

The maximum length of the ﬂ ue outlet is deﬁ ned according to its type (for example C13).

• Whatever the kind of ﬂ ue system chosen, observe the

minimum distances indicated in the chart below to position the ﬂ ue terminals.

• To install the ﬂ ue, refer to the separate ﬂ ue instruction

supplied with your appliance.

• Explain these requirements to the user of the appliance.

DANGER:

a b

In GB the minimum acceptable siting dimensions for the terminal from obstructions, other terminals and ventilation openings are shown in diagram overleaf.

In IE the minimum distances for ﬂ ue 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.

If necessary, you must install a ﬂ ue terminal guard.

ATTENTION:

Caution! The connection between the ﬂ ue elbow and the ﬂ ue outlet must be sealed.

Position Position of the ﬂ ue terminal mm

Horizontal ﬂ ues

B above 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

M vertical from a terminal 1500 N horizontally from a terminal 300

Vertical ﬂ ues

P from another terminal 600 Q above roof level 300 R from adjacent opening window 1000 S from adjacent wall to ﬂ ue 300

directly below an opening, air brick, opening windows

horizontally to an opening, air brick, opening windows

from opening (door/window) in car port into dwelling

300

1200

Being a condensing boiler some pluming may occur from the ﬂ ue outlet. This should be taken into consideration when selecting the position for the terminal.

Carports or similar extensions of a roof only, or a roof and one wall, require special consideration with respect to any openings, doors, vents or windows under the roof. Care is required to protect the roof if made of plastic sheeting. A carport is deﬁ ned as a roof and one wall.

0020167175_01 - 02/13 - Glow-worm

(*) 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.

- 15 -

INSTALLATION

9.2 Flue conﬁ guration description

9.2.1 Horizontal concentric ﬂ ue Ø 60/100 mm or Ø 80/125 mm (C13 type installation)

DANGER:

If necessary, you must install a terminal protection kit.

Ø 60/100 mm

Each time an additional 90° bend is necessary (or 2 at 45°), the length (L) must be reduced by 1 m.

When using the Plume Management Kit, the maximum lengths ﬂ ue pipe A and B (60/100mm) are:

A (m) 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5

B (m) 5.5 5.0 4.5 4.0 3.5 3.0 2.5 2.0 1.5 1.0 0.5

• Refer to the Plume Management Kit installation manual.

9.2.2 Vertical concentric ﬂ ue Ø 60/100 mm or Ø 80/125 mm (C33 type installation)

Key 1 Gasket (ﬁ tted)

Ø 80/125 mm

Type Max length (L)

Ø 60/100 6 m Ø 80/125 10 m

Each time an additional 90° bend is necessary (or 2 at 45°), the length (L) must be reduced by 1 m.

Key 1 Gasket (ﬁ tted)

Ø 60/100 6 m Ø 80/125 10 m

- 16 -

Type Max length

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INSTALLATION

9.2.3 Multiple boiler chimney ﬂ ue Ø 60/100 mm (C43 type installation)

ATTENTION:

The ﬂ ue connecting from the appliance to the ﬂ ue system must be supplied from the manufacturer of the boiler.

ATTENTION:

C43 ﬂ ue systems must not be a 'pressurised system' but act under natural draught principles.

ATTENTION:

C43 type ﬂ ue systems must have their own condensate drain ﬁ tted and not allow condensate to mix into other appliances.

Model 30 35

Exhaust mass rate (g/s)

At min thermal load (40°C/30°C) 2.9 4.1

At max thermal load (80°C/60°C) 11.3 13.8

Exhaust temperature (°C)

At min thermal load (40°C/30°C) 42.7 41

At max thermal load (80°C/60°C) 72.9 73.1

10 Electrical connections

DANGER:

The appliance must be connected directly to an accessible, ﬁ xed, switched, electrical outlet.

The external wiring must be earthed, with correct polarity and in accordance with current standards.

The manufacturer declines any responsibility for damages to persons or others caused by the incorrect installation of the appliance earthing. This includes failure to comply with current standards.

Incorrect installation can cause electric shock or appliance damage. The electrical connection of the appliance must be made only by a qualiﬁ ed engineer.

Key 1 Pressure balancing system 2 Air-inlet pipe 3 Collector pipe 4 Boiler 5 Inspection hatch A Final storey B Ground ﬂ oor

Electrical components have been tested to meet the equivalent requirements of the BEAB.

• Do not use cable greater than 10 mm in diameter for the

electrical connections.

All system components must be of an approved type.

• Do not interrupt the mains supply with a time switch or

programmer.

The boiler is suitable for installation in bathroom zones 2 and 3.

10.1 Access to main board

Type Max length (L)

Ø 60/100 10 m

Each time an additional 90° bend is necessary (or 2 at 45°), the length (L) must be reduced by 1 m.

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Key 1 24 V access cover 2 Terminal blocks for 24 V connection 3 Terminal blocks for 230 V connection 4 230 V access cover

- 17 -

INSTALLATION

10.2 Main board

1 2 3

30mm

max

Key 1 Connector 2 Electrical wires 3 Insulation

• Keep a distance of a maximum of 30 mm between connector

(1) and the start of the insulation (3).

• Fix the cables in the cable-clamp on the eBox.

10.3 Electrical wiring

Connection of the whole electrical system and any heating system controls to the electrical supply must be through a double poled common switched and fused isolator.

The isolator shall have a contact separation of 3mm on each pole. It should be identiﬁ ed as to its use. Wiring to the boiler must be PVC 850C insulated cable not less than 0.75mm² (24/0.20).

10.3.1 230V permanent supply

DANGER:

All cables connected to the appliance should be permanently ﬁ xed to the wall.

IMPORTANT:

This appliance will not operate without a link or system controls ﬁ tted.

A fused three pin plug and shuttered socket outlet may be used instead of a fused spur box provided that it is not used in a room containing a ﬁ xed bath or shower.

Key 1 Power supply cable

• Connect the appliance's power cable to the 230 V single-phase

network + earth.

• Observe correct polarity when connecting the appliance.

Key 1 230V permanent supply 2 Main board terminal block

= Mains earth N = Mains neutral L = Mains live

3 Fuse 4 Double pole connector

• Connect mains supply as described.

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INSTALLATION

10.3.2 230V permanent supply + 230V system controls

DANGER:

All cables connected to the appliance should be permanently ﬁ xed to the wall.

IMPORTANT:

This appliance will not operate without a link or system controls ﬁ tted.

10.4 External accessories

DANGER:

Under no circumstances must any mains voltage be applied to any of the terminals on the 24v connection plug.

BUS

24 V

X17

RT 24V T° extBUS

230

Key 1 230V permanent supply 2 System controls 3 Frost stat 4 Main board terminal block

FP = Frost stat 230V (switchable) RT = Switch live (230V)

= Mains earth N = Mains neutral L = Mains live

5 Junction box 6 Fuse 7 Double pole connector

• Connect the mains supply and system heating controls e.g.

room thermostat as described.

• When installing a 230v controller, the link ﬁ tted to the 24v

terminals (RT/24v) must be removed.

RT 24V T° extBUS

Key 1 24V room thermostat connector 2 Ebus room thermostat connector or Ebus radio receiver 3 Outdoor sensor connector

• Fit external controls in accordance with the rules in force.

• When installing a non eBus controller, the link ﬁ tted to the 24V

terminals (RT/24V) must be removed.

10.5 Testing the electrical connections

Carry out preliminary electrical system checks as below:

- Resistance to earth (<1 Ohm)

- Short circuit test (L-N)

- Resistance to earth (L-E)

- Polarity check

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- 19 -

INSTALLATION

10.6 Wiring diagram

INTERFACECL

X31

X51

X40

X32

X90

X30

X15

X17

1920 18 17 16 15 14 13 12 11

10987654321

1102113124135146157168179

X20

12 34

X21

X13

X14

FUS

X101

X17

NTC

Ebus

24 V

1920 18 17 16 15 14 13 12 11

10987654321

3421

123

12 34521 1 11 1...8921

18 17 16

Key 1 Control accessories connector 2 Reserved for future use 3 Location for external accessories (condensate pump and options

board)

4 Internal timer 5 User interface 6 Fuse 2A 7 Connector for 230 V option 8 Main supply 230V

X20

1102113124135146157168179

9 Pump 10 Combined spark and ﬂ ame recognition electrode 11 Heating outlet temperature sensor 12 Heating return temperature sensor 13 Gas valve 14 Fan 15 Three way valve 16 Thermal fuse 17 Water ﬂ ow sensor 18 Water pressure sensor

Green/Yellow

230 VAC

Green/Yellow

X21

1011121314

- 20 -

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INSTALLATION

11 Commissioning

IMPORTANT:

The commissioning should be carried out by a competent person approved at the time by the Health and Safety Executive and in accordance with the current issue of BS6798.

11.1 Reading the ﬁ lling pressure

The boiler is equipped with an analogue pressure gauge.

The pressure guage is located behind the front panel of the boiler on the ﬂ ow pipe. The guage is intended to be used as an installation aid, the guage is not intended to be used by the customer.

