Glow-worm Ultracom2 cxi User Manual

Ultracom2 cxi

Installation and Servicing

24cxi

G.C. No. 47-019-10

30cxi

G.C. No. 47-019-11

35cxi

G.C. No. 47-019-12

High Efﬁciency Condensing

Combination Boilers

www.glow-worm.co.uk

TABLE OF CONTENTS

INTRODUCTION

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

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

1.2 Associated documents ..........................................................................................3

1.3 Explanation of symbols...........................................................................................3

1.4 Guarantee registration ............................................................................................3

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

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

2.2 Data label ...............................................................................................................4

2.3 Gas category ......................................................................................................... 4

2.4 Regulation and statutory requirements ..................................................................4

2.5 Hydraulic schematic ..............................................................................................5

3 Safety instructions and regulations ....................................................................................................6

3.1 Safety instructions .................................................................................................. 6

3.2 Regulations ............................................................................................................6

4 Recycling ...........................................................................................................................................7

4.1 Appliance ................................................................................................................7

4.2 Packaging ...............................................................................................................7

TECHNICAL DATA

5 Ultracom2 cxi ......................................................................................................................................8

INSTA L L ATION

6 Appliance location ..............................................................................................................................9

6.1 Location ..................................................................................................................9

6.2 Clearances .............................................................................................................9

6.3 Ventilation ..............................................................................................................9

7 Appliance installation ......................................................................................................................10

7.1 Scope of delivery ..................................................................................................10

7.2 Recommendations before installing .....................................................................10

7.3 Dimensions ...........................................................................................................12

7.4 Mounting ..............................................................................................................12

8 Hydraulic connection ........................................................................................................................14

8.1 Gas and water connections ..................................................................................14

8.2 Safety Discharge Valve ........................................................................................ 14

8.3 Connection to the condensate trap ......................................................................15

9 Evacuation of combustion gas .........................................................................................................17

9.1 Regulation ............................................................................................................17

9.2 Flue conguration description ..............................................................................19

10 Remove the front panel ....................................................................................................................21

11 Electrical connections ......................................................................................................................21

11.1 Access to main board ..........................................................................................21

11.2 Main board............................................................................................................21

11.3 Electrical wiring.....................................................................................................22

11.4 External accessories ............................................................................................23

11.5 Testing the electrical connections .........................................................................23

11.6 Wiring diagram .....................................................................................................24

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TABLE OF CONTENTS

12 Commissioning ...............................................................................................................................25

12.1 Switching on ......................................................................................................... 25

12.2 Filling the CH system (Central heating) ................................................................ 25

12.3 Filling DHW Circuit ...............................................................................................25

12.4 Filling the Condensate Trap .................................................................................25

12.5 Initial lighting .........................................................................................................26

12.6 Gas rates ..............................................................................................................26

12.7 Testing heating system ......................................................................................... 27

12.8 Testing domestic hot water system....................................................................... 27

12.9 Completion ...........................................................................................................27

13 Specic adjustment .........................................................................................................................28

13.1 Heating circuit adjustment .................................................................................... 28

13.2 Appliance technical settings and parameter list ...................................................28

13.3 CO2 measurement ............................................................................................... 32

13.4 Re-check and restart ............................................................................................ 32

14 User information ...............................................................................................................................32

MAINTENANCE

15 Trouble-shooting ..............................................................................................................................33

15.1 Fault diagnosis .....................................................................................................33

15.2 Fault memory........................................................................................................34

15.3 Fault codes ...........................................................................................................34

15.4 Functional ow diagram........................................................................................36

16 Gas conversion adjustments ............................................................................................................37

16.1 Settings.................................................................................................................37

16.2 Restart - re-check commissioning ........................................................................ 38

17 Draining ...........................................................................................................................................38

17.1 Heating circuit ...................................................................................................... 38

17.2 Domestic Hot water circuit ................................................................................... 38

18 Servicing ..........................................................................................................................................39

18.1 Annual Maintenance .............................................................................................39

18.2 Casing removing...................................................................................................40

18.3 Combustion check and setting the air/gas ratio valve .......................................... 40

18.4 Servicing ...............................................................................................................41

18.5 Silencer ................................................................................................................42

18.6 Expansion vessel..................................................................................................42

