Glow-worm Ultracom2 sxi User Manual

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Ultracom2 sxi

Installation and Servicing

12sxi

G.C. No. 41-019-12

18sxi

G.C. No. 41-019-13

30sxi

G.C. No. 41-019-14

High Efﬁciency Condensing

System 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 sxi ......................................................................................................................................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 ........................................................................................................... 11

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

8 Hydraulic connection ........................................................................................................................13

8.1 Gas and water connections ..................................................................................13

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

8.3 Connection to the condensate trap ......................................................................14

9 Evacuation of combustion gas .........................................................................................................16

9.1 Regulation ............................................................................................................16

9.2 Flue conguration description ..............................................................................18

10 Remove the front panel ....................................................................................................................20

11 Electrical connections ......................................................................................................................20

11.1 Access to main board ..........................................................................................20

11.2 Main board............................................................................................................20

11.3 Electrical wiring.....................................................................................................21

11.4 External accessories ............................................................................................22

11.5 Testing the electrical connections .........................................................................22

11.6 Wiring diagram .....................................................................................................23

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TABLE OF CONTENTS

12 Commissioning ...............................................................................................................................24

12.1 Switching on ......................................................................................................... 24

12.2 Filling the CH system (Central heating) ................................................................ 24

12.3 Filling the Condensate Trap .................................................................................24

12.4 Initial lighting .........................................................................................................24

12.5 Gas rates ..............................................................................................................25

12.6 Testing heating system ......................................................................................... 26

12.7 Testing domestic hot water system....................................................................... 26

12.8 Completion ...........................................................................................................26

13 Specic adjustment .........................................................................................................................26

13.1 Heating circuit adjustment .................................................................................... 26

13.2 Appliance technical settings and parameter list ...................................................27

13.3 CO2 measurement ............................................................................................... 30

13.4 Re-check and restart ............................................................................................ 30

14 User information ...............................................................................................................................30

MAINTENANCE

15 Trouble-shooting ..............................................................................................................................31

15.1 Fault diagnosis .....................................................................................................31

15.2 Fault memory........................................................................................................32

15.3 Fault codes ...........................................................................................................32

15.4 Functional ow diagram........................................................................................34

16 Gas conversion adjustments ............................................................................................................35

16.1 Settings.................................................................................................................35

16.2 Restart - re-check commissioning ........................................................................ 36

17 Draining ...........................................................................................................................................36

17.1 Heating circuit ...................................................................................................... 36

18 Servicing ..........................................................................................................................................37

18.1 Annual Maintenance .............................................................................................37

18.2 Casing removing...................................................................................................38

18.3 Combustion check and setting the air/gas ratio valve .......................................... 38

18.4 Servicing ...............................................................................................................39

18.5 Silencer ................................................................................................................40

18.6 Expansion vessel..................................................................................................40

18.7 Condensate trap ...................................................................................................41

18.8 Combustion block .................................................................................................42

18.9 Service completion ............................................................................................... 43

19 Replacement of Parts ......................................................................................................................44

19.1 General .................................................................................................................44

19.2 Boiler Access ........................................................................................................44

19.3 Viewing window ....................................................................................................44

19.4 Hydraulic block ..................................................................................................... 46

19.5 Combustion block .................................................................................................48

19.6 Condensate trap ...................................................................................................50

19.7 PCB ...................................................................................................................... 51

20 Spare parts ......................................................................................................................................52

21 Manual Handling ..............................................................................................................................53

22 Declaration of Conformity ................................................................................................................54

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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 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

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.

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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.

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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 (except 12sxi).

• 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 maximum pressure in the heating circuit (PMS)

- 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 Heating safety valve 2 By-pass 3 Heating return thermistor 4 Condensate trap 5 Ignition and control electrode 6 Burner 7 Main heat exchanger 8 Thermal fuse 9 Flue outlet 10 Silencer 11 Heating expansion vessel 12 Fan

13 Gas control valve 14 Ignition module

15 Heatingowthermistor

16 Air vent 17 Pump 18 Filling taps

A Heatingow

B Pipe for heating safety valve C Gas D 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 sxi

Boiler, type C13, C33, C43, C53

Description Unit 12 sxi 18 sxi 30 sxi

Gas category l

SEDBUK rating % 90.4 90.4 90.5

Heating

Maximum heating input power kW 12.3 18.5 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)

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 3.9 4.9 8.5

kW 12 18.2 30

kW 4.4 5.4 9.3

kW 13.2 19.6 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

psi 36/3 36/3 36/3

W 6 6 6

W 151 151 151

A 2 2 2

230V 50Hz

IPX4D IPX4D IPX4D

230V 50Hz

Description Unit 12 sxi 18 sxi 30 sxi

Gas connection Ø O.D. mm

Heating flow and return 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 12 sxi 18 sxi 30 sxi

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

Maximum heating gas ow

rate

Minimum gas ow rate

CO2 at Qmax + "tolerance case ON"

CO2 at Qmax + "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 heating gas ow

rate

Minimum gas ow rate kg/h - 0.4 0.67

CO2 at Qmax + "tolerance case ON"

CO2 at Qmax + "tolerance case OFF"

CO2 at Qmin + "tolerance case ON"

CO2 at Qmin + "tolerance case OFF"

Inlet pressure mbar 37 37 37

kg 37.1 37.1 38.3

lb 81.8 81.8 84.5

kg/h - 1.44 2.37

% -

(copper)

21.5

(plastic)

(copper)

1312

5333

1.3 1.96 3.24

0.43 0.54 0.92

9.2 ±

0.3%

9 ±

0.2%

8.9 ±

0.3%

8.7 ±

0.2%

(copper)

21.5

(plastic)

(copper)

1312

5334

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

4.1

4.2

4.3

4.4

7.2 Recommendations before installing

7.2.1 Heating circuit design

Key 1 Drain point 2 External bypass (if required) 3 Boiler 4 Additional expansion vessel (if required) 5 Heating return circuit

6 Heatingowcircuit

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)   -Heatingowvalve (x1)

- Gas isolation valve (x1)

2.3 Hanging bracket (x1)

2.5 Seals bag (x1)

- Flat seal ½" (x1)

- Flat seal ¾" (x5)

2.6  Compressiontting (x1)

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)

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)

4.5

4.6

General

This boiler is designed to provide central heating from a sealed water system with a fully indirect cylinder. 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.