Key 1 White area, pressure too low 2 Grey area, normal operating pressure 3 Red area, pressure too high

To ensure the correct operation of the heating installation, the indicator on the pressure gauge should be within the grey area (2) in approximately the central position as shown in the diagram. This corresponds to a ﬁ lling pressure of between 0.1 MPa and 0.2 MPa (1.0 bar and 2.0 bar).

11.2 Switching on

• Do not operate the boiler without water.

At the time of commissioning, complete all relevant sections of the Benchmark Checklist located in the centre pages of this document.

11.3 Filling the CH system (Central heating)

• Make sure that the installation's cold water inlet isolating valve is

open.

• Open the isolating valves located on the connections: they must

be positioned in the direction of the ﬂ ow.

Key

1 Air vent 2 Pump 3 Screw for the pump shaft

• Open the plug on the air vent located on the pump and

automatic air vents on the installation.

If the (CH.) pressure falls below 0.4 bar, the display will ﬂ ash the current pressure and the boiler will not operate. To increase the pressure, the CH circuit requires " Topping up".

IMPORTANT:

• Vent air from each radiator until the water ﬂ ows normally, then

• Leave the pump's air vent open.

When turning the 230Vac supply on to the boiler should the water pressure be less than 0.5 bar an automatic air vent function will be activated for a period of 5 minutes. During this time the pressure should be increased and air vented from the system. Note that the burner will not ﬁ re in either the CH or DHW mode and the display will blink displaying the current water pressure.

close the vents.

• Make sure that the system has been thoroughly ﬂ ushed out with

cold water and that all cleanser if used has been removed.

• With the gas service isolation valve closed, with no demand

from any external controls and the power supply to the boiler switched oﬀ .

• Test for gas tightness and purge air from the gas supply.

• Switch on the power supply to the appliance.

• Make sure that the domestic hot water and heating functions

on your appliance are not activated.

0020167175_01 - 02/13 - Glow-worm

IMPORTANT:

• Remove the screw from the pump shaft and introduce a ﬂ at

• Rotate the pump's shaft through several turns, then replace

The following two operations will unblock the pump's engine after a prolonged storage period and will purge the air from the pumps circuit.

screwdriver. A trickle of water, under no pressure should normally come out of the pump.

the screw.

- 21 -

INSTALLATION

11.4 Filling DHW Circuit

• Open the various hot water taps to ﬁ ll the DHW circuit.

11.5 Filling the Condensate Trap

11.6 Initial lighting

11.6.1 Control

IMPORTANT:

• Check that the appliance has been installed in accordance with

• Check the integrity of the ﬂ ue system and ﬂ ue seals.

• Check the integrity of the appliance combustion circuit and

• Check that all internal/external controls are calling for heat.

• Check that the gas service isolation is open.

• To adapt the appliance to another type of gas, see chapter

11.6.2 Adjusting the temperature

The combustion for this appliance has been checked, adjusted and preset at the factory for operation on natural gas (G20) as deﬁ ned on the appliance data label. No measurement of the combustion is necessary.Should the appliance require to be converted to LPG gas ensure you follow the gas conversion section before lighting the boiler.

the instructions.

relevant seals.

"LPG conversion".

Key 1 Filling trap 2 Condensate trap

• Fill the trap with water (1).

• Activate the Heating and Domestic Hot Water functions.

• Run the appliance for at least 15 minutes, with a heating

temperature set to greater than or equal to 50°C (not applicable for an installation with underﬂ oor heating).

• Vent air from each radiator again until the water ﬂ ows

normally, then close the vents.

• If you have diﬃ culties in removing the air, launch the air-

removal programs in the heating circuit (see the chapter ("Technical settings for the appliance and list of parameters").

• Make sure that the pressure indicator shows a value of 0.8

bars; otherwise, ﬁ ll the appliance again.

• Light the appliance by following the procedure below.

• Select the "Heating + domestic hot water" function by pressing

the “Mode” button repeatedly to scroll through your options

are shown.

until

The appliance will enter a self checking routine, then the fan will start and the ignition sequence commence. The boiler, if necessary, will automatically repeat the ignition sequence a further 4 times.

If the burner fails to ignite “F28” will be displayed, initially, this may be due to air in the gas supply line. Press the reset button. Do not use the reset button to purge the installation - never press reset more than 3 times.

• Select the heating function only by pressing the "mode"

button repeatedly (

• Press

• Select the hot water function only by pressing the "mode"

button repeatedly (

• Press

• Check that hot water is available at all taps, then close.

• Return the appliance to the correct mode by pressing "mode"

button unit the desired functions are activated.

or buttons to adjust.

is shown only).

- 22 -

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INSTALLATION

11.7 Gas rates

The supply from the governed meter must be of adequate size to provide a steady inlet working pressure of 20mbar (8in wg) at the boiler.

• On completion, test the gas installation for tightness using the

pressure drop method and suitable leak detection ﬂ uid, purge in accordance with the above standard.

IMPORTANT:

• Activate the test mode "P.01" and set the value to HI in order to

11.7.1 Operational Gas Inlet Pressure

Due to the modulating operation of the boiler and the need to check the gas inlet pressure and measure the gas rate at maximum rate, it will be necessary to force it to maximum.

force the burner at P. max. See chapter "Speciﬁ c adjustment > Appliance technical settings and parameter list > Test modes".

11.7.2 Gas Rate

• Make sure that all other gas burning appliances and pilot

lights are oﬀ .

• Check the gas rate using the gas meter test dial and stop

watch, at least 10 minutes after the burner has lit, see table below for approximate rates.

Gas rates (G20) Gas rates (G31)

(approx) after 10 mins from cold

Model

30 0.65 22.9 3.24 114.4 0.47 1.94

35 0.92 32.5 3.77 133.1 0.67 2.37

In communal or LPG installations where the gas rate cannot be measured it is acceptable to measure the combustion rate as described in the servicing section.

• On completion, press the "reset" button to reset the boiler.

• Gas rates for both central heating and hot water can be veriﬁ ed

using the test program P.03 and P.01 respectively.

MIN MAX MIN MAX

/h ft3 /h m3 /h ft3 /h kg/h kg/h

11.8 Testing heating system

Key 1 Gas service isolation valve 2 Test point

• With all other gas appliances operating, check the operational

supply pressure at the gas service isolation valve test point.

The nominal supply pressure for Natural Gas (G20) is 20mbar. The nominal supply pressure for LPG (G31) is 37mbar.

• Turn the taps and appliances oﬀ , then disconnect the pressure

gauge.

Additionally the safe nominal maximum heat input of the appliance can be achieved at an inlet pressure down to 15mbar.

IMPORTANT:

The burner pressure cannot be measured and is not used to measure the gas rate.

• Ensure that the external controls and programmer are calling

for heat.

• Fully open all radiator valves, see chapter "Appliance

installation > Recommendations before installing > Heating circuit design".

• Activate the C.H. function on the appliance's control panel.

• Balance the radiators as required to give the required system

diﬀ erential.

• Turn oﬀ all radiators that can be shut oﬀ by the user and check

to see if less than the maximum diﬀ erential allowed of 20°C can be achieved across ﬂ ow and return.

IMPORTANT:

• Allow the system to reach maximum temperature then switch

• Drain the entire system rapidly whilst hot, using the drain taps

• Adjust the boiler temperature controls and any system controls

Should the appliance require adjustment refer to the "Speciﬁ c adjustment" section overleaf.

oﬀ the boiler by isolating from the electrical supply.

at all the low points of the system. Fill and vent the system as described previously in chapter "Commissioning > Filling the CH system (Central heating)".

to their required settings.

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- 23 -

INSTALLATION

11.9 Testing domestic hot water system

• Open a hot-water tap.

• Check that the temperature obtained is compliant with the

setting on the appliance.

11.10 Completion

• Ensure that the magnetic lighting instruction label is placed on

the surface of the boiler casing.

GB: It is a requirement that the “Benchmark” Installation, Commissioning and Service Record is completed and left with the user.

IE: it is necessary to complete a “Declaration of Conformity” to indicate compliance to I.S.813. An example of this is given in the current edition of I.S.813.

12 Speciﬁ ed Adjustment

12.1 Heating circuit adjustment

By pass operation is automatic and not adjustable.

• If necessary, ﬁ t an external by-pass.

ULTIMATE 30c

50 40 30 20 10

Key A Available pressure between heating ﬂ ow and return (kPa) B Heating circuit ﬂ ow rate (l/h)

60 50 40 30 20 10

Key A Available pressure between heating ﬂ ow and return (kPa) B Heating circuit ﬂ ow rate (l/h)

500

ULTIMATE 35c

500

1000

1500

- 24 -

0020167175_01 - 02/13 - Glow-worm

INSTALLATION

12.2 Installation settings

• Push in and hold the button for more than 7 seconds to

access the conﬁ guration menu. The screen displays "0".

• Press the

the installer's password.

• Press

button 4 times. The screen displays "96". This is

to validate. The screen displays a ﬂ ashing and

• Press

select with the

• Press button to conﬁ rm and save the changes.

• Press and hold the

exit.

or button to access the parameter to modify.

button to modify the value of the parameter and

or keys.

button for more than 7 seconds to

alternating "d." and "00".