18.7 Heating lter .........................................................................................................43

18.8 Condensate trap ...................................................................................................43

18.9 Combustion block .................................................................................................44

18.10 Service completion ............................................................................................... 45

19 Replacement of Parts ......................................................................................................................46

19.1 General .................................................................................................................46

19.2 Boiler Access ........................................................................................................46

19.3 Viewing window ....................................................................................................46

19.4 Hydraulic block ..................................................................................................... 48

19.5 Combustion block .................................................................................................50

19.6 Condensate trap ...................................................................................................52

19.7 PCB ...................................................................................................................... 53

20 Spare parts ......................................................................................................................................54

20.1 Short List of Parts .................................................................................................54

20.2 Short List of Parts .................................................................................................55

21 Manual Handling ..............................................................................................................................56

22 Declaration of Conformity ................................................................................................................57

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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 Associated documents

- 1 Instructions for use

- 1 magnetic lighting instruction label

- 1 ue guide

- 1 extended guarantee leaet

- 1 guarantee envelope pack

- 1 wall template

- 1 gas conversion label

1.3 Explanation of symbols

The second year of guarantee, from the beginning of the 13th month onwards after installation or manufacture, is conditional upon the boiler having been serviced by a competent person approved at the time by the Health and Safety Executive, in accordance with the manufacturer’s recommendations. We strongly recommend regular servicing of your gas appliance, but where the condition is not met, any chargeable spare parts or components issued within the applicable guarantee period

still benet from a 12 month warranty from the date of issue by

the manufacturer.

We recommend you complete and return as soon as possible your guarantee registration card. If your guarantee registration card is missing you can obtain a copy or record your registration by telephoning the Glow-worm Customer Service number 01773 828100.

2 Appliance description

2.1 Safety devices

2.1.1 Overheating safety

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

2.1.2 Safety discharge valve

A safety discharge valve and discharge pipe are tted to the

boiler. This valve must not be touched.

- The heating safety valve opens when the pressure in the heating circuit exceeds 2.5 bars.

• Should there be any discharge from the pipe, isolate the boiler electrical supply and call your installer or Glow-worm’s own service organisation.

2.1.3 Frost protection

a e b i

DANGER: Risk of injuries.

DANGER: Risk of electric shock.

ATTENTION: Risk of damage to the appliance or to its surroundings.

IMPORTANT: Important information.

1.4 Guarantee registration

Thank you for installing a new Glow-worm appliance in your home. Glow-worm appliances are manufactured to the very highest standard so we are pleased to offer our customers a Comprehensive Guarantee.

This product is guaranteed for 24 months from the date of installation or 30 months from the date of manufacture, whichever is the shorter, for parts and labour.

0020085231_02 - 05/10 - Glow-worm

The 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.

Your domestic water circuit (hot or cold) is not

2.1.4 Condensate drain blockage

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

protected by the boiler.

- 3 -

INTRODUCTION

2.2 Data label

The data label certies the country where the appliance is

intended to be installed.

Data label location:

Key 1 Data label

The data label contains the following data:

- The name of the manufacturer

- The country of intended destination

- The commercial name of the appliance and its serial number

- The types of ues installations authorised

2.3 Gas category

This boiler is for use only on G20, but can be converted for use on G31.

• To adapt the appliance to another type of gas, see the chapter "Gas conversion".

2.4 Regulation and statutory requirements

2.4.1 CE Mark

This boiler meets the requirements of Statutory Instrument,

No. 3083 The Boiler (Efciency) Regulations, and therefore is

deemed to meet the requirements of Directive 92/42/EEC on

the efciency requirements for new hot water boilers red with

liquid or gaseous fuels.

Type test for purposes of Regulation 5 certied by: Notied

body 1312.

Product/production certied by: Noti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

- The appliance's gas category

- The gas type, group and pressure, set in the factory

- The DHW specic ow rate (D)

- The maximum pressure in the heating circuit (PMS)

- The maximum pressure in the domestic water circuit (PMW)

- The NOx class of the appliance

- The type and voltage of electricity supply

- The maximum power rating

- The electrical protection class

- The minimum and maximum heat input (Q)

- The minimum and maximum power output (P)

- The CE number and logo

The appliance shall only be connected to the gas

type(s) indicated on the data label.