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INSTALLATION

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.

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.

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

7.3 Dimensions

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

7 6

130

740

346

418

344

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

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.

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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.

160

170

=246=

160

Ø125* Ø105**

63***

735

709

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.

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

130

90°

123

* 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.

123

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 (2.5º) 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.

Hanging bracket xing

- 12 -

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

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".

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.

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

Always pre-assemble pipes before tting them to

the boiler.

• 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 Gasserviceisolatingvalvewithpressuretestpoint+sealing

washer½" 3 Heatingowisolatingvalve+sealingwasher¾" 4 ConnectionØO.D.22mm 5 ConnectionØO.D.15mm

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• Remove the protective caps from the boiler connections.

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

- 13 -

INSTALLATION

8.2 Safety Discharge Valve

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.

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.

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.

metre away from the boiler.

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

- 14 -

• Always ensure the pipe is installed with the correct fall

• 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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INSTALLATION

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- 15 -

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.

- 16 -

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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

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directly below an opening, air brick, opening windows

horizontally to an opening, air brick, opening windows

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.

- 17 -

INSTALLATION

9.2 Fluecongurationdescription

9.2.1 HorizontalconcentricueØ60/100mm

orØ80/125mm(C13typeinstallation)

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.

9.2.2 VerticalconcentricueØ60/100mm

orØ80/125mm(C33typeinstallation)

Key

1Gasket(tted)

Key

1Gasket(tted)

Ø 80/125 mm

Type

Ø 60/100 10 m Ø 80/125 20 m 25 m

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

Max length

12sxi

Max length

18sxi, 30sxi

Type

Ø 60/100 10 m Ø 80/125 20 m 25 m

Max length

12sxi

- 18 -

Max length

18sxi, 30sxi

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INSTALLATION

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

The ue connecting from the appliance to

b b

the ue system must be supplied from the

manufacturer of the boiler.

C43 ue systems must not be a 'pressurised

system' but act under natural draught principles

C43 type ue systems must have their own condensate drain tted and not allow

condensate to mix into other appliances

Model 12sxi 18sxi 30sxi

Exhaust mass rate (g/s)

At min thermal load (40°C/30°C) 1.9 2.4 4.1

At max thermal load (80°C/60°C) 5.5 8.3 13.8

Exhaust temperature (°C)

At min thermal load (40°C/30°C) 47 45 41

At max thermal load (80°C/60°C) 69 65.7 71.4

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

B Groundoor

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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INSTALLATION

10 Remove the front panel

230

11.1 Access to main board

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

11.2 Main board

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).

11 Electrical connections

Incorrect installation can cause electric shock or

The appliance must be connected directly to an accessible,

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.

appliance damage. The electrical connection of

the appliance must be made only by a qualied

engineer.

1 2 3

30mm

max

Key 1 Connector

2 Electricalwires

3 Insulation

When you connect the electrical wires to a connector on the electronic board:

• Keep a distance of a maximum of 30 mm between connector (1) and the start of the insulation (3).

• If using single core wires are used(2) ensure that the are wrapped together in an insulating sheath.

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

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.

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INSTALLATION

11.3 Electricalwiring

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

Isolation should preferably be by a double pole switched fused spur box having a minimum contact separation of 3mm on each pole. The fused spur box should be readily accessible and

preferably adjacent to the boiler. It should be identied as to its

use.

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 xed bath or shower.

11.3.1 230V permanent supply

All cables connected to the appliance should be

a i

permanently xed to the wall.

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

Key 1 230V permanent supply 2 Main board terminal block

= Mains earth

N = Mains neutral

Key

1 Powersupplycable

• Connect the appliance's power cable to the 230 V singlephase network + earth.

• Connect the appliance in accordance with the live and neutral connections.

L = Mains live 3 Fuse 4 Double pole connector

• Connect mains supply as described.

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- 21 -

INSTALLATION

11.3.2 230V permanent supply + 230V system controls

All cables connected to the appliance should be

a i

permanently xed to the wall.

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

11.4 External accessories

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

X18

Key 1 24V room thermostat connector 2 Ebus room thermostat connector or Ebus radio receiver/Smart

wiringcentre

3 Outdoor sensor connector

4 Overheatingsafetyconnectorforheatingoor

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.