Code Parameter Unit Description Factory setting

d.00 Maximum heating power kW

d.01 Pump over-run time - heating min Choose a value between 2 and 60 5 yes

d.20 Maximum temperature setting for domestic hot water °C

d.34 Speed of fan rpm

d.36 Domestic hot water ﬂ ow

d.40 Heating ﬂ ow temperature °C Display the heating ﬂ ow temperature. - no

d.41 Heating return temperature °C Display the heating return temperature. - no

d.43 Heating curve K

d.47 Exterior temperature °C

Time remaining before the end of the anti-cycle in

d.67

heating mode.

d.71 Maximum temperature setting for heating outlet °C Select a value between 50°C and 80°C. 75 yes

d.90 Detection of eBUS controller -

Choose a value: ULTIMATE 30c > 6 to 25 and ULTIMATE 35c > 8 to 30.

The recommended maximum temperature setting for DHW is 60°C. Choose a value suitable for your needs.

Fan speed is displayed between 0 and 99. Multiply the display value by 100.

Display domestic hot water ﬂ ow. - no

min.

See the instructions for the external sensor connected to the appliance.

Display the temperature measured by the external sensor.

Display the time remaining before the end of

min.

the anti-cycle

0 = Not detected 1 = Detected

25 (ULTIMATE 30c) 30 (ULTIMATE 35c)

60 yes

-no

1.2 yes

-no

Modiﬁ able parameter

yes

12.3 After Sales Service settings

• Press and hold the button for more than 7 seconds to

access the conﬁ guration menu. The screen displays "0".

• Press

password.

• Press

or button and enter the After Sales Service

to validate. The screen displays a ﬂ ashing and

• Press

select with the or keys.

• Press

• Press and hold the

exit the conﬁ guration menu.

or button to access the parameter to modify.

button to modify the value of the parameter and

button to conﬁ rm and save the changes.

button for more than 3 seconds to

alternating "d." and "00".

Code Parameter Unit Description

d.08 Current state of the 230V room thermostat -

d.09 Flow temperature set point from external eBus control °C External eBus set value. - no

d.10 Heating pump status -

d.16 Current state of the 24V room thermostat °C

d.17 Flow or Return temperature control °C

d.22 DHW demand active (tapping) -

d.23 Central heating mode -

d.33 Speed setpoint of fan rpm

230V room thermostat : 0 = open (no heating), 1 = closed (heating mode).

0 = oﬀ 1 = on

0 = open (no heating), 1 = closed (heating mode)

Temperature regulation on ﬂ ow (radiator) or return (under-ﬂ oor heating) temperature sensor.

0 = oﬀ 1 = on

0 = CH not available (summer mode) 1 = CH available (winter mode)

Fan speed is displayed between 0 and 99. Multiply the displayed value by 100.

Factory

setting

Modiﬁ able

parameter

-no

0yes

-no

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INSTALLATION

Code Parameter Unit Description

d.44 Digitalized ionisation voltage V

d.68 Unsuccessfull ignitions at ﬁ rst attempt -

d.69 Unsuccessfull ignitions at second attempt -

d.80 Operating hours in heating mode h

d.81 Operating hours in domestic hot water mode h

d.82 Number of burner starts in heating mode -

d.83 Number of burner starts in DHW mode -

d.93 Device Speciﬁ c Number - Select the product code of the appliance:

d.96 Factory reset -

Display the digitalized ionisation voltage. Multiply the displayed value by 100.

Display the number of unsuccessfull ignitions at ﬁ rst attempt.

Display the number of unsuccessfull ignitions at second attempt.

Display the number of operating hours in heating mode. Multiply the displayed value by 100.

Display the number of operating hours in domestic hot water mode. Multiply the displayed value by 100.

Display the number of burner starts in heating mode. Multiply the displayed value by 100.

Display the number of burner starts in DHW mode. Multiply the displayed value by 100.

All parameters stored in EEPROM (main board + appliance interface) are reset to factory settings if this function is activated. 0 = deactivated 1 = activated

12.4 Status of the appliance

Factory

setting

30 -> 5 35 -> 6

Modiﬁ able

parameter

-no

yes

0yes

• Press button for more than 3 seconds to learn the current

state of functioning of the appliance. The screen displays "S" and the state of the appliance.

• Press and hold the

button

for more than 3 seconds to

exit this menu.

Status Heating Mode

S.00 No request for heating S.01 Pre-run fan S.02 Pre-run pump S.03 Ignition S.04 Burner lit S.05 Post run pump/fan S.06 Post run fan S.07 Post run pump S.08 Time delay anti short-cycles after heating

Status Domestic hot water mode

S.10 Request for domestic hot water S.11 Pre-run fan S.13 Ignition S.14 Burner lit S.15 Post run pump/fan S.16 Post run fan S.17 Post run pump

Status Speciﬁ c messages

Default status, no request for heating or domestic water. If an EBUS controller is connected to the boiler, check that a

S.30

wiring link is present on terminals 3 and 4 of the boiler's main board.

S.31 "Hot water only" mode

Control cycle: the speed of the fan in the functioning phase is

S.32

outside tolerance. S.34 "Frost protection" mode S.41 Water pressure too high

Waiting cycle: temperature diﬀ erential between heating ﬂ ow S.53

and return is too high. If ∆T > 30, forcing to Pmin.

Waiting cycle: lack of water in the installation/temperature S.54

rise between heating ﬂ ow and return is too high. S.96 Test temperature sensor for heating return.

Test temperature sensors for heating ﬂ ow and return, or the S.98

appliance has a fault.

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INSTALLATION

12.5 Test modes

By activating these various test modes, you can enable special functions on the appliance.

• Press the on/oﬀ button to switch oﬀ the appliance.

• While keeping the button

pressed for more than 5 seconds, press the on/oﬀ button. The screen displays the ﬁ rst test mode "P1" and "Oﬀ ".

• Press

or button to choose the test mode that you wish to

launch.

• Test mode "P1" :

- Press

button to display the burner forcing setting. The

screen displays "P1" and "Lo".

- Press on

or button to modify the value of the setting from

"Lo" (0%) to "Hi" (100%).

- Press on

button for 1 second to exit the submenu or for

more than 7 seconds to access the conﬁ guration menu.

• Test mode "P.02" to "P.07" :

- Press

to launch the test mode. The screen displays "PX"

and "On".

- The test mode will be automatically stop after 15 minutes.

• When you have ﬁ nished, press the reset button

to exit the

test modes.

Code Parameter Description

The appliance functions at a power adjustable from "Lo" (Lo = Pmin.) to "Hi" (Pmax.) by using buttons successful ignition.

The appliance functions at ignition power after successful ignition.

The appliance functions at its maximum power after successful ignition.

The function is activated for a period of 5 minutes on the heating circuit. Make sure that the air vent is open.

The function is activated for a period of 5 minutes on the short circuit. Make sure that the air vent is open.

or after

P.01

P.02

P.03

P.06

P.07

Forcing the adjustablepower burner when heating

Forcing the burner to heating ignition power

Forcing the burner to Heating Pmax.

Venting the installation

Venting the appliance

12.6 CO2 measurement

The combustion for this appliance has been pre-set at the factory for operation on Natural Gas G20 as deﬁ ned on the appliance data label.

No adjustment of the combustion is necessary.

12.7 Re-check and restart

• Once the appliance is installed, check the operation of the

appliance.

• Start the appliance to ensure that any adjustments operate

correctly and check that the appliance operates safely.

• Check the gas-tightness and water-tightness of the appliance

and eliminate any leaks.

• Check that the ﬂ ue joints are tested for tightness and ﬁ tted in

accordance with the instructions.

• Check the entire control and safety system, its settings and its

operation.

13 User information

At the end of the installation, the installer must:

- explain the operation of the appliance and its safety devices to the user, if necessary provide a demonstration and answer any questions;

- hand over to the user all the required documentation,

- ﬁ ll in the documents where necessary;

- advise the user of the precautions necessary to prevent damage to the system, appliance and the building;

- remind the user to service the appliance annually.

• Draw attention, if applicable, to the current issue of the Gas

Safety (Installation and Use) Regulations, Section 35, which imposes a duty of care on all persons who let out any property containing a gas appliance in the UK.

The user shall not interfere with or adjust sealed components.

It is the Law that any servicing is carried out by a competent person approved at the time by the Health and Safety Executive.

• Advise the user that, like all condensing boilers this appliance

will produce a plume of condensation from the ﬂ ue terminal in cool weather. This is due to the high eﬃ ciency and low ﬂ ue gas temperature of the boiler.

• Advise the user that the permanent mains electrical supply

should not be switched oﬀ , as the built in frost protection and pump exercise program will not operate.

• Advise the User if the mains electricity and gas are to be

turned oﬀ for any long periods during severe weather, it is recommended that the whole system, including the boiler, should be drained to avoid the risk of freezing.

IMPORTANT:

Sealed system: The system must be reﬁ lled and to the correct pressure as indicated in these instructions

If you wish to check the combustion then follow the instructions in the Servicing section.

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• Leave these instructions and the ‘Benchmark’ Installation,

Commissioning and Service Record with the user.

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MAINTENANCE

To ensure the continued eﬃ cient and safe operation of the boiler it is recommended that it is checked and serviced at regular intervals. The frequency of servicing will depend upon the particular installation and usage, but in general once a year should be enough.