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

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

2.4.2 Local regulations

Benchmark places responsibilities on both manufacturers and installers. The purpose is to ensure that customers are provided with the correct equipment for their needs, that it is installed, commissioned and serviced in accordance with the manufacturer’s instructions by a competent person approved at the time by the Health and Safety Executive and that it meets the requirements of the appropriate Building Regulations. The Benchmark Checklist can be used to demonstrate compliance with Building Regulations and should be provided to the customer for future reference.

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.

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2.5 Hydraulic schematic

INTRODUCTION

Key 1 Gas isolating valve

2 Heatingowisolatingvalve

3 Heating safety valve

4 Filteroncoldwaterinlet

5 By-pass

6 DHWowsensor

7 Domestic plate to plate heat exchanger

8 Heatinglter

9 Heating return thermistor 10 Condensate trap 11 Ignition and control electrode 12 Burner 13 Main heat exchanger 14 Thermal fuse 15 Flue outlet 16 Silencer 17 Heating expansion vessel

18 Fan 19 Gas control valve 20 Ignition module

21 Heatingowthermistor

22 Air vent 23 Pump

24 Threewayvalve

25 Water pressure sensor 26 Filling taps 27 Heating return isolating valve

28 Domesticcoldwaterisolatingvalve A Heating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 specied, the appliance must not be put into operation.

Incorrect installation can cause electric shock or

• 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

• When assembling the connections, correctly position the

• 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

• Should you need to replace hydraulic components, drain the

appliance damage.

precautions:

footwear.

adjust sealed parts.

seals to avoid any leakage of gas or water.

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

if provided.

appliance.

• 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 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 ttings) Regulations 1999 and water

byelaws 2000, Scotland.

- The Health and Safety at Work Act, Control of Substances

Hazardous to Health (COSHH).

- The Current I.E.E. Wiring Regulations.

Where no speci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 specication (CheSS) and

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

BRECSU.

• Protect all the electrical components from water while working on the appliance.

• Use only original spare parts.

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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

uid, purge in accordance with the above standard.

Domestic Hot Water

All domestic hot water circuits, connections, ttings must be

in accordance with the relevant standards and water supply regulations.

GB: Guidance G17 to G24 and recommendation R17 to R24 of the Water Regulations Guide. IE: The current edition of I.S.813 “Domestic Gas Installations”.

Heating System

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

In IE, the requirements given in the current edition of 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.

Isolation should be by a double pole switched fused spur box, with a minimum gap of 3mm for both poles. The fused spur

box should be readily accessible and preferably adjacent to the appliance. It should be identied as to its use.

Alternatively connection can be made through an unswitched shuttered socket and 3A fused 3-pin plug both to the current issue of BS 1363, provided they are not used in a room containing a bath or shower. Wiring to the boiler must be PVC 85OC insulated cable, not less than 0.75mm2 (24/0.20mm).

3.2.2 Other regulations

Gas Safety (Installation and Use) Regulations

In your own interests and that of safety, it is the Law that ALL gas appliances are installed by a competent person approved at the time by the Health and Safety Executive in accordance with the current issue of these regulations.

Control of Substances Hazardous to Health

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

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

• If you do suffer irritation to the eyes or severe irritation to the skin seek medical attention.

4 Recycling

The recycling of the packaging must be carried

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.

• Sort the waste in order to separate those elements which

• Eliminate the waste in accordance with existing regulations.

out by the quali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.

By complying with this directive, you will contribute

to the preservation of natural resources and the protection of human health.

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

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TECHNICAL DATA

5 Ultracom2 cxi

Boiler, type C13, C33, C43, C53

Description Unit 24 cxi 30 cxi 35 cxi

Gas category ll

SEDBUK rating % 90.3 90.3 90.4

Heating

Maximum heating input power kW 18.5 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.) Minimum heating temperature °C 10 10 10 Maximum heating

temperature Minimum heating ow rate l/h 400 400 400

Content of heating expansion vessel

Heating expansion vessel preset pressure

Maximum heating system volume (approx)

Heating safety valve preset pressure (PMS)

Domestic Hot Water

Minimum DHW output power (P min.)

Maximum DHW output power (P max.)