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

11.5 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

- 22 -

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11.6 Wiring diagram

INSTALLATION

X31

X51

X40

X32

X90

X30

X17

X16

X18

T°C

1920 18 17 16 15 14 13 12 11

10 9 8 7 6 5 4 3 2 1

1102113124135146157168179

Ebus

24 V

NTC

X20

X17

1 2

3 4

X21

X14

Green/Yellow

FUS

Green/Yellow

230 VAC

Blue

Brown

Green/Yellow

X101

Green/Yellow

1920 18 17 16 15 14 13 12 11

10 9 8 7 6 5 4 3 2 1

34 2 1

17 16

Key

1 Overheatingsafetyconnectorforheatingoor

2 Control accessories connector 3 Reserved for future use 4 Location for 24V option card 5 Location for external programmer 6 User interface 7 Fuse 2A 8 Connector for 230 V option 9 Main supply 230V

X20

1102113124135146157168179

1 2 345 2 1 1 11 1...89 2 1

10 Pump

11 Combinedsparkandamerecognitionelectrode

12 Heating outlet temperature sensor 13 Heating return temperature sensor 14 Gas valve 15 Fan 16 Thermal fuse 17 Water pressure sensor

X21

1 2

3 4

1 2

1112131415

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- 23 -

INSTALLATION

12 Commissioning

At the time of commissioning, complete all relevant

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.

12.1 Switchingon

• Do not operate the boiler without water.

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

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

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

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

• Make sure that the domestic hot water and heating functions

12.2 Filling the CH system (Central heating)

sections of the Benchmark Checklist located in the centre pages of this document.

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

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

on your appliance are not activated.

12.3 Filling the Condensate Trap

Key 1 Filling trap 2 Condensate trap

• 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 ow.

If the Central Heating (C.H.) pressure falls below 0.4 bar, the

display will ash the current pressure and the boiler will not

operate. To increase the pressure, the CH circuit requires "Topping up".

When turning the 230Vac supply on to the boiler

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

• Leave the pump's air vent open.

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

• Rotate the pump shaft through several turns, then replace

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.

During this time the burner will not re in either CH or DHW mode and the display will blink displaying the current water pressure.

then close the vents.

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.

• Fill the trap 3/4 full with water (1).

• Activate the Heating and, if Glow-worm intelligent controls are tted, 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 underoor heating).

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

normally, then close the vents.

• If you have dif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, ll the appliance again.

12.4 Initial lighting

12.4.1 Control

The combustion for this appliance has been

• Check that the appliance has been installed in accordance

checked, adjusted and preset at the factory for operation on natural gas (G20) as de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.

with the instructions.

- 24 -

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

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INSTALLATION

• Check the integrity of the appliance combustion circuit and relevant seals.

• 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

"LPG conversion".

12.4.2 Adjusting the temperature

1 6

Key

1 Domestichotwatertemperaturecontrolbuttons

2 Display 3 Reset button 4 On/Off button 5 Central heating temperature control button 6 Mode selection button

• Light the appliance by following the procedure below.

• Select the "Heating" function by pressing the “Mode” button

repeatedly to scroll through your options 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.

is shown.

Due to the modulating operation of the boiler and the

• Activate the test mode "P.01" and set the value to 100 in

need to check the gas inlet pressure and measure

the gas rate at maximum rate, it will be necessary to

force it to maximum.

order to force the burner at P. max. See chapter "Specic adjustment ► Appliance technical settings and parameter list ► Test modes".

12.5.1 Operational Gas Inlet Pressure

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.

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.

• Press the the factory setting temperature will be displayed.

• Press

• If Glow-worm intelligent controls are tted, press the

hot water temperature temperature will be displayed.

• Press

central heating water temperature button and

or buttons to adjust.

button and the factory setting

or buttons to adjust.

12.5 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 uid,

purge in accordance with the above standard.

The burner pressure cannot be measured and is not

used to measure the gas rate.

12.5.2 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

12sxi 0.43 15.3 1.3 45.9

18sxi 0.54 19.1 2.7 95.3 0.4 1.98

30sxi 0.92 32.5 3.77 133.1 0.67 2.77

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.

MIN MAX MIN MAX

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

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- 25 -

INSTALLATION

12.6 Testing heating system

• 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

differential.

• Turn off all radiators that can be shut off by the user and check to see if less than the maximum differential allowed of

20°C can be achieved across ow and return.

Should the appliance require adjustment refer to

specic adjustment section overleaf.

• Allow the system to reach maximum temperature then switch off the boiler by isolating from the electrical supply.

• Drain the entire system rapidly whilst hot, using the drain taps at all the low points of the system. Fill and vent the system as described previously in chapter "Commissioning

► Filling the CH system (Central heating)".

• Adjust the boiler temperature controls and any system

controls to their required settings.

12.7 Testingdomestichotwatersystem

• Check that the temperature obtained is compliant with the setting on the appliance (Smart wiring centre only).

12.8 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.

13 Specicadjustment

13.1 Heating circuit adjustment

It may be necessary to adjust the by-pass to the design of the

system. The boiler is delivered pre-set open 1/2 turn (1).

Key

1 Screwforby-pass

• Depending on the design of the system the by-pass may need further adjustment. It is adjusted clockwise to close and

anti-clockwise to open. This should be balanced to ensure

that it operates if the pump output is adjusted.

Output/pressure curve Ultracom

12sxi / 18 sxi

1 2 3 4

Key

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

1 Speed min, bypass closed 2 Speed max, bypass closed 3 Speed max, bypass middle position 4 Speed max, bypass opened

500 1000 1500

Output/pressure curve Ultracom2 30sxi

1 2 3 4

Key

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

1 Speed min, bypass closed 2 Speed max, bypass closed 3 Speed max, bypass middle position 4 Speed max, bypass opened

500 1000 1500

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0020092785_02 - 05/10 - Glow-worm

13.2 Appliance technical settings and parameter list

The access to the boilers technical data allows you to adjust the

boiler to the exact system requirements.

Note: the heating power decrease has no effect on the domestic hot water power.

INSTALLATION

13.2.1 Installation settings

• Press for more than 7 seconds on the button to

access the conguration menu. The screen displays "0".