It is the Law that any servicing is carried out by a competent person approved at the time by the Health and Safety Executive.

• Before commencing with a service or replacement of parts

isolate the boiler from the electrical supply and turn oﬀ the gas supply at the gas isolation valve.

• When replacing a part on this appliance, use only spare parts

that you can be assured conform to the safety and performance speciﬁ cation that we require. Do not use reconditioned or copy parts that have not been clearly authorised by Glow-worm.

• If any electrical connections have been disconnected and

after their connection, checks to the earth continuity, polarity, short circuit and resistance to earth must be repeated using a suitable multimeter, as described in chapter "Trouble-shooting > Fault diagnosis > Check the electrical installation".

• After servicing, complete the relevant Service Interval Record

section of the Benchmark Checklist located in the back pages of this document.

14 Trouble-shooting

14.1.1 Check the electrical installation

Key 1 Main board 2 Neutral 3 Live 4 Multimeter

14.1 Fault diagnosis

The following checks should be performed before proceeding onto speciﬁ c diagnostics:

• Make sure that the electricity supply has not been interrupted

and that the appliance is connected correctly (See chapter "Trouble-shooting > Fault diagnosis > Check the electrical installation")

• Check the appliance’s gas supply (See chapter "Trouble-

shooting > Fault diagnosis > Check the gas supply").

• Ensure that the isolating valves are open.

• Ensure that the pressure indicator displays a value of 0.8 bar

(if the pressure falls below 0.4 bar, the air vent function will run automatically for a period of 5 minutes until you see 0.5 bar on the pressure indicator). If not, ﬁ ll the appliance.

• Check that all external controls are connected correctly.

• If the symbol

code memory (see chapter " Trouble-shooting >Fault memory").

• Press the reset button

• Check the functional ﬂ ow diagram.

is displayed on the screen, display the fault

to restart the appliance.

• Remove the front casing panel

• Check the external electrical supply to the boiler is on and a

supply of 230V is present at the ‘L’ and ‘N’ terminals on the main board.

• Check the electrical installation and appliance, carry out tests

for earth continuity, polarity, short circuit and resistance to earth, using a suitable multimeter.

• Bare metal points such as screws or rivets will act as suitable

earth check points on the appliance.

14.1.2 Check the gas supply

Key 1 Gas service isolation valve 2 Test point

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• Check that there is a gas supply to the boiler and the gas

service isolation valve is turned on.

• Check pressure at the gas service isolation valve.

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14.2 Fault memory

• This menu allows you to display the 10 most recent failure

codes registered by the appliance.

• In order to display the fault code memory, simultaneously

press the buttons

• The screen will display the ﬁ rst fault "1." (record) and after

"XX" (fault code).

• To display the other faults registered by the appliance, press

the button

and for more than 7 seconds.

or .

MAINTENANCE

• Press button

for more than 3 seconds to exit this menu.

• To erase the fault memory registered by the appliance, consult

the “Installation adjustments” chapter and use code “d.94”.

14.3 Fault codes

IMPORTANT:

The faults described in this chapter should be carried out by a qualiﬁ ed engineer and if needed by the After Sales Service.

Fault

Description Cause Solution

codes

F00 Flow heating temperature sensor fault Sensor open circuit

F01 Return heating temperature sensor fault

F10 Flow heating temperature sensor fault Sensor short-circuit F11 Return heating temperature sensor fault Return heating temperature sensor shorted.

F20 Overheating fault Overheating safety device activated (97°C)

Water pressure of the installation (<0.3

F22

bar)

Maximum temperature diﬀ erence

F23

reached between return and ﬂ ow heating

F24 Water circulation fault

F26 Fault in gas valve motor. Disconnected or defective cables

F27 Flame detection fault. Abnormal ﬂ ame detection

F28 Ignition fault

F29 Loss of ﬂ ame during operation

F32 Incorrect air pressure Incorrect fan speed.

F49 EBUS voltage fault

Return heating temperature sensor disconnected

Return water valve closed Pump disconnected Leak in the installation

Water circulation fault

Malfunction of the pump (excessively rapid temperature increase)

No return gas / Insuﬃ cient gas ﬂ ow Gas valve incorrectly adjusted Defective ﬁ ring electrode and ﬂ ame control / Defective igniter unit

Fault in EBUS line Short circuit in EBUS connector

• Check the sensor’s connections.

• Check the wiring harness.

• Check the sensor.

• Check the operation of the pump.

• Check the wiring harness.

• Check that the ﬂ ow and return heating isolation valves are open.

• Fill the installation.

• Purge the installation.

• Check the pump connections.

• Check the ﬂ ow and return heating sensor connections.

• Check that there are no leaks.

• Check the ﬂ ow and return heating sensor connection.

• Check the pump speed.

• Check that the ﬂ ow and return heating isolation valves are open.

• Check the gas valve connections.

• Check the operation of the gas valve.

• Check the operation of the condensate pump (option).

• Check the ﬂ ame detection electrode.

• Check the main board.

• Check the igniter unit.

• Check the return gas circuit (gas valve open).

• Check the observe the ﬂ ame picture and check the CO

setting.

• Check the igniter unit connections.

• Check the state of the electrode (corrosion).

• Check the entire ﬂ ue system.

• Check the fan’s electrical connections.

• Check that the eBus controls are ﬁ tted and wired correctly.

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MAINTENANCE

Fault

Description Cause Solution

codes

F61 F62 Gas valve closure fault

F63 Fault in the main board memory

Fault in the main board

F64

F65 Excessive main board temperature F67 Flame signal fault in the main board

F68 Fluctuation of ﬂ ame signal

User interface incompatible with the

F70

main board

F71 Flow heating temperature sensor fault

Permanent temperature diﬀ erence

F72

between ﬂ ow and return heating

sensors F73 Heating circuit pressure sensor fault The sensor is shorted or disconnected. F74 Heating circuit pressure sensor fault Fault in pressure sensor

F76 Thermal fuse fault

F77 Fault in gas valve motor.

No water in the installation : the F83

temperature does not increase when the

burner is lit

Permanent temperature diﬀ erence F84

between ﬂ ow and return heating

sensors

F85 Flow and return heating sensors fault

F86 Underﬂ oor heating contact fault

Err User interface fault Defective user interface

Gas valve command fault

Rapid ﬂ uctuation of return or ﬂ ow heating sensor.

No return gas / Insuﬃ cient gas ﬂ ow Gas valve incorrectly adjusted Defective ﬁ ring electrode and ﬂ ame control / Defective igniter unit

Incorrect product code

Flow heating temperature sensor unclipped or defective (no temperature variation)

Mismatch between the ﬂ ow and return heating temperatures (permanent diﬀ erence)

Thermal fuse disconnected Defective thermal fuse

Defective gas valve. Defective condensate pump (option)

Return water valve closed Pump disconnected Leak in the installation

Inverted or disconnected ﬂ ow and return heating temperature sensors Defective temperature sensors

Flow and return heating temperature sensor connected to same tube

Floor heating contact open Sensor disconnected or defective

• Check the main boards connections.

• Check the main board.

• Check the appliance DSN number is correct.

• Reset the appliance.

• Check the return gas circuit (gas valve open).

• Check the observe the ﬂ ame picture and check the setting.

• Check the igniter unit connections.

• Check the state of the electrode (corrosion).

• Check that the appliance DSN code on the screen

matches the product code of the nameplate (in the event of a fault and the appliance DSN does not appear, consult menu.d.93 reserved for the code).

• Check the boards reference.

• Check the sensor connections.

• Make sure that the sensor is clipped to the tube.

• Check temperature sensors connections.

• Replace faulty sensors.

• Check the sensor’s connections.

• Check the sensor.

• Check the fuses connections.

• Replace the heat exchanger.

• Check the gas valve connections.

• Check the operation of the gas valve.

• Check the operation of the condensate pump (option).

• Fill the installation.

• Purge the installation.

• Check the pump connections.

• Check the ﬂ ow and return heating sensor

connections.

• Check that there are no leaks.

• Check temperature sensors connections.

• Replace faulty sensors.

• Check temperature sensors connections.

• Check the sensor connections.

• Check that the sensor is connected to the main

board and the shunt is removed.

• Check connection from user interface PCB to main

PCB.

• Replace user interface.

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14.4 Functional ﬂ ow diagram

14.4.1 Central Heating

MAINTENANCE

14.4.2 Domestic Hot Water

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MAINTENANCE

15 Gas conversion adjustments

In order to adjust the appliance to a diﬀ erent gas that it is set to in production.

This conversion should only be carried out by a competent person approved at the time by the Health and Safety Executive.

• During the conversion to Propane, use of a suitable ﬂ ue gas

analyser is necessary.

The person carrying out a combustion measurement should have been assessed as competent in the use of a ﬂ ue gas analyser and the interpretation of the results. The ﬂ ue gas analyser used should be one meeting the requirements of BS7927 or BSEN50379-3 and be calibrated in accordance with the analyser manufacturers’ requirements. Competence can be demonstrated by satisfactory completion of the CPA1 ACS assessment, which covers the use of electronic portable combustion gas analysers in accordance with BS 7967, parts 1 to 4.