Maximum DHW temperature °C 60 60 60

Specic ow rate (∆T of 35 K)

EN 13203

Minimum inlet water pressure

Maximum inlet water pressure

Combustion

Appliance NOx class 5 5 5

Electrical

Electrical supply V/Hz

Standby mode electrical power

Operational mode electrical power (Max)

Internal fuse rating on main PCB

Index of electrical protection (EN 60529)

kW 4.9 5.9 8.5

kW 18.2 24.6 30

kW 5.4 6.6 9.3

kW 19.6 26.7 32.8

°C 80 80 80

l 8 8 8

gallons 1.76 1.76 1.76

bar 0.75 0.75 0.75

psi 10.9 10.9 10.9

l 160 160 160

bar 2.5 2.5 2.5

lbf/in² 36/3 36/3 36/3

kW 5.1 6.1 8.7

kW 25.5 30.6 35.7

l/min 10.4 12.5 14.6

bar 0.3 0.3 0.3

psi 4.3 4.3 4.3

bar 10 10 10

psi 145 145 145

W 6 6 6

W 151 151 151

A 2 2 2

2H3P

230V 50Hz

IPX4D IPX4D IPX4D

2H3P

230V 50Hz

2H3P

230V 50Hz

Description Unit 24 cxi 30 cxi 35 cxi

Gas connection Ø O.D. mm

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

Total weight (installed) kg 42 43 43

Number of CE certicate

Description Unit 24 cxi 30 cxi 35 cxi

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

Maximum DHW gas ow rate

Maximum heating gas ow

rate

Minimum gas ow rate

CO2 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"

Inlet pressure mbar 20 20 20

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

Maximum DHW gas ow rate kg/h 1.98 2.38 2.77

Maximum heating gas ow

rate

Minimum gas ow rate kg/h 0.4 0.47 0.67

CO2 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"

Inlet pressure mbar 37 37 37

kg 37 38 38

lb 82 83 84.5

kg/h 1.44 1.94 2.37

(copper)

21.5

(plastic)

(copper)

1312

5334

2.70 3.24 3.77

1.96 2.65 3.24

0.54 0.65 0.92

9.2 ±

0.3%

9 ±

0.2%

8.9 ±

0.3%

8.7 ±

0.2%

10.3 ±

0.3%

10.1 ±

0.2%

9.8 ±

0.3%

9.6 ±

0.2%

(copper)

21.5

(plastic)

(copper)

1312

5335

9.2 ±

0.3%

9 ±

0.2%

8.9 ±

0.3%

8.7 ±

0.2%

10.3 ±

0.3%

10.1 ±

0.2%

9.8 ±

0.3%

9.6 ±

0.2%

(copper)

21.5

(plastic)

(copper)

1312

5336

9.2 ±

0.3%

9 ±

0.2%

8.9 ±

0.3%

8.7 ±

0.2%

10.3 ±

0.3%

10.1 ±

0.2%

9.8 ±

0.3%

9.6 ±

0.2%

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INSTALLATION

6 Appliance location

6.1 Location

6.1.1 Instructions

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

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

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

• Explain these requirements to the appliance user.

• Do not install the appliance above another appliance that

• The boiler must be tted inside the property and exposed

All the drawings dimensions are shown in mm.

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

within allows the appliance to be installed and the clearances maintained. This will ensure that the connections to the

water, gas and ue can be accessed and inspected (see

chapter Clearances).

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.

pipe work may need to be protected from frost by tting a

frost thermostat.

For ue installations where external access is not practicable,

consideration should be given for the space required to insert

the ue from inside the property, which may necessitate clearance larger than those specied in diagram below.

ØA + 5 min.

ØA

150

min.

600* min.

200

min.

6.1.2 Regulations

Location

This boiler is not suitable for outdoor installation. This boiler may be installed in any room, although particular attention is drawn to the installation of a boiler in a room containing a bath or shower where reference must be made to the relevant requirements. This boiler is suitable for installation in bathroom zones 2 and 3. In GB this is the current I.E.E. WIRING REGULATIONS and BUILDING REGULATIONS. In IE reference should be made to the current edition of I.S.813 “Domestic Gas Installations” and the current ETCI rules.

Timber Frame Buildings

If the boiler is to be installed in a timber frame building it should

be 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.

Additional clearances may be benecial around the boiler for

installation and servicing.

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xedsurface.

The boiler and ue are suitable for installation onto and through

combustible materials provided that:

- Minimum 5mm clearance is maintained around the

circumference of the ue (air intake).

- The combustible surface and 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

Due to the high ef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 ttings.

The ues package will be ordered according to the

• Please check the contents.

2.3

2.2

2.1

conguration of the installation.

2.4

2.5

2.6

4.1

4.4  Extendedguaranteeleaet (x1)

4.5 Guarantee envelope pack (x1)

4.6 Magnetic lighting instruction label (x1)

4.7 Gas conversion label (x1)

7.2 Recommendations before installing

7.2.1 Domestichotwatercircuitdesign

Water pressure

The minimum working pressure to obtain the maximum

domestic 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 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 tted, refer to the manufacturer’s instructions or consult the

local water company for additional advice.

1 4.7

Key 1 Boiler (x1)

2 Accessories bag (x1)

2.1 Pressure relief valve connecting pipe (x1)

2.2 Connection bag (x1)

- Heating return valve (x1)

  -Coldwaterinletvalve (x1)   -Heatingowvalve (x1)   -Domestichotwaterconnection (x1)

- Gas isolation valve (x1)

2.3 Hanging bracket (x1)

2.4 Filling loop extensions (x2)

2.5 Seals bag (x1)

- Flat seal ½" (x2)

- Flat seal ¾" (x5)   -Flatsealforcoldwaterinlet¾" (x4)

2.6  Compressiontting (x1)

4.2

4.3

4.4

4.5

4.6

Domestic water ow rate

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

- 24cxi ►8 l/min,

- 30cxi ►10 l/min,

- 35cxi ►12 l/min.

3 Wall template (x1)

4 Documents bag (x1)

4.1 Installation and servicing manual (x1)

4.2 Flue book (x1)

4.3 Instructions for use (x1)

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INSTALLATION

7.2.2 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 Filling loop - to be unlocked and disconnected after use. 7 Double check valve assembly 8 Additional expansion vessel (if required) 9 Heating return circuit

10 Heatingowcircuit

General

Bypass

The boiler is tted with an automatic bypass which can be adjusted to suit your system requirements.

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

below the gure specied, refer to chapter "Technical data".

Filling the sealed system

The water pressure at the boiler must be at least

Suitable external lling systems are shown diagrammatically,

see diagram below.

1.2bar to operate the lling loop. If the pressure is less than 1.2bar an external lling loop must be tted. If this pressure is not available contact the local water authority.

7 6

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 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.

The heating system volume should be calculated to

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

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

ensure that the expansion vessel is suitable, it may

be necessary to add an additional vessel.

issue of BS5449 and BS7074 Part 1.

Key

1 Heatingowcircuit

2 Heating return circuit 3 Boiler 4 Double check valve assembly

5 Domesticcoldwatersupplyin 6 Temporaryllingloop(removeimmediatelyafterlling)

7 Drain point

8 Backowpreventiondevice

9 Tundish

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

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INSTALLATION

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 ushed.

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

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 ush existing systems rst before tting

the new boiler.

• Ensure all cleanser is removed from the whole system before adding an inhibitor.

For long-term corrosion protection after ushing, an inhibitor

suitable for stainless steel heat exchangers can be used. Either Sentinel X100 or Fernox F1 inhibitor can be used.

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.

160

170

=246=

160

Ø125* Ø105**

63***

735

709

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

7.3 Dimensions

130

740

346

* 80/125ue►Ø150mm ** 80/125ue►Ø130mm *** 80/125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 ue you are tting.

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418

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INSTALLATION

7.4.1 Fixingtothewall

Key 1 Wall template

2 Standarduelengthhorizontal 3 2.5°44mm/metreinclinedextendeduelength

4 Wall plug 5 Hanging bracket

6 Screw(notsupplied)

Flue hole cutting

• Mark the position of the ue centre.

130

90°

7.4.2 Boiler hanging

With regards to the Manual Handling Operations,

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

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

The ue is designed with an internal fall of 44mm/

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

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

• If tting a side ue, extend the ue centre line into the corner

• If tting an extended side ue, determine the ue hole centre

metre (2.5o), therefore the hole can be drilled horizontally.

installation (60/100 ue) (80/125 ue ► Ø130mm).

installation (60/100 ue) (80/125 ue ► Ø150mm).

If 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 (2.5 rise from the boiler. Where this line reaches the side wall, a horizontal line should be marked. The vertical centre line of

the ue should then be marked at 130mm from the back wall. To allow for the ue passing through the wall at this angle

a 125mm hole should be drilled irrespective of internal or external installation.

)

Key 1 Boiler 2 Hanging bracket

• Lifting the boiler into position, lean the top of the boiler slightly to the wall and position just above the hanging

bracket.

• Lower the boiler slowly and engage onto the hanging bracket

Hanging bracket xing

Due to the varied site conditions, xings are not supplied and

advise that the installer should supply those which are suitable.

• Drill the holes for the xing screws in accordance with the

wall template.

• Fix the hanging bracket on the wall.

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INSTALLATION

8 Hydraulic connection

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”.

The appliance may contain a small amount of water,

• Take care to clean the pipes before assembly removing any

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

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 ushing.

Foreign bodies in the system may enter the appliance and interrupt its operation.

the circuit.

Do not perform any 'hot work' directly under the appliance, this may cause damage to the appliance base. Heat may also damage the isolation valves.

Always pre-assemble pipes before tting them to

the boiler.

8.2 Safety Discharge Valve

• Only use original seals supplied with the appliance.

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

Key

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

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

Key

1 Compressiontting

2 PRV pipe 3 Pipe for PRV 4 Draining outlet A PRV outlet - to outside B Appliance drain tap

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

To ease future servicing it is advisable to use a compression

type 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.

• Remove the protective caps from the boiler connections.

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

Before turning on the cold mains supply to the boiler

turn off the cold water inlet to the boiler, lock the lling loop in the closed position and close its lling taps.

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8.3 Connection to the condensate trap

Condensate produced by the appliance is mildly

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

acidic (pH 3.5 - 5.0). Use protective gloves

Condensate must only be discharged in accordance with these instructions.

The volume of condensates evacuated can reach about 15 litres per day for a detached house. This volume is negligible compared to the volume of

waste water discharged by a house, because the condensates are diluted in this water.

condensate.

INSTALLATION

Key 1 Condensate pipe

• Make sure there is no protective plug tted.

• Connect the condensate pipe (1).

The pipe should have a fall of a least 2.5° 44mm/

Condensate should, if possible be discharged into the household internal drainage system.

• If this is not practicable, discharge can be allowed into the

It is recommended that any external condensate drain pipe is protected and also preferably of 32mm diameter, to prevent freezing in adverse weather conditions.

• Always ensure the pipe is installed with the correct fall

metre away from the boiler.

external household drains or a purpose designed soak away, refer to diagram overleaf.

• Use 21.5mm plastic pipe to connect to the condensate

outlet - do not use metal pipes. It is permissible to use a condensate neutraliser providing that it is checked for correct operation.

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- 15 -

INSTALLATION

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INSTALLATION

9 Evacuation of combustion gas

9.1 Regulation

Only ue accessories supplied by Glow-worm

Different ue outlet congurations can be carried out.

• Consult your supplier for more information about the other

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

must be used.

possibilities and associated accessories.

44 mm/m

boiler to drain the condensate. These can be tted level

between the appliance and the termination position. All other

extended ues must have a fall of at least 44mm/m

1 2

If the ue terminal is positioned near a light source insects may enter the ue system.

Where safe and practical to do so advise the

homeowner to check the ue outlet and clear

visible insects from the terminal end.

The maximum length of the ue outlet is dened according to its

type (for example C13).

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

minimum distances indicated in the chart below to position

the ue terminals.

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

supplied with your appliance.

• Explain these requirements to the user of the appliance.

If necessary, you must install a terminal

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 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.

protection kit.

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

Being a condensing boiler some pluming may occur from

the 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. If the carport comprises of a roof and two or more walls, seek advice from the local gas supply company before installing the boiler.

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- 17 -

INSTALLATION

Position Positionoftheueterminal mm

Horizontal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

directly below an opening, air brick, opening windows

horizontally to an opening, air brick, opening windows

- 18 -

300

Position Positionoftheueterminal mm

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

Verticalues

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

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

1200

(*) 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.

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