• Press 4 times on the button

The screen displays "96". This is the installer's password.

• Press on

to validate. The screen displays the

parameter "00" and its value "XX”.

Code Parameter Unit Description

d.00 Maximum heating power kW

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

Blocking time for burner in heating

d.02

mode (anti-cycle time)

The following menu is displayed if a domestic hot water tank is connected to the appliance.

d.03 Temperature of the DHW outlet °C Display the temperature of the DHW outlet. - no

d.04 Temperature of water in the tank °C Display tank water temperature. - no

d.18 Pump function -

d.19 Speed of the pump -

Maximum temperature setting for

d.20

domestic hot water

The following 2 menus are displayed if an option card (not supplied) is installed on the appliance.

under the symbol .

Choose a value: 12sxi ►4 to 12 kW 18sxi ►5 to 18 kW 30sxi ►8 to 30 kW

To prevent the burner frequently switching on and off, the reactivation of the burner is electronically blocked for a period that is determined each time the burner stops. The burner blocking time can be adapted to the usage conditions for the heating

min.

installation and depends on the temperature that is set for heating:

- at 80°C, the period is xed (2 minutes)

- at 10°C, the period is adjustable: choose a value between 2 and

60 minutes.

Mode: 0 = With the burner 1 = Continuous with ambient temperature 2 = Continuous

Functioning mode: 0 = Automatic: maximum speed when the burner is switched on 1 = Minimum speed 2 = Automatic: automatic speed when the burner is switched on 3 = Maximum speed

The recommended maximum temperature setting for domestic hot

°C

water is 60°C. Choose a value suitable for your needs.

• Press on button parameter to modify.

• Press on button value of the parameter.

• Do likewise for each parameter that needs to be modied.

• Press for more than 3 seconds on the button the conguration menu.

or under the symbol to access the

or under the symbol to modify the

Factory setting

Modiable

parameter

12 15 20

20 yes

1 yes

2 yes

60 yes

to exit

yes

d.27 Function relay 1 - Reserved for future use 1 yes

d.28 Function relay 2 - Reserved for future use 2 yes

d.34 Speed of fan rpm

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

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

The following 2 menus are displayed if an outdoor sensor (not supplied) is installed on the appliance.

d.43 Heating curve K

d.47 Exterior temperature °C Display the temperature measured by the external sensor. - no

Time remaining before the end of the

d.67

anti-cycle in heating mode.

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

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

min. Display the time remaining before the end of the anti cycle. - no

- no

1.2 yes

- 27 -

INSTALLATION

Code Parameter Unit Description

Maximum temperature setting for

d.71

heating outlet

d.90 Detection of eBUS controller -

13.2.2 After Sales Service settings

• Press for more than 7 seconds on the button to access the conguration menu. The screen displays "0".

• Press on button

After Sales Service password.

• Press on parameter "00" and its value "XX”.

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 Pump status -

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

d.17 Flow or Return temperature monitoring °C

d.21 DHW status -

d.22 DHW mode (eBus and direct connection to board) -

d.23 Central heating mode -

d.25 DHW mode -

d.33 Speed setpoint of fan rpm

d.44 Digitalized ionisation voltage V Display the digitalized ionisation voltage - no

d.68 Unsuccessfull ignitions at rst attempt -

d.69 Unsuccessfull ignitions at second attempt -

d.80 Operating hours in heating mode h

Operating hours in domestic hot water mode (ebus

d.81

control only and direct thermostat connection to board only)

d.82 Number of burner starts in heating mode -

Number of burner starts in DHW mode (ebus control

d.83

only)

d.93 Device Specic Number -

d.96 Factory reset -

or under the symbol and enter the

to validate. The screen displays the

°C Select a value between 50°C and 80°C. 75 yes

0 = Not detected 1 = Detected

• Press on button or under the symbol to access the parameter to modify.

• Press on button

or under the symbol to modify the

value of the parameter.

• Repeat the process for each parameter modied.

• Press for more than 3 seconds on the button the conguration menu.

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 ow (radiator) or return (under-oor heating) temperature sensor.

0 = DHW function disabled 1 = DHW activated

0 = off 1 = on

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

DHW loading enabled or disabled by Appliance Interface or Ebus or external controls.

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

Display the number of unsuccessfull ignitions at 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.

Select the product code of the appliance: 12sxi = 18 18sxi = 19 30sxi = 20

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

Factory setting

Modiable

parameter

- no

Modiable

parameter

- no

0 yes

- no

18 19 20

0 yes

to exit

yes

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0020092785_02 - 05/10 - Glow-worm

INSTALLATION

13.2.3 Status of the appliance

• Press button under the symbol for more than 3 seconds to learn the current state of functioning of the appliance. The screen displays the state of the appliance "S.XX".

• Press button 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

Status Specicmessages

Domestichotwatermode-ebusonlywithsmartwiring

centre

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

Domestichotwaterheating-ebusonlysmartwiring

centre

S.20 Pre-run pump S.21 Pre-run fan S.23 Ignition S.24 Burner lit S.25 Post run pump/fan S.26 Post run fan S.27 Post run pump S.28 The boiler blocks tank reheating after a reheating cycle.

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

S.30

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

S.31 "Hot water only" mode (ebus control only)

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

S.32

is outside tolerance.

S.34 "Frost protection" mode

S.39 Underoor heating contact open. S.40 Heating mode activated S.41 Water pressure too high

Waiting cycle: temperature differential between heating 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 ow and return is too high.

S.96 Test temperature sensor for heating return.

Test temperature sensors for heating ow and return, or the

S.98

appliance has a fault.

for more than 3 seconds to exit this

13.2.4 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

seconds, press the on/off button.

The screen displays the rst test mode "P01" and "Off".

• Press button

or under the symbol to choose the test

mode that you wish to launch.

• Test mode "P.01" :

- Press button

to display the burner forcing setting. The

screen displays "P.01" and "0".

- Press on button

or under the symbol to modify the

value of the setting from "0" (0%) to "100" (100%).

- Press on button

for 1 second to exit the submenu or

for more than 7 seconds to access the conguration menu.

• Test mode "P.02" to "P.07" :

- Press

to launch the test mode. The screen displays

"P.0X" and "On".

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

• When you have nished, press the reset button

On/Off button to exit the test modes.

Code Parameter Description

The appliance functions at a power

adjustable from "0" (0% = Pmin.) to "100"

(100% = Pmax.) by using buttons

under the symbol after successful

ignition.

The appliance functions at ignition power after successful ignition.

The appliance functions at its maximum power after successful ignition.

The 3 way valve is in the central position, the pump and the burner stop so that

the appliance can be lled. Smart wiring

centre/ebus only.

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.

P.01

P.02

P.03

P.05

P.06

P.07

Forcing the

adjustable-

power burner when heating

Forcing the burner to heating ignition power

Forcing the burner to Heating Pmax.

Filling the appliance

Venting the installation

Venting the appliance

pressed for more than 5

or the

0020092785_02 - 05/10 - Glow-worm

- 29 -

INSTALLATION

13.3 CO2 measurement

The combustion for this appliance has been pre-set at the

factory for operation on Natural Gas G20 as dened on the

appliance data label.

No adjustment of the combustion is necessary.

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

13.4 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 ue joints are tested for tightness and tted in

accordance with the instructions.

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

14 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,

- 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 ue terminal in cool weather. This is due to the high efciency and low 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.

Sealed system: The system must be relled and

• Leave these instructions and the ‘Benchmark’ Installation,

to the correct pressure as indicated in these instructions

Commissioning and Service Record with the user.

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0020092785_02 - 05/10 - Glow-worm

MAINTENANCE

To ensure the continued ef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 speci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 centre pages of this document.

15.1.1 Check the electrical installation

Key 1 Main board 2 Neutral 3 Live 4 Multimeter

• Remove the front casing panel

15 Trouble-shooting

15.1 Fault diagnosis

The following checks should be performed before proceeding

onto speci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 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.

15.1.2 Check the gas supply

• 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, ll the appliance.

• Check that all external controls are connected correctly.

• If the symbol

on the screen, display the fault code memory (see chapter "

Trouble-shooting ►Fault memory").

• Press the reset button

• Check the functional ow diagram.

and the message "rE SEt" are displayed

to restart the appliance.

Key 1 Gas service isolation valve 2 Test point

• Check that there is a gas supply to the boiler and the gas service isolation valve is turned on.

0020092785_02 - 05/10 - Glow-worm

• Check pressure at the gas service isolation valve.

- 31 -

MAINTENANCE

15.2 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 than 7 seconds.

• The screen will display the rst fault "01" (record) and "F.XX"

(fault code).

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

and under the symbol for more

or under the symbol .

• Press button

for more than 3 seconds to exit this

menu.

Record Fault code Description

01 XX Consult the “Fault codes” chapter.

02 XX Consult the “Fault codes” chapter.

03 XX Consult the “Fault codes” chapter.

04 XX Consult the “Fault codes” chapter.

05 XX Consult the “Fault codes” chapter.

06 XX Consult the “Fault codes” chapter.

07 XX Consult the “Fault codes” chapter.

08 XX Consult the “Fault codes” chapter.

09 XX Consult the “Fault codes” chapter.

10 XX Consult the “Fault codes” chapter.

• To erase the fault memory registered by the appliance, consult the “Installation adjustments” chapter and use code

“d.94”.

15.3 Fault codes

The faults described in this chapter should be

carried out by a qualied engineer and if needed by

the After Sales Service.

Fault

codes

Description Cause Solution

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

F20 Overheating fault

F22 Water pressure of the installation (<0.3 bar)

Maximum temperature difference reached

F23

between return and ow heating

F24 Water circulation fault

Return heating temperature sensor disconnected

Return heating temperature sensor shorted.

Overheating safety device activated (97°C)

Return water valve closed Pump disconnected Leak in the installation

Water circulation fault

Malfunction of the pump (excessively rapid temperature increase)

- 32 -

• 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 ow and return heating isolation

valves are open.

• Fill the installation.

• Purge the installation.

• Check the pump connections.

• Check the ow and return heating sensor

connections.

• Check that there are no leaks.

• Check the ow and return heating sensor

connection.

• Check the pump speed.

• Check that the ow and return heating isolation

valves are open.

0020092785_02 - 05/10 - Glow-worm

Fault

codes

Description Cause Solution

F26 Fault in gas valve motor. Disconnected or defective cables

F27 Flame detection fault. Abnormal ame detection

F28 Ignition fault

F29 Loss of ame during operation

F32 Incorrect air pressure Incorrect fan speed.

F49 EBUS voltage fault

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 ame signal

User interface incompatible with the main

F70

board

F71 Flow heating temperature sensor fault

Permanent temperature difference between

F72

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 temperature

F83

does not increase when the burner is lit

Permanent temperature difference between

F84

ow and return heating sensors

F85 Flow and return heating sensors fault

F86 Underoor heating contact fault

Err User interface fault Defective user interface

No return gas / Insufcient gas ow Gas valve incorrectly adjusted Defective ring electrode and ame

control / Defective igniter unit

Fault in EBUS line Short circuit in EBUS connector

Gas valve command fault

Rapid uctuation of return or ow

heating sensor.

No return gas / Insufcient gas ow Gas valve incorrectly adjusted Defective ring electrode and ame

control / Defective igniter unit

Incorrect product code

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

Mismatch between the ow and return

heating temperatures (permanent difference)

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 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

MAINTENANCE

• Check the gas valve connections.

• Check the operation of the gas valve.

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

• Check the ame detection electrode.

• Check the main board.

• Check the igniter unit.

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

• Check the observe the ame picture and check

the CO

setting.

• Check the igniter unit connections.

• Check the state of the electrode (corrosion).

• Check the entire ue system.

• Check the fan’s electrical connections.

• Check that the eBus controls are tted and wired

correctly.

• 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 ame picture and check

the CO

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 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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- 33 -

MAINTENANCE

15.4 Functionalowdiagram

15.4.1 Central Heating

- 34 -

0020092785_02 - 05/10 - Glow-worm

MAINTENANCE

16 Gas conversion adjustments

In order to operate with a gas other than that provided from the factory, it is necessary to some adjustments to the gas valve.

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 ue gas

analyser is necessary.

The person carrying out a combustion measurement should

have been assessed as competent in the use of a ue gas

analyser and the interpretation of the results.

The ue gas analyser used should be one meeting the

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

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.

16.1 Settings

Steps "Switching on" to "Re-pressurising System"

Tools required to make the conversion are a 2mm Allen key and an electricians screwdriver.

Having checked :

- the appliance and system have been installed in

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

- the integrity of the appliance combustion circuit and relevant

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

- the gas service isolation valve is opened.

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ueadaptor

3 Cap

• Remove the front panel rst.

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

the measurement (2).

16.1.1 Adjusting the gas valve

• 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.

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Gas adjustment Model G20►G31 G31►G20

18sxi 3 turns

30sxi 2.5 turns

18sxi 3 turns

30sxi 2.5 turns

16.1.2 Adjustingthemaximumpowersetting

• Activate the test mode "P.01" and set the value to 100 in order to force the burner at P. max. See chapter "Specic adjustment ► Appliance technical settings and parameter list ► Test modes".

• Wait approximately 5 minutes to read a stabilized CO2 value.

- 35 -

MAINTENANCE

• Compare the value measured with the values indicated in the table below.

Gas adjustment

CO2 case ON 9 ± 0.2 % 10.1 ± 0.2 %

CO2 case OFF 9.2 ± 0.3 % 10.3 ± 0.3 %

Safe combustion can only be veried by measuring

CO/CO2 ratio. This must not exceed the value shown in the table under the section "Maximum Rate and Adjustment".

G20 G31

16.1.3 Restarting

• Replace the cap

• Replace the appliance front panel.

Note: following the replacement of the front panel, the CO2 value will change: you can check that the value "case on" is correct by the values in the previous table.

17 Draining

17.1 Heating circuit

Key 1 Serial number stickers 2 Data label location

• Firmly attach the gas conversion label to the appliance in the corresponding location (1) on the electrical box.

16.2 Restart - re-check commissioning

• Before putting the appliance into operation, follow the instructions within the chapter Specic adjustment.

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

• Drain down the heating circuit of the boiler only, by closing the heating ow and return isolating valves. See chapter "Hydraulic connection ► Gas and water connections"

• Attach a length of hose (1) to the drain point and open the

drain valve (2).

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

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MAINTENANCE

18 Servicing

• To ensure the continued ef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.

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

• Servicing/maintenance should be carried out by a

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

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

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

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

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

• Check that the pressure sensor is working properly. The pressure must be displayed on the screen.

• Check the pressure of the expansion vessel.

18.1.2 Other checks

• Check the CO2 rate in the fuel and compare with the values indicated in the chapter "CO2 Measurement".

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

valves.

• Check that there are no gas leaks.

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

• Check the appliance’s electrical safety.

18.1.3 Cleaning of the components

• Clean the following components:

- The condensate trap

- The heat exchanger.

- The burner

- The fan

- 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.

18.1 Annual Maintenance

18.1.1 Vericationofcomponents

• Check that the ow sensor is working properly. See chapter "Specic adjustment ► Appliance technical settings and parameter list ► Installation settings" and use

code “d.36”.

• Check that the fan is working properly. See chapter "Speci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 "Specic adjustment ► Appliance technical settings and parameter list ► Installation settings" and use

code “d.3, d.4, d.40, d.41”.

18.1.4 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 different 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 under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 the ionisation quality.

• Check that the thermal fuse protects the appliance against dry re. Disconnect the thermal fuse and check if "F76" fault

code is displayed on the screen.

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MAINTENANCE

18.2 Casing removing

18.2.1 Front panel

230

18.3 Combustion check and setting the air/gas ratio valve

18.3.1 Competency to carry out the check of

combustion performance

BS 6798: 2009 Specication for installation and

- The person carrying out a combustion measurement must be

- The ue gas analyser used should be one meeting

- Competence can be demonstrated by satisfactory completion

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

• Select the “

maintenance of gas-red boilers of rated input not

exceeding 70kW net advises that:

assessed as competent in the use of a ue gas analyser and

the interpretation of the results.

the 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 function by pressing

the “

” button repeatedly, refer to commissioning

section. The boiler should re automatically.

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).

18.2.2 Control box

230

Key 1 Control box

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

Safe combustion can only be veried by measuring

CO/CO2 ratio. This must not exceed the value shown in the table opposite.

18.3.2 Preliminaries

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

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

• The integrity of the appliance combustion circuit and relevant

seals.

• 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 falt before continuing.

Combustion check and setting the air/gas ratio

• Remove the front casing panel, see diagram above and hinge down the control box. Taking care not to touch any internal components, proceed as follows:

• Connect the CO2 combustion analyser to the relevant test point, see diagram opposite.

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MAINTENANCE

If the combustion reading is not within the acceptable values

and the integrity of the complete ue system and combustion circuit seals have been veried and the inlet gas pressure (and gas rate) have been veried, then, it will necessary to adjust the

combustion rate of the appliance.

Adjustment is made by turning the throttle an ⅛

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

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

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

• Remove the analyser probe and replace the cap on the

of a turn, waiting 1 minute to allow the appliance

to stabilise before checking or making further

adjustments.

if tted.

required CO2, refer to previous diagram and the “Setting” column in the table.

test modes.

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

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

Key 1 Throttle 2 Combustion analyser sample point

2A Flueelbow 2B Verticalueadaptor

3 Cap

18.3.3 Maximum rate check and adjustment

To verify the maximum gas rate CO2 setting the

• Activate the test mode "P.01" and set the value to 100 in

• Wait approximately 5 minutes to read a stabilised CO2 value.

• Check that the value is within the range specied in table in

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

12sxi

18sxi

30sxi

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

18sxi

30sxi

appliance must be checked at the maximum rate.

order to force the burner at P. max. See chapter "Specic adjustment ► Appliance technical settings and parameter list ► Test modes".

the “check” column.

G20 Burner % CO2

9.2 ± 0.3% 9 ± 0.2% 0.004

G31 Burner % CO2

10.3 ± 0.3% 10.1 ± 0.2% 0.004

18.3.4 Gas rate check

• Check the gas rates as described in the commissioning section.

18.3.5 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.

18.4 Servicing

If the Combustion CO2, CO/CO2 ratio & Gas rate

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,

18.4.1 Service interval record

checks did not require adjustment then it will not be

necessary to complete a full service.

isolate the boiler from the electrical and gas supplies.

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• Refer to benchmark book stapled in the centre pages of this manual.

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MAINTENANCE

18.5 Silencer

12sxi / 18sxi

Key 1 Fixed silencer 2 Silencer retaining clip 3 Removable silencer

• Unclip 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.

18.6 Expansion vessel

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.

30sxi

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, ll and

purge the appliance or installation, if necessary.

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18.7 Condensate trap

Warning: condensate is mildly acidic. Use

protective gloves.

MAINTENANCE

Key 1 The condensate trap 2 Discharge of condensates 3 Siphon 4 Condensate trap retaining clips 5 Hose

• Place a container under the condensate trap (1).

• Remove the siphon (3) from he recoverer and clean.

• Disconnect the condensation discharge (2).

• Disconnect the heat exchanger hose (5).

• Remove the condensate trap (1) using the clips (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 ll with water.

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MAINTENANCE

18.8 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

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10 Coil 11 Heat exchanger 12 Burner gasket 13 Burner 14 Gas valve 15 Fan 16 Fan connection 17 Gas pipe

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MAINTENANCE

18.8.1 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.

18.8.2 Dismantling the burner

Warning: The gasket (12) must be replaced each

• 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

time the burner is dismantled.

unit.

(15).

• Following the verication or replacement of the burner,

assemble the burner group as described in the following chapter.

18.8.5 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.

18.9 Service completion

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

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

• Remove the retaining screw of the silencer.

• Loosen the 4 nuts (7).

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

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

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

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

18.8.3 Cleaning the heat exchanger

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

18.8.4 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.

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MAINTENANCE

19 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 Glowworm’s own service organisation.

Replacement of parts must be carried out by a

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 ue system and the ue seals,

- The integrity of the boiler combustion circuit and the relevant

- The operational (working) gas inlet pressure at maximum

- The gas rate,

competent person approved at the time by the Health and Safety Executive.

seals,

rate,

19.3 Viewingwindow

230

Key

1 Fibrewasher 2 Steelwasher

3 Glass

4 Steelwasher

5 Circlip

- The combustion performance.

19.1 General

The replacement of parts described in sections

Replacement parts that have associated components that need replacing on removal, i.e. ‘O’ ring, seals, gasket, etc., will be

supplied and should be tted.

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

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

• After replacing any parts, always test for gas soundness and

"Combustion block" will require the removal of the burner module assembly and the replacement of seal and self locking nuts.

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

if necessary carry out functional test of the controls.

19.2 Boiler Access

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

• Remove the circlip (5).

• Remove the steel washer (4).

• Remove bre washer (1).

• Remove the glass (3).

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

casing and lift off.

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19.3.1 Expansion vessel

MAINTENANCE

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.

• Rell, vent and pressurise the boiler.

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MAINTENANCE

19.4 Hydraulic block

9 10

7 11

4 13

Key 1 Water pressure sensor 2 Water pressure sensor connector 3 Pressure relief valve clip 4 Pressure relief valve outlet pipe 5 Pressure relief valve 6 Plate-to-plate heat exchanger retaining arm 7 Plate-to-plate heat exchanger retaining

screws

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8Heatingowpiperetainingclip 9Heatingowpipe

10 Heating return pipe 11 System plate 12 Heting return pipe clip 13 Expansion vessel pipe 14 Automatic air vent 15 Pump housing 16 Pump housing retaining clip 17 Bypass retaining clip

18 Bypass 19 Pump head earth lead 20 Pump head connector

21Pumpheadretainingscrews

22 Pump head 23 Automatic air vent retaining clipc air vent

retaining clip

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MAINTENANCE

19.4.1 Pump (head only)

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

• Disconnect the electrical plug (26) from the main board.

• Disconnect the electrical plug (25) from the pump head.

• Remove the four cap head screws (27).

• Carefully remove the pump head (28) together with cable.

Do not strain cable.

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

• Fit the new pump head by repeating the operations in

reverse.

19.4.2 Safety discharge valve

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

• Undo the safety discharge valve union and remove from the pipework (7).

• Remove the securing clip (6) and withdraw the safety discharge valve (8).

19.4.5 Bypass

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

• Remove the retaining clip (23) to remove the bypass screw (24).

• After replacing the bypass, rell, vent and pressurise the

boiler.

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

19.4.3 Automatic air vent

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

• Remove the retaining clip (29).

• Remove the automatic air vent (20).

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

cap is left loose.

• Rell, vent and pressurise the boiler.

19.4.4 Lowwaterpressuresensor

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

• Disconnect the electrical lead (15).

• Remove the retaining clip (17), remove the low water

pressure sensor (16).

• Fit the new low water pressure sensor.

• Rell vent and pressurise the boiler.

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MAINTENANCE

19.5 Combustion block

2019

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MAINTENANCE

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 - gasket 14 Burner gasket 15 Burner

16 Burnerretainingscrew 17 Heatexchangerretainingscrew

18 Heat exchanger retaining bracket

19 Burnergateretainingscrew

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owpipe 28 Flowheatingtemperaturesensor 29 Heating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

19.5.3 Removing the combustion/burner door assembly

Warning: The gasket (13) must be replaced each

• 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)

• 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

• The combustion/burner door assembly insulation should be

time the combustion/burner door assembly is removed.

and the fan (34).

exchanger (11).

need to replace the heat exchanger.

inspected and replaced if damaged.

19.5.4 Burner

• Remove the 3 burner retaining screws (16).

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

• Fit the new burner and the new gasket.

19.5.5 Heat exchanger

19.5.1 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.

19.5.2 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).

There will be water in the heat exchanger.

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

• Remove the 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)

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

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

Carefully ease heat exchanger out.

the appropriate chapter "Draining".

exchanger.

refering to chapter "Removing the combustion/burner door assembly".

the 2 retaining plates (18) and (22) from the heat exchanger.

side rails.

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MAINTENANCE

19.5.6 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.

19.5.7 HeatingFlowThermistor

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

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

When reconnecting, the polarity of the wiring to

thermistors is not important.

• 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”.

19.6 Condensate trap

Warning: condensate is mildly acidic. Wear

protective gloves.

19.5.8 Heating Return Thermistor

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

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

When reconnecting, the polarity of the wiring to

thermistors is not important.

19.5.9 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 CO2.

19.5.10 Fan

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

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

Key 1 Condensate trap 2 Condensate outlet pipe 3 Condensate reservoir 4 Condensate reservoir retaining clips 5 Hose

• Place a container under the condensate trap (1).

• Remove the condensate (3) from the reservoir.

• Disconnect the condensation discharge (2).

• Disconnect the heat exchanger hose (5).

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

• Remove the condensate trap (1) using the clips (4).

• IMPORTANT: Partially ll the condensate trap with water before replacing. Start the siphon (3) and ll with water.

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

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

• Fit the new gasket (35).

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

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MAINTENANCE

19.7 PCB

When replacing the board refer to instructions

19.8.1 Main PCB

supplied with the spare part.

19.8.3 User interface PCB

Key 1 User interface

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

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

• 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 retting the rear panel, ensure the leads are not

trapped.

19.8.2 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".

• 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 retting the user interface, ensure the leads are not

trapped.

19.8.4 Mains supply cable

The main supply cable must be replaced by a

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

qualied and competent electrician.

chapter "Electrical connection".

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MAINTENANCE

20 Spare parts

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

This appliance displays a CE Mark of conformity.

• Ensure that spare parts are correctly mounted in the right

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

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

Only use the manufacturer’s genuine, new spare

parts.

position and direction. After tting any spare part or servicing,

the appliance must be tested for its safe operation.

Short List of Parts

service organisation.

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 (ow and return)

0020097279 Gas valve 18sxi

0020097280 Gas valve 12sxi

0020038071 Gas valve 30sxi 5 0020038441 Electrode assembly 6 0020097299 User interface PCB

0020097216 Pump (head assembly) 12sxi / 18sxi 7

0020097220 Pump (head assembly) 30sxi 8 A000024135 Low water pressure sensor 9 801635 Burner Door Seal Kit

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Manual Handling

IMPORTANT. With regards to the Manual Handling Operations, 1992

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

Generalrecommendationswhenhandling

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

rstorhigher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,

ooring and adequate lighting are provided in the roof space. It is

recommended a risk assessment of the roof space area be carried out before moving the appliance into the area to take into account access,

stability of ooring, lighting and other factors, and appropriate measures

taken.

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 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 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 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 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 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 posi-

tion. Obtain 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 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 rm grip

supporting base of boiler. Ensure safe lifting techniques are used – keep

back straight – bend using legs - when lifting load from 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.

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 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 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 rec-

ommend obtain rm grip supporting base of boiler. Ensure safe lifting

techniques are used - keep back straight – bend using legs - when lifting

load from 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 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 ttings.

Declaration of Conformity

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

Glow-worm, Nottingham Road, Belper, Derbyshire. DE56 1JT

0020092785_02 - 05/10

Glow-worm Ultracom2 sxi User Manual

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Frequently Asked Questions

User Manual