15.1 Settings

IMPORTANT:

Tools required to make the conversion are a 4mm Allen key and an electricians screwdriver.

Having checked :

- the appliance and system have been installed in

- the integrity of the ﬂ ue system and ﬂ ue seals....

- the integrity of the appliance combustion circuit and relevant

Steps "Switching on" to "Re-pressurising System" will need to be completed before the appliance can be converted (See chapter "Commissioning").

accordance with the instructions.

seals....

Key 1 Throttle 2 Combustion analyser sample point 2A Flue elbow 2B Vertical ﬂ ue adaptor 3 Cap

• Remove the front panel ﬁ rst.

• Remove the cap (3) and connect a CO2 analyser to eﬀ ect the

measurement (2).

15.1.1 Adjusting the gas valve

- that all internal/external controls are calling for heat.

- the gas service isolation valve is opened.

• Press the on/oﬀ button to turn the appliance oﬀ .

• Turn the screw in the direction and the number of times

indicated in the following table.

Gas adjustment Model G20 > G31 G31 > G20

30 3 turns

35 2.5 turns

30 3 turns

35 2.5 turns

15.1.2 Adjusting the maximum power setting

• Activate the test mode "P.01" and set the value to HI in order to

force the burner at P. max. See chapter "Speciﬁ c adjustment > Appliance technical settings and parameter list > Test modes".

• Wait approximately 5 minutes to read a stabilized CO

value.

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MAINTENANCE

• Compare the value measured with the values indicated in the

table below.

Gas adjustment G20 G31

CO2 case ON 9 ± 0.2 % 10.1 ± 0.2 %

case OFF 9.2 ± 0.3 % 10.3 ± 0.3 %

IMPORTANT:

Safe combustion can only be veriﬁ ed by measuring CO/ CO2 ratio. This must not exceed the value shown in the table under the section "Maximum Rate and Adjustment".

15.1.3 Restarting

• Replace the cap

• Replace the appliance front panel.

Note: following the replacement of the front panel, the CO will change: you can check that the value "case on" is correct by the values in the previous table.

value

16 Draining

16.1 Heating circuit

Key 1 Length of hose (not supplied) 2 Drain valve

Key 1 Serial number stickers 2 Data label location

• Firmly attach the gas replacement label to the appliance in the

corresponding location (1) on the electrical box.

15.2 Restart - re-check commissioning

• Before putting the appliance into operation, follow the

instructions within the chapter Speciﬁ c adjustment.

• Drain down the heating circuit of the boiler only, by closing

the heating ﬂ ow and return isolating valves. See chapter "Hydraulic connection > Gas and water connections"

• Open the drain point (2). Attach a length of hose (1) if

required.

• After draining, close the drain valve (2) and remove the hose.

16.2 Domestic Hot water circuit

• Drain the Domestic Hot Water circuit by closing the cold-water

isolation valve.

• Open one or more hot water taps to drain the hot water circuit.

17 Servicing

• To ensure the continued eﬃ cient and safe operation of the

boiler it is recommended that it is checked and serviced as necessary at regular intervals.

The frequency of servicing will depend upon the particular installation conditions and usage. However it is recommended that the boiler is inspected as part of a service at least once a year.

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If this appliance is installed in a rented property there is a duty of care imposed on the owner of the property by the current issue of the Gas Safety (Installation and Use) Regulations, Section 35.

• Servicing/maintenance should be carried out by a competent

person approved at the time by the Health and Safety Executive in accordance with the rules in force in the countries of destination.

- 33 -

MAINTENANCE

• To obtain service, please call your installer or Glow-worm’s

own service organisation.

PLEASE NOTE: During routine servicing, and after any maintenance, we recommend that the following must be checked:

- The integrity of the ﬂ ue system and the ﬂ ue seals,

- The integrity of the boiler combustion circuit and the relevant seals,

- The operational (working) gas inlet pressure at maximum rate,

- The gas rate,

- The combustion performance.

• See the "Safety instructions" chapter for a list of operations to

be performed prior to the maintenance of the application.

• Once the maintenance operations have been completed,

consult the ¨Start Up¨ chapter to restart the appliance.

17.1 Annual Maintenance

17.1.1 Veriﬁ cation of components

• Check that the ﬂ ow sensor is working properly.

See chapter "Speciﬁ c adjustment > Appliance technical settings and parameter list > Installation settings" and use code “d.36”.

17.1.3 Cleaning of the components

• Clean the following components:

- The condensate trap

- The heat exchanger.

- The burner

- The fan

17.1.4 Corrosion and anti-sludge protection

In order to avoid corrosion, the addition of a corrosion inhibiter to the heating circuit water is recommended. The inhibiter will stop electrolytic reaction and bacterial growth between the diﬀ erent metals used in the installation.

It will also avoid the formation of gas which could be produced following the chemical reactions.

It is especially important to treat the water in underﬂ oor heating systems, as low temperatures favour bacterial growth. This can lead to the formation of sludge, which in turn may block some or all of the circuits.

In order to add the correct dosage of these products, you must know the volume of water contained in the installation. It is recommended that you note down the volume for future needs.

The inhibitors must be compatible with the materials employed in the installation.

• Check that the fan is working properly.

See chapter "Speciﬁ c adjustment > Appliance technical settings and parameter list > Installation settings" and use code “d.34”.

• Check that the temperature sensors are working properly.

See chapter "Speciﬁ c adjustment > Appliance technical settings and parameter list > Installation settings" and use code “d.3, d.4, d.40, d.41”.

• Check the ionisation quality.

• Check that the thermal fuse protects the appliance against dry

ﬁ re. Disconnect the thermal fuse and check if "F76" fault code is displayed on the screen.

• Check that the pressure sensor is working properly. The

pressure must be displayed on the screen.

• Check the pressure of the expansion vessel.

17.1.2 Other checks

• Check the CO

indicated in the chapter "CO2 Measurement".

• Check that there are no leaks in the joints and the safety

valves.

rate in the fuel and compare with the values

17.2 Casing removing

17.2.1 Front panel

230

• Check that there are no gas leaks.

• Verify that the ﬂ ue system is sound and complete.

• Check the appliance’s electrical safety.

- 34 -

Key 1 Front panel 2 Front panel retaining screw

• Undo the two screws (2) on the underside of the front panel

and remove the front panel (1).

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MAINTENANCE

17.2.2 Control box

230

Key 1 Control box

• Position the control box (1) into the service position.

17.3 Combustion check and setting the air/gas ratio valve

17.3.1 Competency to carry out the check of

combustion performance

• Electrical, gas and water connections.

• System pressure.

• The combustion performance, refer to the following procedure.

• The operational gas inlet pressure and gas rates, refer to the

commissioning section paragraph 12.5. Correct any fault before continuing.

Combustion check and setting the air/gas ratio

• Remove the front casing panel and hinge down the control box.

Taking care not to touch any internal components, proceed as follows:

• Connect the CO

point.

combustion analyser to the relevant test

IMPORTANT:

- The person carrying out a combustion measurement must be

- The ﬂ ue gas analyser used should be one meeting the

- Competence can be demonstrated by satisfactory completion

• Ensure that the gas analyser is set to the correct fuel setting.

• Select the “

BS 6798: 2009 Speciﬁ cation for installation and maintenance of gas-ﬁ red boilers of rated input not exceeding 70kW net advises that:

assessed as competent in the use of a ﬂ ue gas analyser and the interpretation of the results.

requirements of BS7927 or BS-EN50379-3 and be calibrated in accordance with the analyser manufacturers’ requirements.

of the CPA1 ACS assessment, which covers the use of electronic portable combustion gas analysers in accordance with BS 7967, parts 1 to 4.

+ ”, constant central heating with DHW function by pressing the “ ” button repeatedly, refer to commissioning section. The boiler should ﬁ re automatically.

IMPORTANT:

Safe combustion can only be veriﬁ ed by measuring CO/ CO2 ratio. This must not exceed the value shown in the table opposite.

17.3.2 Preliminaries

Prior to, during servicing and after any maintenance or changed parts, the following inspection must be carried out.

• The integrity of the ﬂ ue system and ﬂ ue seals.

• The integrity of the appliance combustion circuit and relevant

seals.

• A visual inspection of the ﬂ ame quality.

Key 1 Throttle 2 Combustion analyser sample point 2A Flue elbow 2B Vertical ﬂ ue adaptor 3 Cap

17.3.3 Maximum rate check and adjustment

IMPORTANT:

• Activate the test mode "P.01" and set the value to HI in order to

• Wait approximately 5 minutes to read a stabilised CO

• Check that the value is within the range speciﬁ ed in table in

To verify the maximum gas rate CO2 setting the appliance must be checked at the maximum rate.

force the burner at P. max. See chapter "Speciﬁ c adjustment > Appliance technical settings and parameter list > Test modes".

value.

the “check” column.

G20 Burner % CO

Model Check (case on) Setting (case oﬀ ) CO/CO2 ratio

9.2 ± 0.3% 9 ± 0.2% 0.004

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- 35 -

MAINTENANCE

G31 Burner % CO

Model Check (case on) Setting (case oﬀ ) CO/CO2 ratio

If the combustion reading is not within the acceptable values and the integrity of the complete ﬂ ue system and combustion circuit seals have been veriﬁ ed and the inlet gas pressure (and gas rate) have been veriﬁ ed, then, it will necessary to adjust the combustion rate of the appliance.

• Remove the sticker covering the “throttle” adjustment screw,

if ﬁ tted.

• Rotate the “throttle” (1) (anti-clockwise to increase), to the

required CO column in the table.

• When you have ﬁ nished, press the On/Oﬀ button to exit the

test modes.

• Remove the analyser probe and replace the cap on the

sampling point, replace the controls fascia, and the front casing panel.

10.3 ± 0.3% 10.1 ± 0.2% 0.004

IMPORTANT:

Adjustment is made by turning the throttle an ⅛ of a turn, waiting 1 minute to allow the appliance to stabilise before checking or making further adjustments.

, refer to previous diagram and the “Setting”

17.4 Servicing

IMPORTANT:

All routine servicing requirements can be achieved by the removal of the front panel.

• Position the control box into the service position.

• Before commencing with a service or replacement of parts,

If the annual check of combustion CO2, CO/CO2 ratio checks did not require adjustment and the inspections described in "Preliminaries" were satisfactory then it will not be necessary to complete a full service.

isolate the boiler from the electrical and gas supplies.

17.4.1 Service interval record

• Refer to benchmark Service Interval Record at the rear of this

manual.

17.5 Silencer

IMPORTANT:

Remember to replace the sample point cap on completion of the test.

17.3.4 Gas rate check

• Check the gas rates as described in the commissioning

section.

17.3.5 Completion

If it is not possible to achieve the required results for either the combustion or gas rates, it will be necessary to complete a full service of the appliance and then repeat the combustion check procedure. If after servicing and adjustment of the appliance the combustion values are still unacceptable and after further remedial work has been carried out, the appliance must be disconnected until the CO/CO2 ratio is acceptable.

• Advice can be sought from the Glow-worm Technical Helpline.

Key 1 Silencer retaining screw 2 Fixed silencer 3 Removable silencer

• Remove the silencer retaining screws (1) and remove the

silencer (3).

• Clean the interior of the silencer with a dry cloth if necessary,

taking care not to damage the internal foam.

• Repeat the operation in reverse order to replace the silencer.

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MAINTENANCE

17.6 Expansion vessel

Key 1 Expansion vessel 2 Expansion vessel pressure inlet

• Check the expansion vessel's supply pressure (see « Technical

Data » chapter) by means of the pressure inlet located on the expansion vessel. Adjust the pressure if necessary.

• Following the installation of a new expansion vessel, ﬁ ll and

purge the appliance or installation, if necessary.

The condense trap will contain water, lift taking care not to spill the water.

• Remove the condensate trap (5) using the retaining screw (4).

• Clean the hose, the trap and the siphon, remove any

accumulated dirt.

• Reassemble the components, taking care to position the

gaskets correctly.

• Start the siphon (3) and ﬁ ll with water.

17.7 Condensate trap

Warning:

Key 1 Condensate cleaning cap 2 Condensate pipe 3 Condensate outletv 4 Condensate retaining screw 5 Condensate trap 6 Hose

condensate is mildly acidic. Use protective gloves.

4 3

• Place a container under the condensate trap (5).

• Remove the condensate from the reservoir (1).

• Disconnect the condensation discharge (2).

• Disconnect the heat exchanger hose (6).

0020167175_01 - 02/13 - Glow-worm

- 37 -

MAINTENANCE

17.8 Combustion block

Legend 1 Gas valve connection 2 Grounding cable 3 Spark electrode inlet 4 Spark electrode retaining screw. 5 Spark electrode gasket 6 Spark electrode 7 Burner retaining nut 8 Burner retaining screw 9 Thermal fuse connection 10 Coil 11 Heat exchanger 12 Burner door seal 13 Burner 14 Gas valve 15 Fan 16 Fan connection 17 Gas pipe

17.8.1 Spark electrode

• Disconnect the electrode inlet (3) and the grounding cable (2).

• Remove the 2 spark electrode retaining screws (4).

• Carefully remove the electrode from the combustion chamber.

• Check that the extremes of the electrode (6) are not damaged.

• Clean away any accumulation of dirt and check that the

distance between the two electrodes is between 3.5 and 4.5 mm.

• Check that the gasket (5) is not damaged. Replace if necessary.

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0020167175_01 - 02/13 - Glow-worm

MAINTENANCE

17.8.2 Dismantling the burner

Warning:

• Disconnect the spark electrode connector (6) from the igniter

• Remove the gas pipe (17).

• Remove the connectors from the gas valve (1) and the fan (15).

• Remove the retaining screw of the silencer.

• Loosen the 4 nuts (7).

• Remove the burner group from the heat exchanger (11).

• The studs (8) ﬁ xed to the heat exchanger must not be

• The burner gate insulation should not be damaged. Replace if

The burner door seal (12) must be replaced each time the burner is dismantled.

unit.

damaged. Should it be damaged, replace the heat exchanger.

damaged.

17.8.3 Cleaning the heat exchanger

• Clean the coil (19) in the heat exchanger (11) with water.

17.8.4 Burner control

• The burner (13) does not require maintenance and should not

be cleaned.

• Check that its surface is not damage. Replace the burner if

necessary.

17.9 Service completion

• Re-check the combustion, see chapter "Combustion check".

On completion of the service, the "Benchmark" Service Record sould be completed.

18 Replacement of Parts

• Do not use reconditioned or copy parts, only use original parts

supplied by Glow-worm.

• If a part is required, contact the Glow-worm service

organisation.

• Please quote the name of the appliance, this information will

be on the name badge on the front of the appliance.

• If in doubt seek advice from the local gas company or Glow-

worm’s own service organisation.

DANGER:

PLEASE NOTE: During change of part of the combustion circuit, we recommend that the following is the following must be checked:

- The integrity of the ﬂ ue system and the ﬂ ue seals,

- The integrity of the boiler combustion circuit and the relevant seals,

- The operational (working) gas inlet pressure at maximum rate,

- The gas rate,

- The combustion performance.

Replacement of parts must be carried out by a competent person approved at the time by the Health and Safety Executive.

• Following the veriﬁ cation or replacement of the burner,

assemble the burner group as described in the following chapter.

17.8.5 Re-assembling the burner group

• Place the burner group on the heat exchanger (11).

• Progressively tighten the 4 nuts (7) in an alternate order.

• Reassemble the silencer.

• Connect the gas tube (17) with a new gasket to the burner

group.

• Connect the spark electrode connector (6) to the igniter unit.

• Connect the connector to the gas valve (1) and the fan (15).

• Open the appliance gas input.

• Check the watertightness of the gas connection.

18.1 General

ATTENTION:

Replacement parts that have associated components that need to be replacing on removal, i.e. ‘O’ ring, seals, gasket, etc., will be supplied and should be ﬁ tted.

• Before replacing any parts of the boiler, isolate from the mains

Unless stated otherwise parts are replaced in the reverse order to removal.

• After replacing any parts, always test for gas tightness and if

The replacement of parts described in sections "Combustion block" will require the removal of the burner module assembly and the replacement of seal and self locking nuts.

electric supply and turn oﬀ the gas at the gas service isolation valve on the boiler.

necessary carry out functional test of the controls.

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- 39 -

MAINTENANCE

18.2 Boiler Access

For replacement of parts, the front casing panel of the boiler will need to be removed.

• To remove undo the two screws on the underside of the front

casing and lift oﬀ .

18.3 Viewing window

Key 1 Fibre washer 2 Steel washer 3 Glass 4 Steel washer 5 Circlip

• Remove the circlip (5).

• Remove the steel washer (4).

• Remove ﬁ bre washer (1).

• Remove the glass (3).

18.3.1 Expansion vessel

Key 1 Connector 2 Expansion vessel 3 Upper support bracket 4 Retaining screw 5 Gasket

Drain the boiler heating circuit as described in the appropriate chapter "Draining".

• Remove the two screws (4).

• Undo the connector (1) at the base of the vessel.

• Remove upper support bracket (3).

• Remove the expansion vessel (2).

• Fit a new gasket between the expansion vessel and connector.

• Reﬁ ll, vent and pressurise the boiler.

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18.4 Hydraulic block

MAINTENANCE

7 6

12 13

17 19

24 23

Key 1 Three-way valve 2 Three-way valve electrical plug 3 Three-way valve electrical plug retaining clip 4 Low water pressure sensor connector 5 Low water pressure sensor 6 Low water pressure sensor retaining clip 7 Heating ﬂ ow pipe retaining clip 8 Manometer 9 Manometer retaining clip 10 Heating ﬂ ow pipe 11 Gas pipe 12 Flow sensor electrical plug 13 Flow sensor 14 Heating return pipe 15 Expansion vessel pipe 16 Plate-to-plate heat exchanger 17 Automatic air vent 18 Expansion vessel pipe clip 19 Automatic air vent retaining clip 20 Pump head retaining screws 21 Pump housing 22 Pump head connector 23 Plate-to-plate heat exchanger retaining screws 24 Safety Discharge Valve 25 Bypass Valve

26 Bypass Valve retaining nut 27 Bypass Valve retaining nut 28 Impeller housing 29 Safety discharge valve plastic housing 30 Retaining clip

18.4.1 Pump (head only)

• Drain the boiler heating circuit as described in the appropriate

chapter "Draining".

• Disconnect the electrical plug (22) from the main board.

• Remove the four cap head screws (20).

• Carefully remove the pump head (21) together with cable.

Do not strain cable.

• Reconnect wiring to new pump head and ﬁ t cover.

• Fit the new pump head by repeating the operations in reverse.

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- 41 -

MAINTENANCE

18.4.2 Automatic air vent

• Drain the boiler heating circuit as described in the appropriate

chapter "Draining".

• Remove the retaining clip (19). Remove the automatic air vent

(18).

• Fit the new automatic air vent and ‘O’ ring ensuring the vent

cap is left loose.

• Reﬁ ll, vent and pressurise the boiler.

18.4.3 Low water pressure sensor

• Drain the boiler heating circuit as described in the appropriate

chapter "Draining".

• Disconnect the electrical lead (4).

• Remove the retaining clip (6), remove the low water pressure

sensor (5).

• Fit the new low water pressure sensor.

• Reﬁ ll vent and pressurise the boiler.

18.4.4 Safety discharge valve

• Disconnect the electrical plug (2).

• Remove the retaining clip (3).

• Remove the three way valve motor (1).

• Remove the diverter valve retaining nut.

• Remove the diverter valve.

• Fit new three way valve motor and diverter valve assembly.

• Reﬁ ll, vent and pressurise the boiler.

18.4.8 Plate-to-plate heat exchanger

• Drain the boiler heating and domestic hot water circuits as

described in the appropriate chapter "Draining".

• Remove the two securing screws (23).

• Remove the plate-to-plate heat exchanger (17).

• When replacing the plate-to-plate heat exchanger, ensure that

the four rubber sealing washers are ﬁ tted into the hydroblock.

NOTE: The plate-to-plate heat exchanger only ﬁ ts one way.

• Reﬁ ll, vent and pressurise the boiler.

• Drain the boiler heating circuit as described in the appropriate

chapter "Draining".

• Remove the low water pressure sensor as described in the

previous section.

• Undo the safety discharge valve union and remove the pipe.

• Disconnect the Central Heating isolation valve.

• Remove the securing clips and withdraw the safety discharge

valve plastic housing (29).

• Remove the safety discharge valve.

• Fit new ‘O’ ring. Reﬁ ll, vent and pressurise the boiler.

18.4.5 Flow sensor and impeller

• Remove the the electrical connection (12).

• Unclip the ﬂ ow sensor (13).

• Unscrew the impeller housing (28) and remove the impeller.

18.4.6 Bypass

• Drain the boiler heating circuit as described in the appropriate

chapter "Draining".

• Remove the bypass valve retaining nut (26) to remove the

bypass from its housing (25).

• After replacing the bypass, reﬁ ll, vent and pressurise the

boiler.

18.4.7 3 way valve motor and diverter valve

• Drain the boiler heating circuit as described in the appropriate

chapter "Draining".

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18.5 Combustion block

MAINTENANCE

2019

Legend 1 Igniter unit retaining bracket 2 Igniter unit 3 Igniter unit retaining screw 4 Igniter unit electrical connector 5 Electrode / igniter unit connection cable 6 Earth cable 7 Spark electrode cap 8 Spark electrode retaining screw 9 Spark electrode gasket 10 Spark electrode 11 Combustion burner door assembly 12 Combustion burner door assembly - nut 13 Combustion burner door assembly - seal 14 Burner gasket 15 Burner 16 Burner retaining screw 17 Heat exchanger retaining screw 18 Heat exchanger retaining bracket 19 Burner gate retaining screw

0020167175_01 - 02/13 - Glow-worm

20 Thermal fuse connection 21 Heat exchanger 22 Heat exchanger retaining bracket 23 Heat exchanger retaining screw 24 Heating return pipe 25 Heating return pipe retaining clip 26 Return heating temperature sensor 27 Heating ﬂ ow pipe 28 Flow heating temperature sensor 29 Heating ﬂ ow pipe retaining clip 30 Gas valve retaining screw 31 Gas valve 32 Gas valve gasket 33 Fan 34 Fan electrical connection 35 Fan/burner gasket 36 Gas pipe 37 Gas valve electrical connection 38 Fan retaining screw

- 43 -

MAINTENANCE

18.5.1 Spark electrode

• Disconnect the electrode cap (7) and the earthing cable (6).

• Remove the 2 spark electrode retaining screws (8).

• Carefully remove the electrode (10) from the combustion

chamber.

• Remove the gasket (9).

• Check that the distance between the 2 electrodes is between

3.5 and 4.5 mm.

• Install the electrode and a new gasket.

18.5.2 Igniter unit

• Remove the ignition lead (2).

• Remove electrical connections (4).

• Loosen the screws (3) located on the igniter unit (2).

• Remove the igniter unit (2).

18.5.3 Removing the combustion/burner door assembly

ATTENTION:

• Disconnect the spark electrode cap (7) from the igniter unit.

• Disconnect the gas supply pipe (36) at the gas valve.

• Remove the electrical connectors from the gas valve (37) and

• Remove the retaining screw of the silencer.

• Loosen the 4 nuts (12).

• Remove the combustion/burner door assembly from the heat

• The studs (19) must not be damaged. If damaged you will need

The burner door seal (13) must be replaced each time the combustion/burner door assembly is removed.

the fan (34).

exchanger (11).

to replace the heat exchanger.

18.5.5 Heat exchanger

ATTENTION:

• Drain the boiler heating and hot water circuits as described in

• Remove the ﬂ ue connection.

• Undo the two screws located on the top of each side panel.

• Remove the thermal fuse connector (20).

• Remove the 2 heating pipe retaining clips (25) and (29).

• Release the heating pipes (24) and (27) from the heat

• Release the condensate trap pipe from the heat exchanger.

• Remove the combustion/burner door assembly (11) refering to

• Unscrew the 4 retaining screws (17) and (23) and remove the 2

• Pull the heat exchanger towards you to extract it from its 2 side

There will be water in the heat exchanger.Carefully ease heat exchanger out.

the appropriate chapter "Draining".

exchanger.

chapter "Removing the combustion/burner door assembly".

retaining plates (18) and (22) from the heat exchanger.

rails.

18.5.6 Re-assembling the burner group

• Place the burner assembly on the heat exchanger (21).

• Progressively tighten the 4 nuts (12) in an alternate order.

• Reassemble the silencer.

• Connect the gas pipe (36) with a new gasket to the burner

group.

• Connect the spark electrode connector (5) to the igniter unit.

• Connect the connector to the gas valve (37) and the fan (34).

• Open the appliance’s gas input.

• Check the tightness of the gas connection.

• The combustion/burner door assembly insulation should be

inspected and replaced if damaged.

18.5.4 Burner

• Remove the 3 burner retaining screws (16).

• Remove the burner (15) and the gasket (14).

• Fit the new burner and the new gasket.

- 44 -

18.5.7 Heating Flow Thermistor

• Remove the electrical connections from the thermistor (28).

• Remove the retaining clip from the ﬂ ow pipe (27).

IMPORTANT:

When reconnecting, the polarity of the wiring to thermistors is not important.

18.5.8 Heating Return Thermistor

• Remove the electrical connections from the thermistor (26).

• Remove the retaining clip from the return pipe (24).

IMPORTANT:

When reconnecting, the polarity of the wiring to thermistors is not important.

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MAINTENANCE

18.5.9 Gas valve

• Remove the burner door (11) refering to chapter "Dismantling

the burner door".

• Remove the two gas valve retaining screws (30).

• Remove the gas valve (31) and the gasket (32).

• Fit the new gas valve and the new gasket by repeating the

operations in reverse.

• After assembly test for gas tightness and purge in accordance

with the current issue of BS6891or in IE, the current edition of I.S.813 “Domestic Gas Installations”.

• Check the combustion CO

18.5.10 Fan

• Remove the burner door (11) refering to chapter "Dismantling

the burner door".

• Remove the gas valve (31) (see previous paragraph).

• Loosen the 3 screws (38) located on the burner door (11).

• Remove the fan (33) and the gasket (35).

• Place a container under the condensate trap (5).

• Remove the condensate from the reservoir (1).

• Disconnect the condensation discharge (2).

• Disconnect the heat exchanger hose (6).

The condense trap will contain water, lift taking care not to spill the water.

• Remove the condensate trap (5) using the retaining screw (4).

• IMPORTANT: Partially ﬁ ll the condensate trap with water before

replacing. Start the siphon (3) and ﬁ ll with water.

18.7 PCB

IMPORTANT:

18.7.1 Main PCB

When replacing the board refer to instructions supplied with the spare part.

• Fit the new gasket (35).

• Screw the new fan to the burner door (11).

• After assembly test for gas tightness and purge in accordance

with the current issue of BS6891or in IE, the current edition of I.S.813 “Domestic Gas Installations”.

18.6 Condensate trap

ATTENTION:

Condensate is mildly acidic. Wear protective gloves.

4 3

Key 1 Control panel 2 Rear panel 3 Retainings clips 4 Main PCB

Key 1 Condensate reservoir 2 Condensate discharge 3 Condensate outlet 4 Condensate retaining screw 5 Condensate trap 6 Hose

0020167175_01 - 02/13 - Glow-worm

• Remove the 24V and 230V connections.

• Remove the rear panel (2).

• Ease back the two PCB retaining clips (3) and withdraw the

PCB from the retaining lugs.

• Remove the electrical connections to the PCB (appliance

interface cable).

• When reﬁ tting the rear panel, ensure the leads are not trapped.

- 45 -

MAINTENANCE

18.7.2 2A Fuse Rating

• For access, refer to chapter "Main PCB".

• The fuse is located at top right hand side of the PCB, see

chapter "Electrical connection >Wiring diagram".

18.7.3 User interface PCB

19 Spare parts

In order to guarantee the safe and prolonged life of the product, manufacturers genuine spare parts must be used.

IMPORTANT:

• Ensure that spare parts are correctly mounted in the right

This appliance displays a CE Mark of conformity. Only use the manufacturer’s genuine, new spare parts.

position and direction. After ﬁ tting any spare part or servicing, the appliance must be tested for its safe operation.

Key 1 User interface 2 Retaining slots 3 User interface PCB 4 Retainings clips 5 Control Panel

• Remove the user interface (1) easing back the two retaining

slots (2).

• Ease back the two PCB retaining clips (4) and withdraw the

PCB from the retaining lugs.

• Remove the electrical connections to the PCB.

• When reﬁ tting the user interface, ensure the leads are not

trapped.

18.7.4 Mains supply cable

DANGER:

The main supply cable must be replaced by a qualiﬁ ed and competent electrician.

• If the main supply cable is damaged, replace it refering to the

chapter "Electrical connection".

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0020167175_01 - 02/13 - Glow-worm

Short List of Parts

MAINTENANCE

• When ordering spare parts, contact Glow-worm’s own service

organisation.

• Please quote the name of the appliance and serial number, to

be found on the data label. If ordering from British Gas also quote the G.C. number of the part.

Key

Part No. Description GC Part No.

No.

1 0020097277 Fan 2 A000035144 Spark igniter 3 2000801935 Thermistor (ﬂ ow and return) 4 0020097279 Gas valve 5 0020038441 Electrode assembly 6 0020118159 User interface PCB

Key

Part No. Description GC Part No.

No.

0020136541 Plate to plate heat exchanger 30c

0020173017 Plate to plate heat exchanger 35c

8 2000801912 3 way valve motor

0020118139 Pump 30c

0020173018 Pump 35c 10 0020118178 Water ﬂ ow sensor 11 0020061608 Water ﬂ ow sensor 12 0020118138 Main PCB 13 0020079644 Low water pressure sensor 14 801635 Burner Door Seal Kit 16 002011896 Diverter valve

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- 47 -

Manual Handling

IMPORTANT. With regards to the Manual Handling Operations, 1992 Regu-

lations, the following lift operation exceeds the recommended weight for a one man lift.

General recommendations when handling

Clear the route before attempting the lift. Ensure safe lifting techniques are used – keep back straight – bend using legs. Keep load as close to body as possible. Do not twist – reposition feet instead. If 2 persons performing lift, ensure co-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

Carriage of carton from point of delivery to point of installation – ground ﬂ oor.

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 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 – ﬁ rst or higher ﬂ oor, cellar.

Recommend 2-person lift or 1 person with use of sack truck. If 1 person is performing lift, straddle the load, tilt and place carton into position on truck. Recommend secure appliance onto truck with suitable straps. Ensure safe lifting techniques are used – keep back straight – bend using legs. Keep load as close to body as possible. If 2 persons performing lift, ensure co-ordinated movements during lift. Avoid upper body/top heavy bending - do not lean forward/sideways. Clear the route before attempting the lift. If removing boiler from truck straddle the load and tilt forwards to facilitate secure grip. Ensure safe lifting techniques are used – keep back straight – bend using legs. Do not twist – reposition feet instead. Take care to avoid trip hazards, slippery or wet surfaces and when climbing steps and stairs. Always use assistance if required.

Carriage of carton from point of delivery to point of installation – roofspace.

Recommend 2-person lift. Ensure co-ordinated movements during lift. Avoid upper body/top heavy bending - do not lean forward/sideways. Clear the route before attempting the lift. Take care to avoid trip hazards, slippery or wet surfaces and when climbing steps and stairs. When transferring appliance into roofspace, recommend 1 person to be in roofspace to receive the appliance and other person to be below to pass up and support appliance. Ensure safe lifting techniques are used – keep back straight – bend using legs. Keep load as close to body as possible. Always use assistance if required. It is assumed safe access, adequate lighting are provided in the roof space. It is recommended a risk assessment of the roof space area be carried out before moving the appliance into the area to take into account access, stability of ﬂ ooring, lighting and other factors, and appropriate measures taken.

ﬂ ooring and

Positioning of Appliance for Final Installation – no obstructions.

Recommend 2 persons lift appliance to position into place. Fit bracket securely onto wall before lifting appliance into position. Obtain ﬁ rm 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 ﬂ oor level. Do not twist – reposition feet instead. Keep boiler as close as possible to body throughout lift to minimise strain on back. Ensure co-ordinated movements to ensure equal spread of weight of load. Always use assistance if required. Recommend wear suitable cut resistant gloves with good grip to protect against sharp edges and ensure good grip when handling appliance.

Positioning of Appliance for Final Installation – above worktop, foreseeable obstructions etc.

Recommend 2 persons lift appliance to position into place. Fit bracket securely onto wall before lifting appliance into position. Obtain ﬁ rm 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 ﬁ rm 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 from ﬂ oor 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 ﬁ rm 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 ﬁ rm 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 ﬁ rm grip supporting base of boiler. Ensure safe lifting techniques are used – keep back straight – bend using legs - when lifting load from ﬂ oor level. Do not twist – reposition feet in- stead. Keep boiler as close as possible to body throughout lift to minimise strain on back. Always use assistance if required. Recommend wear suitable cut resistant gloves with good grip to protect against sharp edges and ensure good grip when handling appliance.

Positioning of Appliance for Final Installation – in roof space restricting installation.

Recommend 2 persons lift appliance to position into place, space permitting. Fit bracket securely onto wall before lifting appliance into position. Obtain ﬁ rm grip on front and sides of appliance, lift upwards, ensure stable balance achieved and lift upwards to drop into place onto bracket. If 2 persons positioning onto bracket obtain ﬁ rm 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 ﬁ rm grip supporting base of boiler. Ensure safe lifting techniques are used - keep back straight – bend using legs - when lifting load from ﬂ oor 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 ﬂ ooring, lighting and other factors, and appropriate measures taken.

Unpacking of appliance from carton.

Recommend 2 persons unpack appliance from carton. Always keep working area clear. Cut the carton straps, lift carton up and slide over polystyrene end packs. Remove top polystyrene pack with ﬁ ttings.

Declaration of Conformity

Installation,

Commissioning and

Service Record

SERVICE INTERVAL RECORD

It is recommended that your heating system is serviced regularly

and that you complete the appropriate Service Interval Record Below.

Service Provider. Before completing the appropriate Service Interval Record below, please ensure you have carried out the service

as described in the boiler manufacturer’s instructions. Always use the manufacturer ‘s specified spare part when replacing all controls.

SERVICE 1 Date

EnerJ\(I¿ ciency Checklist completed? Engineer Name Company Name Telephone Number Engineer ID Number Comments

Signature

Yes No

SERVICE 3 Date

EnerJ\(I¿ ciency Checklist completed? Yes Engineer Name Company Name Telephone Number Engineer ID Number Comments

Signature

SERVICE 5 Date

EnerJ\(I¿ ciency Checklist completed? Yes Engineer Name Company Name Telephone Number Engineer ID Number Comments

Signature

SERVICE 2 Date

EnerJ\(I¿ ciency Checklist completed? Engineer Name Company Name Telephone Number Engineer ID Number Comments

Signature

Yes No

SERVICE 4 Date

EnerJ\(I¿ ciency Checklist completed? Yes Engineer Name Company Name Telephone Number Engineer ID Number Comments

Signature

SERVICE 6 Date

EnerJ\(I¿ ciency Checklist completed? Yes Engineer Name Company Name Telephone Number Engineer ID Number Comments

Signature

SERVICE 7 Date

EnerJ\(I¿ ciency Checklist completed? Yes Engineer Name Company Name Telephone Number Engineer ID Number Comments

Signature

SERVICE 9 Date

EnerJ\(I¿ ciency Checklist completed? Yes Engineer Name Company Name Telephone Number Engineer ID Number Comments

Signature

SERVICE 8 Date

EnerJ\(I¿ ciency Checklist completed? Yes Engineer Name Company Name Telephone Number Engineer ID Number Comments

Signature

SERVICE 10 Date

EnerJ\(I¿ ciency Checklist completed? Yes Engineer Name Company Name Telephone Number Engineer ID Number Comments

Signature

GLOW-WORM

Subject to engineering changes

0020167175_01 - 02/13

Nottingham Road, Belper, Derbyshire. DE56 1JT

www.glow-worm.co.uk

Because of our constant endeavour for improvement, details may vary slightly from those shown in these instructions.

Glow-worm Ultimate c User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual