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Ultracom 30hxi

Glow-worm Ultracom 12hxi, Ultracom 24hxi, Ultracom 30hxi, Ultracom38hxi, Ultracom 15hxi Installation And Servicing Manual

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1
Installation and Servicing
High Efficiency
Condensing Boilers
Ultracom
15hxi
G.C. No. 41-019-02
12hxi
G.C. No. 41-019-01
18hxi
G.C. No. 41-019-03
30hxi
G.C. No. 41-019-05
24hxi
G.C. No. 41-019-04
38hxi
G.C. No. 41-019-06
www.glow-worm.co.uk
2
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.
The second year of the parts guarantee, from the beginning of the 13th month onwards after
installation or manufacture, is conditional upon the boiler having been serviced by a CORGI
registered gas installer,
in accordance with the manufacturer’s recommendations. We strongly recommend regular
servicing of your gas appliance, but where the condition is not met, any chargeable spare parts or
components issued within the applicable guarantee period still benefit from a 12 month warranty
from the date of issue by the 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.
Guarantee Registration
Customer Service:
01773 828100
Technical Helpline:
01773 828300
General and Sales enquiries:
Tel. 01773 824639
Fax: 01773 820569
To register your Glow-worm appliance
call:
0800 0732142
3
CONTENTS DESCRIPTION SECTION PAGE
Warnings 4 Important Information 4 Statutory Requirements 5 Boiler Design 6 Safety Devices 6 Servicing, Maintenance and Spare Parts 6
Boiler Specification 1 7 Boiler Dimensions & Hydraulic Schematic 2 8 Boiler Location, Clearances and Ventilation 3 9 Flue Options and Terminal Clearances 4 10 Water Systems 5 12 Installation Preparation 6 16 Boiler Fixing 7 17 Gas/Water & Condensate Connection 8 18 Flue Length Preparation and Installation 9 20 Electrical Connection 10 35 Commissioning 11 37
Servicing 12 40 Fault Finding 13 44 Replacement of Parts 14 52 Spare Parts 15 57 Manual Handling 16 58 Declaration of Conformity - 59
INTRODUCTION
INSTALLATION
MAINTENANCE
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.
4
Gas Category
This boiler is for use only on G20 natural gas, but may be converted for use on G31 gas (Propane L.P.G.).
Gas Safety (Installation and Use) Regulations
In your own interests and that of safety, it is the Law that ALL gas appliances are installed by a
competent person in
accordance with the current issue of 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.
Manual Handling
With regards to the “Manual Handling Operations, 1992 Regulations”, the appliance exceeds the recommended weight for a one man lift, refer to section 16 for more information.
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 identified as to its use.
Alternatively connection can be made through an unswitched shuttered socket and 3A fused 3-pin plug both to the current issue of BS 1363, 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).
Testing and Certification
This boiler is tested and certificated for safety and performance. It is, therefore, important that no alteration is made to the boiler, without permission, in writing, by Glow­worm.
Any alteration not approved by Glow-worm, could invalidate the certification, boiler warranty and may also infringe the current issue of the statutory requirements.
CE Mark
This boiler meets the requirements of Statutory Instrument, No. 3083 The Boiler (Efficiency) Regulations, and therefore is deemed to meet the requirements of Directive 92/42/EEC on the efficiency requirements for new hot water boilers fired with liquid or gaseous fuels.
Type test for purposes of Regulation 5 certified by: Notified body 0087.
Product/production certified by: Notified body
0086.
The CE mark on this appliance shows compliance with:
1. Directive 90/396/EEC on the approximation of the laws of the Member States relating to appliances burning gaseous fuels.
2. Directive 73/23/EEC on the harmonisation of the Laws of the Member States relating to electrical equipment designed for use within certain voltage limits.
3. Directive 89/336/EEC on the approximation of the Laws of the Member States relating to electromagnetic compatibility.
WARNINGS
Gas Leak or Fault
Turn off the gas emergency control valve immediately. Eliminate all sources of ignition, i.e.smoking, blowlamps,
hot air guns etc. Do not operate electrical lights or switches either on or off. Open all doors and windows,
ventilate the area.
Metal Parts
This boiler contains metal parts (components) and care should be taken when handling and cleaning,
with particular regard to edges.
Sealed Components
Under no circumstances must the user interfere with or adjust sealed parts.
Important Information
5
IMPORTANT
Where no British Standards exists, materials and equipment should be fit for their purpose and of suitable quality and workmanship.
The installation of this boiler must be carried out by a competent person in accordance the rules in force in the countries of destination.
Manufacturer’s instructions must not be taken as overriding statutory requirements.
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 as described in the following regulations:
The manufacturer’s instructions supplied.
The Gas Safety (Installation and Use) Regulations.
The appropriate Buildings Regulations either The Building Regulations, The Building Regulations (Scotland),The Building Regulations (Northern Ireland).
The Water Fittings Regulations or Water byelaws in Scotland.
The Health and Safety at Work Act, Control of Substances Hazardous to Health (COSHH).
The Current I.E.E. Wiring Regulations.
Where no specific instructions are given, reference should be made to the relevant British Standard Code of Practice.
In IE, the installation must be carried out by a competent person and installed in accordance with the current edition
of I.S.813 “Domestic Gas Installations”, the current Building Regulations and reference should be made to the current ETCI rules for Electrical Installation.
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 specification (CheSS)
and
2) Controls for domestic central heating system and hot water. BRECSU.
Statutory Requirements
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 fluid, purge in accordance with the above standard.
Domestic Hot Water
All domestic hot water circuits, connections, fittings 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.
6
Boiler Design
Boiler Design
These boilers are designed to provide central heating from a fully pumped open vented or sealed water system and domestic hot water using a fully indirect cylinder.
Once the controls are set the boiler operates automatically.
Condensate Drain
A plastic drain pipe must be fitted to allow discharge of condensate to a drain.
Electrical Supply Failure
The boiler will not work without an electrical supply.
Normal operation of the boiler should resume when the electrical supply is restored.
Reset any external controls, to resume normal operation of the central heating.
If the boiler does not resume normal operation press the reset button. If the boiler does not resume normal operation after this call your Installation/Servicing company or Glow­worm service.
Overheating Safety
The boiler software is designed to recognise the potential for an overheat lockout and will shutdown before this happens. To restart the boiler, press the reset button on the controls fascia.
If the boiler fails to resume normal operation and all external controls are calling for heat, then call your Installation/ Servicing company or Glow-worm service.
Safety Devices
Frost protection
The appliance has a built in frost protection device that protects the boiler from freezing. With the gas and electric supplies ON and irrespective of any room thermostat setting, the frost protection device will operate the pump when the temperature of the boiler water falls below 8
O
C.
A timer is used so that the temperature can be checked periodically. After 10 minutes the pump will be stopped if the temperature is higher than 10
O
C or has already reached 35OC.
The burner will activate if the boiler temperature does not reach 10
O
C after 30 minutes or at any time if the temperature
drops to 5OC.
The burner will switch off when the temperature reaches 35OC.
Condensate Drain Blockage
As a safety feature the boiler will stop working if the condensate drain becomes blocked. During freezing conditions this may be due to the forming of ice in the condense drain external to the house. Release an ice blockage by the use of warm cloths on the pipe. The boiler should then restart.
Condensate should, if possible, be discharged into the internal household draining system. If this is not practical, discharge can be made externally into the household drainage system or a purpose designed soak away, see section 8 for more details.
Pluming from flue terminal
Like all condensing boilers this appliance will produce a plume of condensation from the flue terminal in cool weather. This is due to the high efficiency and hence low flue gas temperature of the boiler.
This is normal and not an indication of a fault.
Servicing, Maintenance and Spare Parts
Servicing and Maintenance
To ensure the continued efficient 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 in accordance with the rules in force in the countries of destination. To obtain service, please call your installer or Glow-worm’s own service organisation using the telephone number on the inside front cover of this literature.
“Benchmark” scheme
Glow-worm support the Benchmark initiative. It is very important that the Installation, Commissioning and Service Record is completed by the installation engineer and handed over to the user.
Spare Parts
Remember, when replacing a part on this appliance, use only spare parts that you can be assured conform to the safety and performance specification that we require. Do not use reconditioned or copy parts that have not been clearly authorised by Glow-worm. If a part is required contact Glow-worm’s own service organisation using the telephone number on the inside front cover of this booklet. Please quote the name of the appliance, this infomation 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 using the telephone number on the inside front cover of this booklet.
7
1 Boiler Specification
BOILER SPECIFICATION 12hxi 15hxi 18hxi
Lift weight 25kg (55Ib) 25kg (55Ib) 25kg (55lb)
Total weight (installed) 30kg (66Ib) 30kg (66Ib) 30kg (66lb)
Gas connection Rc1/2 (1/2in BSPT) Rc1/2 (1/2in BSPT) Rc1/2 (1/2in BSPT)
Heating flow and return connection Ø O.D. 22mm. copper 22mm. copper 22mm. copper
Condensate connection Ø I.D. 21.5mm. plastic 21.5mm. plastic 21.5mm. plastic
Water circuit 3 bar (43/5Ibf/in2) 3 bar (43/5Ibf/in2) 3 bar (43/5Ibf/in2)
Electrical supply 230V~50Hz fused 3A 230V~50Hz fused 3A 230V~50Hz fused 3A
Electrical rating 60W fused 3A 60W fused 3A 60W fused 3A
EN60529 IP clasification IPX4D IPX4D IPX4D
Internal fuse rating on main PCB 2A 2A 2A
Gas supply (governed meter only) / category G20 natural gas /
II
2H3P
G20 natural gas /
II
2H3P
G20 natural gas /
II
2H3P
Inlet gas working pressure 20mbar 20mbar 20mbar
Burner % CO2 case on 9.3 nominal 9.3 nominal 9.3 nominal
Burner % CO2 case off 9.1 nominal 9.1 nominal 9.1 nominal
1.29 m3/h 1.61 m3/h 2.00 m3/h
45.6 ft3/h 57 ft3/h 70.6 ft3/h
0.53 m3/h 0.53 m3/h 0.53 m3/h
18.7 ft3/h 18.7 ft3/h 18.7 ft3/h
Flue type C13, C33, C53 C13, C33, C53 C13, C33, C53
NOx Class 5 Class 5 Class 5
Heat output condensing mode 12.9kW 16.2kW 20.02kW
Heat input Nett Q = kW max. 12.20 min. 5 max. 15.26 min. 5.0 max. 18.9 min. 5
Heat output P = kW max. 12 min. 4.95 max. 15 min. 4.95 max. 18.57 min. 4.95
SEDBUK rating Band A 90.5% Band A 90.5% Band A 90.4%
Approximate max. gas rate after 10 mins. from cold
Approximate min. gas rate after 10 mins. from cold
BOILER SPECIFICATION 24hxi 30hxi 38hxi
Lift weight 28kg (62Ib) 28kg (62Ib) 28kg (62lb)
Total weight (installed) 33kg (73Ib) 33kg (73Ib) 33kg (73lb)
Gas connection Rc1/2 (1/2in BSPT) Rc1/2 (1/2in BSPT) Rc1/2 (1/2in BSPT)
Heating flow and return connection Ø O.D. 22mm. copper 22mm. copper 22mm. copper
Condensate connection Ø I.D. 21.5mm. plastic 21.5mm. plastic 21.5mm. plastic
Water circuit 3 bar (43/5Ibf/in2) 3 bar (43/5Ibf/in2) 3 bar (43/5Ibf/in2)
Electrical supply 230V~50Hz fused 3A 230V~50Hz fused 3A 230V~50Hz fused 3A
Electrical rating 60W fused 3A 60W fused 3A 60W fused 3A
EN60529 IP clasification IPX4D IPX4D IPX4D
Internal fuse rating on main PCB 2A 2A 2A
Gas supply (governed meter only) / category G20 natural gas /
II
2H3P
G20 natural gas /
II
2H3P
G20 natural gas /
II
2H3P
Inlet gas working pressure 20mbar 20mbar 20mbar
Burner % CO2 case on 9.3 nominal 9.3 nominal 9.0 nominal
Burner % CO2 case off 9.1 nominal 9.1 nominal 8.8 nominal
2.58 m3/h 3.02 m3/h 4.06 m3/h
91.1 ft3/h 107 ft3/h 143 ft3/h
0.56 m3/h 0.56 m3/h 0.67 m3/h
19.8 ft3/h 19.8 ft3/h 23.8 ft3/h
Flue type C13, C33, C53 C13, C33, C53 C13, C33, C53
NOx Class 5 Class 5 Class 5
Heat output condensing mode 25kW 30.6kW 41kW
Heat input Nett Q = kW max. 24.4 min. 5.3 max. 28.6 min. 5.3 max. 38.35 min. 6.7
Heat output P = kW max. 24 min. 5.25 max. 28.2 min. 5.25 max. 38 min. 6.3
SEDBUK rating Band A 90.5% Band A 90.6% Band A 90.8%
Approximate max. gas rate after 10 mins. from cold
Approximate min. gas rate after 10 mins. from cold
8
2 Boiler Dimensions & Hydraulic Schematic
Diagram 2.1
Diagram 2.2
CONDENSATE CONNECTION
2.1 Boiler Dimensions & Hydraulic Schematic
All dimensions are given in millimetres (except as noted).
The general arrangment of the boiler is shown in diagram 2.1. and the hydraulic and gas schematic, diagram 2.2.
The data label is positioned on the front of the inner casing panel.
9
3 Boiler Location, Clearances and Ventilation
3.1 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.
3.2 Clearances
The boiler should be positioned so that at least the minimum operational and servicing clearances are provided, see diagram 3.1.
Additional clearances may be beneficial around the boiler for installation and servicing.
For flue installations where external access is not practicable, consideration should be given for the space required to insert the flue internally, which may necessitate clearance larger than those specified in diagram 3.1.
3.3 Timber Frame Buildings
If the boiler is to be installed in a timber frame building it should be fitted in accordance with the Institute of Gas Engineers document IGE/UP/7/1998. If in doubt seek advice from local gas undertaking or Glow-worm.
3.4 Combustible Material
The boiler and flue are suitable for installation onto and through combustible materials provided that:-
1) Minimum 5mm clearance is maintained around the circumference of the flue (air intake).
2) The combustible surface and fixings are suitable for supporting the load.
3) The minimum clearances from the boiler case are maintained.
3.5 Room Ventilation
The boiler is room sealed so a permanent air vent is not required.
3.6 Cupboard or Compartment Ventilation
Due to the high efficiency and hence low casing temperature of this boiler, cupboard or compartment ventilation is not necessary.
Leave existing air vents.
Diagram 3.1
150
200
*5 600
CLEARANCES
5
5
mm clearance to combustible material
5
5
10
4 Flue Options and Terminal Clearances
Diagram 4.1
Top horizontal telescopic flue (Ø60/100) Part No. A2043600 - Section 9, page 20
Top horizontal standard flue
(Ø60/100)
Part No. A2043400 - Section 9, page 24
Twin Flue Twin Flue Adapter, concentric flue (Ø80) Part No. A2011000 - Section 9, page 31
Plume Management Kit basic set, white, concentric flue (Ø60/100) - Part No. A2044100 for use with Part No. A2043400 and Part No. A2043600 - Section 9, page 34
Vertical Flue Vertical Flue Adapter, concentric flue (Ø60/100) Part. No. A2024600 - Section 9, page 28 Vertical flue terminal kit, concentric flue (Ø60/100) Part. No. 2000460480 - Section 9, page 28
11
HORIZONTAL FLUES
A DIRECTLY BELOW AN OPENING, AIR BRICK, OPENING WINDOWS 300 B ABOVE AN OPENING, AIR BRICK, OPENING WINDOWS 300 C HORIZONTALLY TO AN OPENING, AIR BRICK, OPENING WINDOWS 300 D BELOW GUTTER, DRAIN/SOIL PIPE 25 E BELOW EAVES 25 F BELOW A BALCONY OR CAR PORT 25 G FROM VERTICAL DRAIN PIPES AND SOIL PIPES 25 H FROM INTERNAL/EXTERNAL CORNERS 25
H* TO A BOUNDARY ALONGSIDE THE TERMINAL 300 I ABOVE ADJACENT GROUND OR BALCONY LEVEL 300
J* FROM SURFACE OR A BOUNDARY FACING THE TERMINAL 600 K FACING TERMINALS 1200 L FROM OPENING (DOOR/WINDOW) IN CAR PORT INTO DWELLING 1200 M VERTICAL FROM A TERMINAL 1500 N HORIZONTALLY FROM A TERMINAL 300
VERTICAL FLUES
P FROM ANOTHER TERMINAL 600 Q ABOVE ROOF LEVEL 300 R FROM ADJACENT OPENING WINDOW 1000 S FROM ADJACENT WALL TO FLUE 300
Diagram 4.2
4.1 Flue Options
There are various flue options to choose from as illustrated in diagram 4.1. The flue lengths and installation are described in section 9.
4.2 Flue Terminal Position
In GB the minimum acceptable siting dimensions for the
terminal from obstructions, other terminals and ventilation openings are shown in diagram 4.2.
In IE the minimum distances for flue terminal positioning must be those detailed in I.S.813 “Domestic Gas Installations”.
The terminal must be exposed to the external air, allowing free passage of air across it at all times.
Being a condensing boiler some pluming may occur from the flue outlet. This should be taken into consideration when selecting the position for the terminal.
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.
H* and J* See diagram 4.2 . 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.
4.3 Terminal Guard
A terminal guard is required if persons could come into contact with the terminal or the terminal could be subject to damage.
If a terminal guard is required, it must be positioned to provide minimum of 50mm clearance from any part of the terminal and be central over the terminal.
The guard should be similar to that shown in diagram 4.3.
A suitable guard is manufactured by: -
Tower Flue Components Morley Rd. Tonbridge Kent TN9 1RA. Size: 280mm x 280mm x 270mm.
4 Flue Options and Terminal Clearances
Diagram 4.3
12
5 Water Systems
0 1000800600400
0
1
0.5
1.5
2
2.5
200
Diagram 5.1
13
5 Water Systems - General
5.1 General
This boiler is designed to provide central heating from a fully pumped open vented or sealed water system and domestic hot water using a fully indirect cylinder.
An options board accessory is available to link the internal programmer with a Honeywell S or Y plan system.
5.2 Draining Points
Draining taps must be provided at all low points of the system, which will allow the entire system to be drained.
Draining taps shall be to the current issue of BS2879.
5.3 Pump
The pump should be fitted on the flow pipe from the boiler and have isolating valves each side.
A variable duty pump should be set to give a temperature difference of no greater than 200C between the flow and return, with the thermostat set at “MAX”, which is about 800C, to give a flow rate as given in the table.
See chart for pressure loss of the boiler, diagram 5.1.
High resistance microbore systems may require a higher duty pump.
5.4 Flow Rate
If it is necessary to alter the flow rate, the system can be fitted with a lockable balancing valve in the main flow or return pipes shown as valve “A” in diagram 5.3. The flow rate through the boiler must not be allowed to fall below that given in diagram 5.1.
5.5 Bypass
A system bypass will be required fitted at least 1.5 metres away from the boiler, refer to the current issue of the central heating system specifications (CHeSS).
5.6 Water Treatment
Existing system- It is ESSENTIAL that prior to installing the
new boiler the system is thoroughly flushed.
New system- For optimum performance after installation, the boiler and its associated central heating system should also be flushed.
Flushing should be carried out in accordance with BS7593: 1992 using a cleanser such as Sentinel X300 or X400, Fernox Restorer or Salamander corrosion guard cleaner.
IMPORTANT: Ensure all cleanser is removed from the whole system before adding an inhibitor.
For long-term corrosion protection, after flushing, an inhibitor suitable for stainless steel exchangers should be used, refer to the current issue of BS 5449 and BS 7593 on the use of inhibitors in central heating systems. Examples are Sentinel X100 Fernox Protector or Salamander corrosion guard inhibitor.
14
5 Water Systems - Open Vented
Diagram 5.3
5.7 Open (Vented) Water System
The boiler must be supplied from an unrestricted water supply taken from a feed and expansion cistern situated at a maximum height of 27 metres (90ft) above the boiler.
The cold feed must be 15mm minimum size.
The vent must rise continuously and be unrestricted.
It is important that the relative positions of the pump, cold feed and open vent are as shown in diagram 5.2.
5.8 Combined Feed and Vent
For combined feed and vent, a 22mm pipe must be fitted in accordance with BS 5449.
5.9 Safety Valve
A safety valve need not be fitted to an open-vented system.
5.10 Domestic Hot Water Cylinder
SINGLE FEED INDIRECT CYLINDERS ARE NOT SUITABLE.
The domestic hot water cylinder must be of the double feed fully indirect coil type.
5.11 DHW. System - unvented
General - All domestic hot water circuits, connections, fittings must be in accordance with the relevant standards and water supply regulations.
For GB: Guidance G17 to G24 and recommendation R17 to R24 of the Water Regulations Guide.
For IE: The current edition of I.S.813 “Domestic Gas Installations”.
Where a storage system will not have a vent to atmosphere the installation must comply with the building regulations and local Water Company bylaws, see also the current issue of BS5546 and BS6700.
If fitting to an existing system the local authority should be informed.
Diagram 5.2
Open (vented) system. Recommended relationship between pump, cold feed and vent.
22mm (MIN.) VENT
FEED AND EXPANSION CISTERN
15mm (MIN.) AUTOMATIC BY-PASS
15mm (MIN.) COLD FEED
CYLINDER
RETURN
FLOW
HEATING
PUMP
BOILER
150mm MAX.
1000mm MIN.
450mm MIN. HEIGHT
15
5.12 Sealed water Systems
The installation must comply with the appropriate requirements of the current issue of BS4814, BS5449, BS6759, BS6798 and BS7074 Part 1 and 2.
See diagram 5.3 for a suggested layout.
5.13 Safety Valve
A safety valve must be fitted to a sealed system. It shall be preset, non-adjustable with a lift pressure of 3 bar, incorporating seating of a resilient material, a test device and a connection for drain.
The drain from the safety valve must be routed outside the building, must not discharge above an entrance or window or any type of public access area, be clear of any electrical fittings and positioned so that any discharge can be seen.
5.14 Expansion Vessel
A diaphragm type expansion vessel, conforming to the current issue of BS4814 (see also BS7074 Part 1 and 2) must be connected at a point close to the inlet side of the circulating pump, see the diagrammatic layout, diagram 5.3 unless laid down differently by the manufacturer.
The expansion vessel volume depends on the total water system volume and the initial system design pressure. For any system an accurate calculation of vessel size is given in the current issue of BS5449 and BS7074 Part 1.
Example: For an initial design pressure of 0.7 bar, the minimum total vessel volume required is 0.063 x Total System Volume.
NOTE: A higher initial design pressure requires a larger volume expansion vessel.
In GB, guidance on vessel sizing is also given in the current issue of BS5449 and BS7074 Part 1.
In IE refer to the current edition of I.S.813 “Domestic Gas Installations”.
The charge pressure must not be less than the static head of the system, that is, the height of the highest point of the system above the expansion vessel.
5.15 Pressure Gauge
A pressure gauge with a set pointer and covering at least 0 to 4 bar (0 to 60 lb/in2) shall be fitted permanently to the system in a position where it can be seen when filling the system.
5.16 Domestic Hot Water Cylinder
SINGLE FEED INDIRECT CYLINDERS ARE NOT SUITABLE
The domestic hot water cylinder must be of the double feed fully indirect coil type. It must be suitable for working at a gauge pressure of 0.35 bar above the safety valve setting.
5.17 Water Makeup
Provision should be made for replacing water loss from the system using a make up bottle mounted in a position higher than the top point of the system, connected through a non­return valve to the return side of either the heating circuit or the hot water cylinder. Alternatively, provision for make up can be made using a filling loop.
TEMPORARY CONNECTION
HOSE UNION
HOSE
UNION
SUPPLY
PIPE
CONTROL VALVE
CONTROL
VALVE
DOUBLE CHECK VALVE
HEATING CIRCUIT
DRAIN POINT
SUPPLY
PIPE
AIR GAP
TUNDISH
CONTROL
VALVE
CONTROL
VALVE
TYPE CA BACKFLOW
PREVENTION DEVICE
BOILER
RETURNFLOW
BOILER
RETURNFLOW
HEATING CIRCUIT
DRAIN POINT
Method 1
Method 2
Diagram 5.4
5 Water Systems - Sealed
5.18 Filling a Sealed Water System
Provision for filling the system at low level must be made, see diagram 5.4. There must be no permanent connection to the mains water supply, even through a non-return valve.
We do not recommend filling using artificially softened water.
16
6.1 Appliance Pack
The top polystyrene pack contains all the items illustrated in diagram 6.1.
Remove the carton sleeve and top pack then lift the boiler and its polystyrene base support out of the lower pack.
6.2 Site Requirements
The boiler mounting wall should be suitable for the weight of the appliance and be true and flat.
NOTE: Due to the varied site conditions we do not supply fixings and advise that the installer should supply those which are suitable.
6.3 Wall Template
Take the wall template from the document pack and place in
the desired position on the wall, giving due consideration to the required boiler clearances and the flue you are fitting.
Mark the position of the flue centre, if fitting a side flue, extend the flue centre line into the corner then 176mm along the adjacent wall, see diagram 6.2.
For extended side flues, the flue hole centre should be determined by extending the dashed inclined line on the template to the side wall. This dashed line is drawn at 44mm/ metre (2.5°) rise from the boiler. Where this line reaches the side wall, a horizontal line should be marked. The vertical centre line of the flue should then be marked at 176mm from the back wall.
To allow for the flue passing through the wall at this angle a 125mm hole should be drilled irrespective of internal or external installation.
Remove the wall template whilst drilling the flue hole.
6.4 Flue Hole Cutting
External access flue installation can use a 105mm diameter core drill.
Internal access only flue installation will need a 125mm diameter core drill.
NOTE: The flue is designed with an internal fall of 44mm/ metre (2.5°), therefore the hole can be drilled horizontally.
If flue 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 (2.5°) towards the boiler.
6 Installation Preparation
Documentation Pack
(not illustrated)
Electrical Cartridge
Wall Template, User Instructions,
Installation and Servicing Instructions
and Guarantee Pack.
Hanging Bracket
Gas Valve
Cover Plate
Diagram 6.2
Diagram 6.1
17
7 Boiler Fixing
Diagram 7.1
Diagram 7.2
HANGING BRACKET
WALL PLUG
SCREW NO 12 x 50mm
WALL TEMPLATE
Preferred
fixing points
HANGING BRACKET
7.1 Hanging Bracket Fixing
If previously removed, reposition the wall template over the flue hole and mark the position of the fixing holes for the hanging bracket, see diagram 7.1.
Mark and drill the fixing holes and secure the hanging bracket which is supplied in the polystyrene base pack.
NOTE: Due to the varied site conditions we do not supply fixings and advise that the installer should supply those which are suitable.
7.2 Boiler Hanging
IMPORTANT: With regards to the Manual Handling
Operations, 1992 Regulations, the following lift operation exceeds the recommended weight for a one man lift, refer to section 17 Manual Handling.
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, see diagram 7.2.
Remove the polystyrene base support.
18
8 Gas / Water & Condensate Connection
8.1 Gas Connection
Before connection check the supply of local gas.
Refer to diagram 8.1, the gas supply can be connected from below or through the wall at the rear of the boiler.
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”.
8.2 Water Connections
Provision is made for the water connections to be made from above the boiler, see diagram 8.2.
Flush out the heating systems before connecting to the boiler, refer to section 5.6.
8.3 Condensate Trap and Siphonic Drain Connection
The condensate drain, see diagram 8.1, is suitable for use with standard “Push fit” overflow pipe and couplings. DO NOT use adhesive when connecting to the spigot. The drain pipe should be non corrosive plastic.
IMPORTANT: Please remove spigot bung before fitting condensate drain connection.
The condensate drain pipe should have a fall of at least
2.5o 44mm/metre away from the boiler and if possible be discharged into the household internal drainage system. If this is not practicable, discharge can be allowed into the external household drains or a purpose designed soak away, refer to diagram 8.3.
It is recommended that any external condensate drain pipe is insulated and also preferably of 32mm diameter, to prevent freezing in adverse weather conditions.
The condensate is discharged periodically in ‘slugs’ by siphonic action.
It is not necessary to provide air breaks or extra traps in the discharge pipe as there is already a 75mm high trap inside the boiler. Fitting an extra trap may cause the boiler siphon to work incorrectly.
Refer to BS5546 or BS6798 for advice on disposal of boiler. condensate.
Diagram 8.2
FLOW
RETURN
22mm compression is the recommended fixing for servicing. (not supplied)
GAS SERVICE ISOLATION VALVE LINER
GAS SERVICE ISOLATION VALVE (shown open)
GAS SUPPLY PIPE IN
COUPLING
SPIGOT
CONDENSATE DRAIN PIPE
UNION CONNECTOR
PRESSURE TEST POINT
Diagram 8.1
19
8 Gas / Water & Condensate Connection
INTERNAL SOIL AND VENT STACK
BOILER
MIN. DIA. 21mm NO RESTRICTION ON LENGTH
EXTERNAL SOIL AND VENT STACK
MIN. DIA. 21mm NO RESTRICTION ON LENGTH
BOILER
BOILER
MIN. DIA. 21mm
EXTERNAL LENGTH OF PIPE 3M MAX.
OPEN END OF PIPE DIRECT INTO GULLEY BELOW GROUND BUT ABOVE WATER LEVEL
MIN. DIA. 21mm NO RESTRICTION ON LENGTH
BOILER
SINK (CONSTITUTES AIR
BREAK)
BOILER
MIN. DIA. 21mm NO RESTRICTION ON LENGTH
SINK
OPEN END OF PIPE DIRECT INTO GULLEY BELOW GROUND LEVEL BUT ABOVE WATER LEVEL.
Ø22mm MIN. TERMINATION FROM APPLIANCE
.
EXTERNAL LENGTH OF PIPE 3M MAX.
25mm MIN.
SEAL
BOTTOM OF TUBE SEALED
Ø100mm PLASTIC
TUBE
300mm MIN.
GROUND (either/or)
500mm MIN.
HOLE
DEPTH
400mm MIN.
LIMESTONE CHIPPINGS
2 ROWS OF 3 x 12mm HOLES AT 25mm CENTRES 50mm FROM BOTTOM OF TUBE. HOLES TO FACE AWAY FROM HOUSE.
External Soil and Vent Pipe or Rainwater Pipe
Internal Soil and Vent Pipe
External Termination into Soakaway
Internal Termination Downstream of Sink Waste
Internal Termination into Combined Sink Waste
External Termination to a Gulley or Hopper
*
NOTE: PIPEWORK SHOULD ALWAYS FALL AWAY FROM BOILER BY AT LEAST 2.5
44mm FOR EVERY 1M.
o
EXTERNAL MAX. 3M
*NOTE: FOR EXTENDED PIPE RUNS 32mm DIA. PIPE SHOULD BE USED.
Diagram 8.3
20
380 min. to 590 max.
WALL THICKNESS
BOILER MOUNTING WALL
OUTSIDE WA
LL FACE
203 min. to 413 max.
87min
65
112
176
NOTE. If necessary, it is permitted to increase this dimension to 600mm max.
FLUE LENGTH
9.1 Flue Length
The maximum permissable horizontal flue length is 10 metres plus the flue terminal assembly, this can be achieved by use of the accessories, see diagram 9.3.
However should an additional 90o or 2 x 45o elbows be used then the length MUST be reduced by 1metre.
The diagram 9.1 shows the length achievable by using the kit A2043600.
9 Telescopic Flue - Length, Preparation and Installation
L
FLUE
C
Min flue length 380mm
Max flue length 590mm
134
240
5mm min. clearance
A
A
Max. distance from outside
wall face to min clearance. LH - 345mm RH - 451mm
Min. distance from outside wall face to min clearance. LH - 135mm RH - 241mm
OUTSIDE WA
LL FACE
87min
NOTE. If necessary, it is permitted to increase this dimension to 600mm max.
INTERNAL SURFACE
When extension pipes are used the flue system must be designed to have a continuous fall to the boiler of at least
2.5
o
44mm/metre to allow condensate to run back into the
boiler and out via the condensate drain.
The flue can be installed from inside the building, when access to the outside wall face is not practicable.
Horizontal Telescopic Flue - Rear
Diagram 9.1
Horizontal Telescopic Flue - Side
21
TELESCOPIC TERMINAL ASSEMBLY
SEALING COLLAR
TRIM RING
SECURING COLLAR
FLUE ELBOW
GASKET (fitted)
SEALING TA
PE (telescopic only)
A2043600 Top Outlet Horizontal telescopic flue pack
SCREW x 1
SCREW x 2
SCREW x 2
SCREW x 4
Diagram 9.3
9 Telescopic Flue - Length, Preparation and Installation
Diagram 9.2
22
BUTT JOINT
BUTT JOINT
9.2 Horizontal Telescopic Flue - A2043600
Refer to diagram 9.2 for kit contents.
9.3 REAR Flue
If a wall thickness is between 203mm min. to 413mm max. then the flue can be used without extensions.
With the flue elbow temporarily fitted, measure the distance from the outside wall to the butt joint, see diagram
9.4. If
the measurement ‘Y’ exceeds 525mm, then the appropriate length of extension pipe is required.
If the dimension is less than 315mm DO NOT cut the flue, it can project to a maximum of 600mm, see diagram 9.5. If this is not desirable then a Standard flue MUST be used and cut to length.
9.4 SIDE Flue
With the flue elbow temporarily fitted, measure the distance from the outside wall to the butt joint, see diagram 9.6. If the measurement ‘Y’ exceeds 525mm, then the appropriate length of extension pipe is required.
If the dimension is less than 315mm DO NOT cut the flue, it can project to a maximum of 600mm, refer to diagram 9.5, if this is not desirable then a Standard flue MUST be used and cut to length.
Diagram 9.4
Diagram 9.5
9 Telescopic Flue - Length, Preparation and Installation
Diagram 9.6
REAR FLUE
SIDE FLUE
FLUE TERMINAL
Left Hand illustrated
23
Diagram 9.7
Diagram 9.8
Diagram 9.9
9 Telescopic Flue - Length, Preparation and Installation
9.5 Flue Fitting
With the air duct seams aligned and the flue set to the required length ‘Y’, mark the securing hole position in the air duct. Drill a 3mm diameter hole at this position, take care not to pierce the inner flue duct. Secure with screw provided and tape the joint, see diagram 9.7.
Fit the sealing collar onto the locating ring on the flue terminal, see diagram 9.8.
With the flue elbow removed, push the flue assembly into the wall, externally or internally, until the end of the assembly protrudes a short way from the inside face of the wall. This will enable the internal trim ring (if required) to be positioned and allow the flue assembly to be drawn back up to the flue elbow.
Secure the flue elbow in position on top of the boiler with the four screws supplied.
Draw the flue assembly from wall and engage the flue duct into the elbow and butt fit between the air duct and flue elbow.
Check the correct alignment of the flue.
Fit the securing collar in position, mark through two of the pre drilled holes in the securing collar. Remove securing collar and drill two 3mm diameter holes one in the elbow and one in the air duct, take care not to pierce the inner flue duct. Fit the securing collar and secure with screws provided, see diagram
9.9.
Slide the internal trim ring back against the wall, securing in place with a small amount of sealant if required.
The cut ducts must be de-burred and all filings and debris removed.
Insert the flue duct into the air duct terminal assembly, remembering to engage the catch within the terminal.
NOTE: If the seals require lubricant to ease installation, do not use mineral oils or grease, only silicon grease or water is recommended.
24
WALL THICKNESS
BOILER MOUNTING WALL
OUTSIDE WALL FACE
75 min. to 553 max.
87min
112
176
NOTE. If necessary, it is permitted to increase this dimension to 600mm max.
L
FLUE
C
Max flue length 730mm
211
239
5mm min. clearance
A
A
Max. distance from outside
wall face to min clearance. LH - 485mm RH - 591mm
Min. distance from outside wall face to min clearance. LH/RH - 75mm
OUTSIDE WA
LL FACE
87min
NOTE. If necessary, it is permitted to increase this dimension to 600mm max.
INTERNAL SURFACE
Standard Horizontal Flue - Rear
9.6 Flue Length
The maximum permissable horizontal flue length is 10 metres plus the flue terminal assembly, this can be achieved by use of the accessories, see diagram 9.12.
However should an additional 90o or 2 x 45o elbows be used then the length MUST be reduced by 1metre.
The diagram 9.10 shows the length achievable by using the kit A2043400.
When extension pipes are used the flue system must be designed to have a continuous fall to the boiler of at least
2.5
o
44mm/metre to allow condensate to run back into the
boiler and out via the condensate drain.
The flue can be installed from inside the building, when access to the outside wall face is not practicable.
9 Standard Flue - Length, Preparation and Installation
Diagram 9.10
Standard Horizontal Flue - Side
25
Diagram 9.12
9 Standard Flue - Length, Preparation and Installation
SEALING COLLAR
SECURING COLLAR
FLUE ELBOW
GASKET (fitted)
A2043400 Top Outlet Standard Horizontal Concentric Flue Pack
STANDARD TERMINAL ASSEMBLY
SCREW x 2
SCREW x 2
SCREW x 4
TRIM RING
Diagram 9.11
26
BUTT JOINT
BUTT JOINT
9.7 Standard Horizontal Flue
Refer to diagram 9.11 for kit contents.
9.8 REAR Flue
With the flue elbow temporarily fitted, measure the distance from the outside wall to the butt joint, see diagram
9.13. If
the measurement ‘Y’ exceeds 665mm, then the appropriate length of extension pipe is required. The minimum dimension is 187mm to suit a 75mm min wall thickness. The flue can project to a maximum of 600mm, if this is desirable, refer to diagram 9.14.
9.9 SIDE Flue
With the flue elbow temporarily fitted, measure the distance from the outside wall to the butt joint, see diagram 9.15. If the measurement ‘Y’ exceeds 665mm, then the appropriate length of extension pipe is required. The minimum dimension for Lhd is 255 and Rhd 149 to suit a minimum wall thickness of 75mm. The flue can project to a maximum of 600mm, if this is desirable, refer to diagram 9.14.
Diagram 9.15
Left Hand illustrated
9 Standard Flue - Length, Preparation and Installation
Diagram 9.13
Diagram 9.14
REAR FLUE
SIDE FLUE
FLUE TERMINAL
27
AIR DUCT
FLUE DUCT
13mm
L
L + 11mm
L
TERMINAL CATCH
Diagram 9.16
Diagram 9.17
9 Standard Flue - Length, Preparation and Installation
9.10 Flue Fitting
Remove the flue elbow.
Separate the flue duct from the terminal by twisting to release the terminal catch, then pull out of the retaining seal, refer to diagram 9.16.
The flue duct cutting length (L + 11mm.) is shown in diagram
9.16.
The air duct should be cut at the opposite end to the terminal
The plastic flue duct MUST be cut at the opposite end to the terminal catch.
The plastic flue duct extensions MUST be cut at the opposite end to seal.
The cut ducts must be de-burred and all filings and debris removed.
Insert the flue duct into the air duct terminal assembly, remembering to engage the catch within the terminal.
NOTE: If the seals require lubricant to ease installation, do not use mineral oils or grease, only silicon grease or water is recommended.
Fit the sealing collar behind the locating lugs on the flue terminal, see diagram 9.17.
Push the flue assembly into the wall, externally or internally, initially until the end of the assembly protrudes a short way from the inside face of the wall. This will enable the internal trim ring (if required) to be positioned and allow the flue assembly to be drawn back into the flue elbow.
Secure the flue elbow in position on top of the boiler with four torque headed screws supplied.
Draw the flue assembly from wall and engage the flue duct into the elbow and butt fit between the air duct and flue elbow.
Ensuring the correct alignment of the terminal.
Fit the securing collar into position, mark through two of the pre drilled holes in the securing collar. Remove securing collar and drill two 3mm diameter holes one in the elbow and one in the air duct, take care not to pierce the inner flue duct. Fit the securing collar and secure with screws provided, see diagram 9.17.
Slide the internal trim ring back against the wall, securing in place with a small amount of sealant if required.
NOTE: If the air and flue ducts have been correctly cut to the instructions the sealing collar should fit flush with the outside wall, check this.
28
Diagram 9.18
9 Vertical Flue - Length, Preparation and Installation
9.11 Vertical flue
The vertical flue system is available as an option where the boiler position does not permit the use of the top horizontal or rear flue system.
The system is made up from accessories. The accessories include terminal assembly, bends 45º and 90º, flue extensions, fixing bracket and appropriate weather collar, see diagram 9.19.
The maximum permitted straight flue length is 10 metres plus the terminal. for each 90o or 2x45o bends fitted, the maximum length must be reduced by 1 metre, see diagram 9.18.
NOTE: 2x45º bends can replace 1x90º bend if necessary. When using 90º bends any horizontal extension pipe should be inclined by a minimum of 44mm/metre (2.5°) towards the boiler to facilitate condense removal, see (a) in diagram 9.18.
Alternatively use 45º bends to avoid horizontal runs, see (b) in diagram 9.18.
The terminal should be as shown in diagram 4.2.
Measure the distance of flue length required for the installation.
The flue must be designed with a continuous fall towards the boiler.
29
9 Vertical - Flue Length, Preparation and Installation
Diagram 9.19
Flue Terminal Installation
Refer to diagram 9.20 and secure the flue adapter in position on top of the boiler with the screws supplied, making sure the nib fits into the locating slot in the boiler casing to ensure correct orientation.
NOTE: The rubber ‘O’ rings of each section should be lubricated prior to assembly. Do not use mineral oils or grease, silicon grease or water is recommended.
Secure the first extension pipe to the flue adapter with the securing collar supplied by positioning the collar centrally over the joint, then tighten the two screws on the securing collar, see diagram 9.21.
Fit more extension pipes as required using the collar and screws supplied with each extension pipe. To fit position the collar centrally over the joint, tighten the two screws on the securing collar. Using the holes provided in the securing collar drill and insert the two self tapping srews supplied, see diagram 9.22.
The rubber ‘O’ rings of each section should be lubricated prior to assembly.
NOTE: Do not use mineral oils or grease, silicon grease or water is recommended.
When installing the flue it is recommended that it is supported every 2 metres and at every bend by a fixing bracket.
Project the rise of the flue pipe to roof level and cut a 150mm hole in the roof.
Flue Terminal Installation
(a) Pitched Roof
Fit the required pitched roof weather collar over the 150mm hole in the roof. Make good the tiling or slating around the collar incorporating the flashing of the weather collar. Position the angle cap over the weather collar in the correct orientation to attain the correct angle for your roof.
(b) Flat Roof
Fit the aluminium weather collar over the 150mm hole in the roof ensuring a weather tight seal.
From above carefully place the flue terminal through the weather collar.
Flue Terminal to Boiler Connection
Should the clearances above the boiler to roof not allow for extensions, it is permitted to cut the flue terminal ensuring the relationship of flue and air duct lengths are retained.
30
9 Vertical Flue - Length, Preparation and Installation
Diagram 9.20
Diagram 9.21
Diagram 9.22
Completion of Installation
With the flue terminal positioned in the roof the length of the final pipe can be determined. If a telescopic length cannot be used, then a standard flue length can be cut to make the correct length. Cut the flue to the desired length measuring from the ‘O’ ring end and discard the plain end of the tube. The cuts must be square and made free of burrs to allow correct assembly. (NOTE: The flue pipe is 10mm
longer than the air pipe), see diagram 9.23. Carefully push the terminal assembly upwards to allow room for fitting the final flue piece. Fit a fixing bracket to the terminal assembly. Pull the terminal assembly down and join to the flue system. Ensure that the terminal is making a weather tight seal on the weather collar. Secure the fixing bracket fitted to the terminal to the roofing struts or a purpose made batton.
Diagram 9.23
31
9 Twin Flue - Length, Preparation and Installation
Diagram 9.24
32
9 Twin Flue - Length, Preparation and Installation
9.12 Twin flue
The twin flue system is available as an option when the top horizontal or vertical flue system is not appropriate.
The system can provide an independent horizontal air inlet and flue outlet, horizontal air inlet and vertical flue outlet or vertical air inlet and flue outlet via a concentric terminal.
The system is made up from accessories, see diagram 9.25.
NOTE: The air and flue outlets do not have to be equal lengths. 2x45° bends can replace 1x90° bend if necessary.
The maximum permitted combined (air inlet + flue outlet) flue length is 40 metres plus terminal assemblies. For each 90° or 45° x 2 bends fitted, the maximum length must be reduced by 1 metre, see diagram 9.24.
NOTE: When using 90° bends any horizontal run should be inclined by a minimum of 44mm/metre (2.5°) towards the boiler to facilitate condense removal.
Alternatively use 45° bends to avoid horizontal runs in the flue pipe.
Terminal Position
The clearances for a flue outlet are given in the "Flue Location and Ventilation" section.
In addition the horizontal air inlet must not be closer than 300 mm from a flue outlet on the same wall or 1200mm from an opposing flue outlet.
Diagram 9.25
33
9 Twin Flue - Length, Preparation and Installation
Diagram 9.26
Installation Details
The parts available for a twin flue system installation are shown in diagram 9.25.
Boiler Connection
Push the twin flue adaptor onto the outlet of the boiler with the air inlet to the left hand side. Secure the adaptor to the top panel with the screws provided. Care should be taken when inserting the screw through the hole in adaptor top.
To facilitate engagement, it is recommended that the rubber ‘O’ rings are lubricated with silicone grease or water prior to assembly.
Air and Flue Pipe Installation
The air and flue pipes can now be built up from the boiler.
The flue must be designed with a continuous fall towards the boiler. If using the horizontal flue pipe or 90° bends the pipe must be inclined at 44mm/metre (2.5°)
minimum, see diagram
9.24.
Alternatively if space allows, use 45° bends in place of 90º bends.
The rubber ‘O’ rings of each section should be lubricated prior to assembly with silicone grease.
When building the flue up it is recommended that it is supported every 2 metres and at every bend by a fixing bracket.
Horizontal Terminal Installation
With due consideration to terminal clearances mentioned in Section 4.2 drill the one or two holes as required with a 90mm core drill.
Push the horizontal terminal through the wall allowing approx. 100mm to protrude outside.
Push a grey rubber wall seal onto either side of the wall ensuring that both wall seals are pushed up to the wall surface, see examples (b) and (c) diagram 9.24.
Vertical Terminal Installation
With due consideration to terminal clearances mentioned in Section 4.2, project the rise of the flue pipe to roof level and cut 150mm hole in the roof.
(a) Pitched Roof
Fit the required pitched roof weather collar over the 150mm hole in the roof. Make good the tiling or slating around the collar incorporating the flashing of the weather collar. Position the angle cap over the weather collar in the correct orientation to attain the correct angle for your roof. One way round gives a pitch of 25°-38° and the other gives 37°- 50°.
(b) Flat Roof
Fit the aluminium weather collar over the 150mm hole in the roof ensuring a weather tight seal.
Horizontal Pipes-Completion of Installation
Having built the pipe(s) from the boiler to the terminal(s), the length of the final pipe piece can be determined. Cut pipes at the opposite end to the ‘O’ ring seal making square and free from burrs. Push the horizontal terminal through the wall to engage the final pipe piece and pull back ensuring the grey wall seals are fully pulled up to the outside and inside wall faces.
Vertical Pipes-Completion of Installation
Refer to diagram 9.24.
For installation of (a), attach the twin pipe to concentric flue adaptor, part number A2011600, to the base of vertical terminal assembly. For installation of (b), attach the single pipe to concentric adaptor, part number A2011500, to the base of vertical terminal assembly.
With the vertical terminal assembly positioned in the roof, the length of the final pipe can be determined. Cut the flue to the desired length measuring from the ‘O’ ring seal end and discard the plain end of the tube. The cut end should be square and free from burrs. Carefully push the terminal assembly upwards to allow room for fitting the final flue piece(s). Fit a 100mm fixing bracket to the terminal assembly Part No2000460486. Pull the terminal assembly down and join to the flue system. Ensure that the terminal is making a weather tight seal on the weather collar. Secure the fixing bracket fitted to the terminal to the roofing struts or a purpose made batton.
34
9 Plume Management Kit
9.13 Plume Management Kit
The Plume Management Kit: Part No. A2044100 (white) or A2044000 (black) can be used to overcome many site issues.
The Plume Management Kit will fit to the Top Horizontal Telescopic, Rear Horizontal Telescopic and Standard Horizontal Flue. This enables the flue products to exhaust further away from the boiler, thereby reducing the impact of pluming.
NOTE: The flue air inlet can be sited closer to doors, opening windows and air bricks, than stated in section 4.2, see diagram 9.27.
The maximum length of the Plume Management Kit must NOT exceed 6m with a horizontal concentric flue length of 2m max.
For each 90o bend or 2 x 45o bends the maximum length of the Plume Management Kit must be reduced by 1m.
For more information contact Glow-worm, refer to page 2.
The Plume Management Kit is supplied with installation instructions.
Refer to BS5546 or BS6798 for advice on disposal of boiler condensate.
Diagram 9.27
FLUE OUTLET
FLUE PRODUCTS
AIR INLET
PLUME MANAGEMENT KIT
25mm. MIN.
AIR BRICK
OPENING WINDOW OR DOOR
50mm. MIN.
IMPORTANT: The flue outlet must not be positioned within 300mm from an opening, air brick or opening windows.
35
10 Electrical Connection
WARNING: This appliance must be earthed.
This appliance must be wired in accordance with these instructions. Any fault arising from incorrect wiring cannot be put right under the terms of the Glow-worm guarantee.
All system components must be of an approved type.
Electrical components have been tested to meet the equivalent requirements of the BEAB.
Do not interrupt the mains supply with a time switch or programmer.
Connection of the whole electrical system and any heating system controls to the electrical supply must be through a common isolator.
Isolation should preferably be by a double pole switched fused spur box having a minimum contact separation of 3mm on each pole. The fused spur box should be readily accessible and preferably adjacent to the boiler. It should be identified as to its use.
A fused three pin plug and shuttered socket outlet may be used instead of a fused spur box provided that both the plug and socket comply with the current issue of BS1363.
This boiler is suitable for installation in bathroom zones 2 and 3.
10.1 Electrical Wiring
Remove the electrical cartridge from the fittings pack.
Remove the securing screw to open the cartridge, see diagram 10.1.
NOTE: There are two screws supplied loose in the electrical cartridge, these will be required to secure the cartridge into the electrical interface housing.
Slacken the cable strain relief screws in the electrical cartridge.
Route the mains supply and system cables through the strain relief and connect to the relevant plug , see diagram 10.2.
10.2 Pump Wiring
Ensure that a seperate pump supply cable is routed through the strain relief and connected to the relevant plug, see diagram 10.2.
Slacken the cable strain relief and route the pump electrical supply cable and connect as shown in diagrams 10.1 and
10.2.
10.3 System Controls
If you are fitting the Glow-worm Options Board Kit, please refer to the instructions supplied with the kit for the system wiring.
ELECTRICAL CARTRIDGE
CABLE STRAIN RELIEF
SECURING SCREW
Diagram 10.1
36
10 Electrical Connection
10.4 Electrical Cartridge Securing
Close the cartridge and secure with the previously removed screw.
Push the electrical cartridge into the interface housing on completion of the wiring, see diagram 10.3.
Secure with the two cartridge retaining screws provided in the cartridge body.
10.5 Electrical Connections - Testing
Carry out preliminary electrical system checks as below:
1. Test insulation resistance to earth of mains cables.
2. Test the earth continuity and short circuit of cables.
3. Test the polarity of the mains.
NOTE: If you require to test the appliance refer to section 13.
Diagram 10.3
ELECTRICAL CARTRIDGE
FIXING SCREWS
Diagram 10.2
230Vac SYSTEM CONTROLS
- Zone valve
- Programmer
- Room thermostat
- Cylinder thermostat
NOTE: ALL CABLES CONNECTED TO THE APPLIANCE SHOULD BE PERMANENTLY FIXED TO THE WALL
L
N
E
PUMP
NOTE: This appliance will not operate without a link or system
controls fitted.
37
11 Commissioning
11.1 Preliminaries - All Systems
The commissioning should be carried out by a competent person in accordance with the current issue of BS6798.
DO NOT operate the boiler without water.
Make sure that the system has been thoroughly flushed out with cold water and that all cleanser, if used, has been removed.
Isolate the boiler from the mains electrical supply.
Test for gas tightness and purge air from the gas supply.
11.2 LPG Conversion
All models can be converted to run on LPG-Propane (G31). This conversion should be carried out by a competent
person as described in section 11.11.
11.3 Filling the Heating Circuit
With the gas isolation valve closed and with no demand from any external controls.
1. Fill the heating system.
Sealed system only - fill the system to a pressure of
1.0bar.
2. Vent all air from the system - repeat as neccessary until the system is full and all the air has been vented.
11.4 Initial Lighting
NOTE: If you have fitted a Glow-worm Options Board Kit,
please refer to the instructions supplied with the kit for completion of commissioning.
Do not operate the boiler without water.
Refer to diagram 11.1
1. With no demand from any external controls, switch on the electrical supply to the boiler.
Open the gas service isolation valve, see diagram 11.2.
2. Select your required function by pressing “ Mode “, scroll through your options and select one of the following:-
Central heating.
Boiler functions ALL swicthed off.
“OFF”
3. Turn ON your external controls and select the room temperature required.
The boiler will operate automatically.
NOTE: The display will indicate the Heating system water temperature or a fault code if in a fault condition.
11.5 Gas Inlet Pressure
Check the supply pressure at the gas service isolation valve test point, see diagram 8.1.
The nominal supply pressure should be 20mbar when the appliance is operating at the maximum heat input. This can be achieved by turning on several hot water taps.
NOTE: There is a pressure drop over the gas service isolation valve prior to the inlet pressure test point, this is normal and the inlet pressure to the main gas valve can be up to 2mbar less than the supply pressure to the boiler at the maximum heat input. Additionally the safe nominal maximum heat input of the appliance can be achieved at an inlet pressure down to 15mbar.
Diagram 11.1
GAS SUPPLY PIPE IN
GAS PIPE BRACKET SECURING SCREW
GAS SERVICE ISOLATION VALVE
UNION NUT
SEALING GROMMET
CONDENSE TRAP & SIPHONIC DRAIN
Diagram 11.2
MODE
PROG
SYMBOLS DISPLAYED ON THE LCD AND DESCRIPTIONS
Max burner display
Min burner display
Temperature
Appliance OFF
Central Heating Functio
n
LCD
DISPLAY
RESET
BUTTON
NOT USED
CH TEMPERATURE
ADJUSTMENT
TO
GGLE BUTTON
MODE and PROG
Glow-worm control (Optional)
Ext
System pressure - not applicable
38
11.6 Gas Rate
The gas valve is factory set for natural gas (G20) and should need no adjustment.
Should any doubt exist about the gas rate, check it using the gas meter test dial and stop watch, at least 10 minutes after the burner has lit, see diagram 11.3 for approximate rates. Make sure that all other gas burning appliances and pilot lights are off.
It should be noted that the appliance will modulate the heat input according to demand. This may affect the gas rates measured if the appliance reaches its operating temperature during the measurement.
Adjusting the gas valve requires a combustion analyser and should only be carried out by a competent person, but in the unlikely event that the gas valve needs adjusting, refer to section 12.7.
Flue Gases: If any doubt exists that the flue products are not exhausting correctly, investigate by use of a flue gas analyser (FGA).
NOTE: The burner pressure cannot be meas­ured at the gas valve as it is altered by the suction of the fan and modulated according to demand.
11.7 Heating System
Check that all external controls are calling for heat. The boiler will fire automatically. Fully open all radiator valves, flow control valve ‘A’ and bypass valve ‘B’, see diagram 5.3.
Balance the radiators as required and if fitted adjust valve ‘A’ to give the required system differential. Turn off all radiators that can be shut off by the user and check to see if less than the maximum differential allowed of 20
O
C can be achieved
across flow and return.
Allow the system to reach maximum temperature then switch off the boiler by isolating from the electrical supply.
The pump overrun will continue for 5 mins.
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.
Lock or remove the handle from control valve ‘A’ to prevent unauthorised adjustment.
11.8 Completion
Fit the base coverplate, see diagram 11.4.
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.
11.9 Instruct the User
Demonstrate, then instruct the User about the lighting procedure and heating system controls operation.
Advise that to ensure the continued efficient and safe operation of the boiler it is recommended that it is checked and serviced at regular intervals. The frequency of servicing will depend upon the installation conditions and usage, but in general, once a year should be enough.
11 Commissioning
COVER PLATE
Diagram 11.4
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.
Advise the user that, like all condensing boilers this appliance will produce a plume of condensation from the flue terminal in cool weather. This is due to the high efficiency and hence low flue gas temperature of the boiler.
Advise the user of the precautions necessary to prevent damage to the system, boiler and the building, in the event of the heating system being out of use during frost or freezing conditions.
Advise the user that the permanent mains electrical supply SHOULD NOT be switched off, as the built in frost protection and pump saver program 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.
NOTE Sealed System: Contact your installation/servicing company as draining, refilling and pressurising MUST be carried out by a competent person.
Leave these instructions and the ‘Benchmark’ Installation, Commissioning and Service Record with the user.
Diagram 11.3
4.06 143
3.02 107
2.58 91.1
2.00 70.6
1.61 57
1.29 45.6
0.67 23.8
0.56 19.8
0.56 19.8
0.53 18.7
12hxi
15hxi
18hxi
24hxi
30hxi
38hxi
GAS RATES (G20)
MIN
m3/h ft3/h
MAX
m3/h ft3/h
0.53 18.7
0.53 18.7
2.98
2.22
1.9
1.47
1.19
0.95
0.52
0.41
0.41
0.39
GAS RATES (G31)
MIN
kg/hr
MAX
kg/hr
0.39
0.39
Model
approx. after 10 mins from cold approx. after 10 mins from cold
39
GAS VALVE
OFFSET ADJUSTMENT
THROTTLE
ELECTRICAL PLUG
PRESSURE TEST POINT
11 Commissioning - Nat. Gas (G20) to LPG (G31) Conversion
11.10 LPG CONVERSION - all models
NOTE: Steps 11.1 and 11.3 will need to be completed before
the appliance can be converted.
This conversion should only be carried out by a competent
person.
During the conversion to Propane use of a suitable flue gas analyser is necessary.
As an option a chargeable boiler only commissioning service can be provided by Glow-worm Service by calling telephone No. 01773 828100.
Tools required to make the conversion are a 2mm Allen key and an electricians screwdriver.
Ensure that the appliance supply pressure = 37mbar.
(1) Access the gas valve.
(2) Refer to diagram 11.5 and turn the gas valve throttle fully clockwise.
(3) Turn the throttle anti-clockwise by the number of turns shown in the table.
(4) Ensure that the gas analyser is set to the correct fuel setting - Propane.
(5) Attach combustion analyser to the combustion test point, refer diagram 12.10.
IMPORTANT:
Remember to replace the cap on
completion of the test.
(6) Turn on the mains electrical supply and turn on the gas service isolation valve. Switch the boiler on.
(7) Ensure external controls are calling for heat (i.e, generate a hot water demand by fully opening a hot water tap. The boiler should fire automatically.
NOTE: If the appliance does not light & goes to lockout (F1) turn the throttle anti-clockwise a further turn and press the reset button. The appliance will (after a short delay) again attempt to fire. Repeat this procedure (up to a total of 2 extra turns on the throttle screw) until the appliance lights. PLEASE NOTE several ignition attempts may be needed, to purge gas through the appliance, before a successful ignition is achieved.
(8) Check and adjust the burner %CO
2
at maximum rate.
Press the “reset” button on the controls fascia, release and immediately press and hold in the “+” button. After approximately 5 seconds “Hi” will be displayed. Pressing the mode button when “Hi” is selected will force the boiler to maximum rate, the display will flash between “Hi” and the “default display” this will indicate the boiler has been forced to maximum.
(9) Adjust, if necessary, the burner % CO
2
to the value shown in the “SETTING” column of the table, with the throttle screw, see diagram 12.5(rotate anti-clockwise to increase).
(10) To exit the check sequences press the “mode” and “+” buttons simultaneously, this will reset the boiler to the default display.
(11) Check the burner % CO
2
, at minimum rate, to the value
shown in the “SETTING” column of the table.
(12) If adjustment is required, press the “reset” button on the controls fascia, release and immediately press and hold in the “+” button. After approximately 5 seconds “Hi” will be displayed. Pressing the “+” or “-” buttons will cycle between “Hi” and “Lo”. Pressing the mode button when “Lo” is selected will force the boiler to minimum rate, the display will flash between “Lo” and the “default display” this willindicate the boiler has been forced to minimum.
Diagram 11.5
(13) Adjustment of the %CO2 is very coarse so carefully adjust the %CO
2
to the value shown in the “SETTING” column of the table with the offset adjustment, see diagram 12.5 and %CO
2
Table (Rotate clockwise to
increase).
(14) To exit the function press the “mode” and “+” buttons simultaneously, this will reset the boiler to the default display.
(15) Repeat (8) and check CO
2
at maximum rate - adjust if
necessary.
Please remember after finishing this procedure to turn off the hot water tap.
(16) Remove analyser probe from the test point and replace the cap. Refit the control panel.
(17) IMPORTANT: Fit the LPG conversion label supplied
in the documentation pack to the inner front panel alongside the data label. Refit the inner door and outer door.
(18) Continue commissioning from 11.6.
MODEL
12hxi
15hxi
18hxi
24hxi
30hxi
38hxi
G31 BURNER % CO2
CHECK
(case on)
SETTING
(case off)
9.2 to 10.2
9.8 to 10.8
9.2 to 10.2
9.2 to 10.2
10.0 to 11.0
9.2 to 10.2
10.1
10.1
10.1
10.1
10.5
9.8
+ 0.0
- 0.8
+ 0.5
- 0.5
+ 0.0
- 1.0
+ 0.3
- 0.8
+ 0.3
- 0.8
+ 0.2
- 0.8
Throttle
TURNS
5
5
5
5
5
8
4
4
40
12 Servicing
12.1 General Inspection
Before servicing inspect the following:
1. condition of case and flue.
2. flue terminal for obstructions.
3. electrical supply connections.
4. water connections.
5. gas connection.
6. system pressure.
correct any fault before continuing.
12.2 Functional Checks
With the appliance operational carry out the following:
COMBUSTION
CHECK - with a flue gas analyser as described in
section 12.7.
If
NO flue gas analyser is available, it will be necessary
to remove the front and inner casing panels, diagram
12.1 and taking care not to touch any internal components, check the flame picture through the viewing window, diagram 12.2.
If the flame shows signs of lift, sooting or appears yellow, it will be necessary to service the burner and heat exchanger as described in paragraphs 12.5 and
12.6.
If the servicing does not correct the condition a flue gas analyser will have to be used as described in paragraph
12.7.
However should the flame indicate correct combustion it will not be necessary to service the heat exchanger and burner.
GAS RATE
CHECK - the gas rates, see table on page 38.
If you cannot measure the gas rate it is acceptible to measure the combustion rate as described in section
12.7. However if you do not have either facility then the appliance
MUST be turned off and disconnected until
such equipment is available.
If the gas rate requires adjustment you MUST NOT adjust the gas valve without a gas analyser, refer to section 12.7.
CASING PANEL
INNER CASING PA
NEL
SECURING SCREWS (2 OFF)
SECURING SCREWS
Diagram 12.1
VIEWING WINDOW
IMPORTANT NOTES:
1. To ensure the continued efficient and safe operation of the boiler it is recommended that it is checked and serviced at regular intervals. The frequency of servicing will depend upon the particular installation and usage, but in general once a year should be enough.
2. It is the Law that any servicing is carried out by a
competent person.
3. Before commencing with a service or replacement of parts the boiler should be isolated from the electrical supply and the gas supply should be turned off at the gas isolation valve.
4. When replacing a part on this appliance, use only spare parts that you can be assured conform to the safety and performance specification that we require. Do not use reconditioned or copy parts that have not been clearly authorised by Glow-worm.
5. 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 section 13.
6. On completion the “Benchmark” Service Record should be completed.
Diagram 12.2
41
EARTH LEAD
SECURING SCREW (2 OFF)
SPARK ELECTRODE
HEAT EXCHANGER
GASKET
SPARK GAP
3.5 to 4.5mm
Diagram 12.5
12 Servicing
12.3 Servicing
Note: If the Combustion & Gas rate checks did not
require adjustment then it will not be necessary to service the Combustion Chamber, Heat Exchanger or Burner. Complete this section, 12.4 and then proceed to
12.9.
All routine servicing requirements can be achieved by the removal of the front and inner panels, see diagram 12.1.
Position the control box into the service position, see diagram 12.3.
Before commencing with a service or replacement of parts. The boiler should be isolated from the electrical and gas supplies. Remove the base cover, diagram 11.2 to gain access to the gas service isolation valve, see diagram 12.4.
12.4 Spark Electrode
Disconnect the spark electrode plug and earth lead. Remove the two securing screws and withdraw the spark electrode carefully from the combustion chamber, see diagram 12.5.
Inspect the tips for damage.
Clean away any debris and check the spark gap is 3.5 to 4.5 mm.
Check the electrode gasket for signs of damage and replace if necessary.
NOTE: If the burner is not to be serviced, do not perform the following instructions 12.5, 12.6, 12.7 and 12.8 but continue to section 12.9 to complete the servicing.
Diagram 12.4
Diagram 12.6
SECURING SCREW (4 OFF)
CHASSIS FRONT
CONTROL BOX SERVICE POSITION
Diagram 12.3
GAS SUPPLY PIPE IN
GAS PIPE BRACKET SECURING SCREW
GAS SERVICE ISOLATION VALVE
UNION NUT
SEALING GROMMET
CONDENSE TRAP & SIPHONIC DRAIN
42
12 Servicing
12.5 Burner
NOTE: If the functional checks did not indicate poor combustion then it is not necessary to service this component.
The following procedure will require that you replace the burner door seal and nyloc nuts.
Remove the two gas pipe bracket securing screws from underside of inner case, see diagram 12.4.
NOTE: When replacing ensure that the sealing grommet,
situated below the gas valve is correctly re-seated.
Disconnect the gas valve electrical plug at the gas valve, see diagram 11.3.
Disconnect the electrical plug from the fan.
Disconnect the spark electrode plug and earth lead, refer to diagram 12.5.
Remove the five combustion chamber/burner door securing nuts, these should be discarded and replaced with the new nylocs nuts, see diagram 12.7, supplied in the burner door seal kit.
Gently remove the fan, gas valve and burner assembly from the combustion chamber.
Clean the burner with a soft brush taking great care not to damage the front insulation. DO NOT use wire or sharp instruments to clean the holes of the burner.
Inspect the burner for any signs of damage.
Remove and discard the burner door seal and replace with new, see diagram 12.7.
NOTE: Removal of the burner is not necessary during a
normal service, but if it is removed it will require a new
gasket, see diagram 12.8.
BURNER
FRONT
INSULATION
GASKET
SECURING SCREW
(4 OFF)
SPARK ELECTRODE
Diagram 12.8
12.6. Combustion Chamber and Heat Exchanger.
NOTE: If the functional checks did not indicate poor combustion then it is not necessary to service this component.
Remove loose debris from combustion chamber using a soft brush and vacuum cleaner.
Carefully flush by spraying water any remaining debris through the condensate trap (Ensure the water is kept away from electrical components).
BURNER
GAS PIPE BRACKET AND SEAL
GAS VALVE
FAN
NYLOC SECURING NUTS (5 OFF)
COMBUSTION CHAMBER
SECTION THROUGH BURNER DOOR SHOWING POSITION OF SEAL
SEAL
Diagram 12.7
43
FLUE ELBOW
COMBUSTION ANALYSER SAMPLE
POINT
VERTICAL FLUE ADAPTOR
12 Servicing
12.7 Combustion Check
With the appliance operational connect the CO2 combustion analyser to the test point, see diagram 12.10.
IMPORTANT:
Remember to replace the cap on
completion of the test.
Check the burner % CO
2
at maximum rate is as shown in the “CHECK” column of the table and if the reading falls within the tolerance, disconnect the analyser, fit the test point cap and return to functional checks - gas rate.
If adjustment is required remove the front and inner casing panels, see diagram 12.1. Taking care not to touch any internal components, proceed as follows:
Press the “reset” button on the controls fascia, release and immediately press and hold in the “+” button. After approximately 5 seconds “Hi” will be displayed. Pressing the mode button when “Hi” is selected will force the boiler to maximum rate, the display will flash between “Hi” and the “default display” this will indicate the boiler has been forced to maximum.
Adjust the %CO2 to the value shown in the “SETTING” column of the table with the throttle, see diagram 11.3. (Rotate anti-clockwise to increase).
To exit the check sequences press the “mode” and “+” buttons simultaneously, this will reset the boiler to the default display.
Check the burner %CO
2
at minimum rate is as shown in the
“CHECK” column of the table.
Press the “reset” button on the controls fascia, release and immediately press and hold in the “+” button. After approximately 5 seconds “Hi” will be displayed. Pressing the “+” or “-” buttons will cycle between “Hi” and “Lo”. Pressing the mode button when “Lo” is selected will force the boiler to minimum rate, the display will flash between “Lo” and the “default display” this will indicate the boiler has been forced to minimum.
Adjustment of the %CO2 at minimum rate is very coarse so carefully adjust the %CO2 to the value shown in the “SETTING” column of the table with the offset adjustment, see diagram 11.3 (Rotate clockwise to increase).
To exit the function press the “mode” and “+” buttons simultaneously, this will reset the boiler to the default display.
12.8 Gas Rate Adjustment
This appliance incorporates a pre-mix burner and cannot be adjusted, however, it is acceptible to set the combustion rate with a flue gas analyser as described in section 12.7.
12.9 Inner Casing Panel Seal check
Check the condition of the seal, if worn or damaged remove the seal and thoroughly clean the casing surface before fitting the new seal, see diagram 12.11.
Refit the inner casing panel.
NOTE: Ensure the seal is fitted correctly giving an airtight joint.
12.10 Service Completion
On completion of the service the “Benchmark” Service Record should be completed.
Diagram 12.10
INNER CASING PA
NEL
FRONT CASING PA
NEL
SEAL
Diagram 12.11
Diagram 12.9
MODEL
12hxi
15hxi
18hxi
24hxi
30hxi
38hxi
G31 BURNER % CO2
CHECK
(case on)
SETTING
(case off)
9.2 to 10.2
9.8 to 10.8
9.2 to 10.2
9.2 to 10.2
10.0 to 11.0
9.2 to 10.2
10.1
10.1
10.1
10.1
10.5
9.8
MODEL
12hxi
15hxi
18hxi
24hxi
30hxi
38hxi
G20 BURNER % CO2
CHECK
(case on)
SETTING
(case off)
8.5 to 9.6
8.5 to 9.6
8.5 to 9.6
8.5 to 9.6
8.5 to 9.6
8.5 to 9.3
9.1
9.1
9.1
9.1
9.1
8.8
44
13 Fault Finding
13.1 Preliminary fault finding
The following checks should be performed before proceeding onto specific diagnostics:
• 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 installer interface, refer to section 10.3 for access and diagram 13.3.
•Check the electrical installation and carry out tests for, earth continuity, polarity, short circuit and resistance to earth, using a suitable multimeter.
An Aid to Test
To access the connector plug and pins remove the front casing panel, see diagram 13.1 and the control panel securing screw then lower into service the position.
Remove the rear panel by prising the retaining clips, see diagram 13.1.
• Check the electrical supply of 230v is present at L and N terminals, position X17 on the main PCB and chassis earth at a bare metal point on the boiler, see diagram 13.2.
• Check that there is a gas supply to the boiler and the gas service isolation valve is turned on, see diagram 11.2.
• Check pressure at the gas service isolation valve, refer to section 11.5.
• Check that the heating system pressure indicates at least 1mb, if not, fill and vent the system as described in section
11.3.
• Check that all external controls are on.
• Check the functional flow diagram, 13.5.
13.2 Fault Codes
Fault codes take priority over all other display functions in the event of a fault occuring, see diagram 13.6.
If multiple faults occur the codes will be displayed for approx. 2 seconds, alternatively.
13.3 Fault Memory
The Fault memory stores details of the ten most recent faults.
To access this menu, refer to diagram 13.3
a) Press and hold ‘MODE’ for 5 seconds.
b) When the display shows a flashing ‘0’ press ‘MODE’
button.
c) Press a ‘+’ button to scroll back through the fault memory (Position 1 is most recent), see fault memory display.
To exit this menu, press the ‘MODE’ button.
13.4 Diagnostic Menu
The Diagnostic Menu provides the ability to view and change certain parameters. See diagram 13.7 for available parameters.
13.5 Status Codes
The status codes provide information about the current operating condition of the boiler and can be accessed through the diagnostic display, refer to diagram 13.8.
Diagram 13.1
REAR PANEL
CHASSIS FRONT
CONTROL BOX SERVICE POSITION
SECURING SCREW
CLIPS
Diagram 13.2
MAIN PCB BOARD
N
L
230Vac 50Hz LIVE (PIN 3) AND NEUTRAL (PIN 1) TEST POINT AT MAIN PCB BOARD POSITION X17
230V
X 1 7
X17
24
X1
9
Indicates fault memory position
Fault code
Fault memory display
Diagram 13.3
45
13 Fault Finding
Diagram 13.4
r
br
b
g/y
br
b
g/y
g/y
g/y
br
b
g/y
w
bk
bk
b
bk
r
bk
r
bk
b
br BROWN b BLUE g/y GREEN/YELLOW gy GREY bk BLACK y YELLOW
w WHITE
r RED
KEY
w
gy
b
y
w
r
46
Diagram 13.5
CENTRAL HEATING
13 Fault Finding
47
13 Fault Finding
Diagram 13.6
Fault Codes
48
13 Fault Finding
Diagram 13.6
Fault Codes (continued)
49
13 Fault Finding
Diagnostic Menu
The Diagnostic Menu provides the ability to view and change certain parameters. See Diagram 13.7 for available parameters.
To enter the diagnostic menu:
a) Press and hold the ‘MODE’ button for 5 seconds. The display will change to flashing ‘
0’.
b) Use the ‘+’ or ‘-’ buttons to scroll to
96 (This is
the installer level access password).
c) Press ‘MODE’ to confirm, see diagnostic display 1.
Use the ‘+’ or ‘-’ buttons to view the appropriate diagnostic number, see diagram 13.7.
If necessary the values can be changed by:
a) Pressing the ‘MODE’ button.
b) The diagnostic value flashes, see diagnostic display 2.
c) Use the ‘+’ and ‘-’ buttons to cycle through available values.
d) The change is saved by pressing ‘MODE’ once more.
(NOTE: Only certain parameters can be adjusted)
To exit the diagnostic menu press and hold the ‘MODE’ button for 5 seconds.
Diagnostic value
Diagnostic number
Diagnostic display 1
Diagnostic display 2
50
Diagram 13.7
Indicates read and write function - all other diagnostics are read only
Diagnostic Menu - Level 1 Installer Access
13 Fault Finding
d.99 State List (see diagram 14.8)
d.28 Option Relay 2 Reserved for future use
d.27 Option Relay 1 Reserved for future use
d.91 Internal Programmer type 0:24 hour (default) 1:7 day
d.92 Enable/Disable Internal Programmer 0: CH Off, DHW Off (default) 1: CH Off, DHW On 2: CH On, DHW Off 3: CH On, DHW On
Tank temperature
Flow temperature setpoint
Description Range
-99 will be displayed. Reserved for future use.
intelligent control
Sta
tus additional heating pump (option)
Sta
tus central heating pump
> 80 no flame < 40 good flame
Minutes
External intelligent control connected
51
Central heating mode (Priority 3) Description
S.00 no heating required S.01 fan pre-run S.02 pump pre-run S.03 ignition S.04 burner on S.05 pump / fan overrun S.06 fan overrun S.07 pump overrun S.08 Anti cycling period
Check flow & return thermistor connections to pipes. Check harness connection to thermistor. Check harness wires are not trapped between any internal components.
Check flow & return thermistor connections to pipes. Check harness connection to thermistor. Check harness wires are not trapped between any internal components.
Special cases of status messages
S.30 No Heating demand from external controls 230V Check wiring in external controller.
Check wiring at Installer Interface.
S.31 summer mode Check CH setpoint / Check external controls S.32 Fan speed variation too high Check fan connection. – waiting during blocking function S.34 frost protection active (Priority 4) Temperature below 8O C - check thermistor
connection if this is not true. S.42 Accesory Module is blocking burner operation Check accessory module. S.53 waiting time: temperature difference flow
- return sensor too high (Check thermistor fit)
S.54 waiting time: no water in system, temperature (gradient error) rise flow / return sensor too high
S.76 Waiting period – pressure sensor Check system pressure - default display. S.96 Return-Sensor check is running, demand Check return thermistor connection to pipe. (DHW or heating) is blocked Check harness connection to thermistor. S.98 Flow/Return-Sensor check is running, Check flow & return thermistor connections to pipes. demand (dhw or heating) is blocked Check harness connection to thermistor. Check harness wires are not trapped between any internal components.
NORMAL OPERATING STATE FOR CENTRAL HEATING
Diagram 13.8
STATE LISTS
State list - Accessed through Diagnostic Codes - Level 1, Installer Access d.99
13 Fault Finding
52
14 Replacement of Parts
14.1 General
IMPORTANT: The replacement parts described in sections
14.5 to 14.9 and section 14.12, will require the removal of the burner module assembly and the replacement of the burner door seal and self locking nuts.
Replacement parts that have associated components that need replacing on removal, i.e. ‘O’ ring, seals, gasket, etc., will be supplied and should be fitted.
Replacement of parts must be carried out by a competent person.
Before replacing any parts of the boiler it should be isolated from the mains electric supply and the gas should be turned off at the gas service isolation valve on the boiler, see diagram 12.4.
Unless stated otherwise parts are replaced in the reverse order to removal.
After replacing any parts always test for gas tightness and if necessary carry out functional test of the controls.
Boiler Access
For replacement of parts the front casing and the inner casing panel of the boiler will need to be removed. To remove undo the two screws on the underside of the front casing and lift off. Undo the two screws on the front of the inner front panel and lift off.
The side panels can be hinged sideways and removed to aid replacement of parts.
To hinge a side panel undo and remove the three screws securing each side panel to the boiler, two at the front and one at the top.
14.2 Spark Electrode
For access, refer to section 14.1.
Refer to section 12.4 for removal.
14.3 Igniter Unit
For access, refer to section 14.1.
Remove ignition lead and electrical connections then remove igniter unit by removing two securing screws, see diagram
14.1.
14.4 Ignition Lead
For access, refer to section 14.1.
Refer to diagram 12.5 and 12.6.
Pull the spark plug style connector off the spark electrode and the spade connector connected to the igniter unit.
14.5 Gas Valve
For access, refer to section 14.1.
Refer to section 12.5 for removal of the fan, gas valve and burner assembly.
Before removing the gas valve note its position on the fan.
Remove the three securing screws, which fix the gas valve and plastic swirl plate to the venturi on the fan, see diagram
14.2.
Diagram 14.1
IGNITION LEAD
ELECTRICAL CONNECTIONS PLUG
IGNITER UNIT
SPADE CONNECTOR
IGNITER SECURING SCREWS (2)
BRACKET
IGNITER BRACKET SECURING SCREW
VENTURI PLATE
SECURING SCREW (3)
Diagram 14.2
Withdraw the gas valve.
After re-fitting check the combustion CO
2
and adjust if
necessary, refer to section 12.7.
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”.
53
SECURING SCREW (2)
GAS MANIFOLD
14 Replacement of Parts
14.6 Fan
For access, refer to section 14.1.
Refer to section 12.5 for removal of the fan, gas valve and burner assembly.
Remove the gas valve as described in the relevant parts of section 14.5.
Remove the venturi plate secured with three screws, see diagram 14.2, and remove the two screws securing the fan to the gas manifold.
Check the gasket and replace if necessary.
NOTE: The 30hxi and 38hxi fan is secured through an extension piece with two securing screws, check and replace any seals or gaskets if necessary.
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”.
14.7 Burner
For access, refer to section 14.1.
Refer to section 12.5 for removal of the fan, gas valve and burner assembly.
Refer to section 12.5 for removal of the burner module.
Remove the four screws that secure the burner, see diagram
12.8.
NOTE: The burner will require a new gasket when refitted.
14.8 Front Insulation
For access, refer to section 14.1.
Refer to section 12.5 for removal of the fan, gas valve and burner assembly.
Refer to section 12.5 for removal of the burner module.
Remove spark electrode, see section 12.4.
Remove burner as described in section 14.7, refer to diagram
12.8.
NOTE: The burner will require a new gasket when refitted.
14.9 Rear Insulation
For access, refer to section 14.1.
Refer to section 12.5 for removal of the fan, gas valve and burner assembly.
Refer to section 12.5 for removal of the burner module.
Remove securing screw and washer in the centre of the insulation and withdraw insulation, see diagram 14.4.
14.10 Viewing Window
For access, refer to section 14.1.
Refer to diagram 14.5.
Remove circlip.
Remove steel washer.
Remove glass.
Remove fibre washer.
Replace in reverse order.
Diagram 14.3
SECURING SCREW
HEAT EXCHANGER
WASHER
REAR INSULATION
Diagram 14.4
FIBRE WASHER
GLASS
STEEL WASHER
CIRCLIP
Diagram 14.5
54
CONDENSE HOSE SECURING CLIP
HEAT EXCHANGER
14 Replacement of Parts
14.11 Condensate Trap and Siphonic Drain
For access, refer to section 14.1.
Refer to diagram 14.6.
Remove the igniter unit as described in section 14.3 to improve accessibility.
Remove the securing clip from the heat exchanger adapter, then disconnect the adapter and flexible hose.
Lift the siphon adapter and hose out of the condensate trap and siphonic drain, do not disconnect the hose.
Disconnect the the drain connection.
Slacken to disengage but do not remove the the two securing screws.
The condense trap will contain water, lift taking care not to spill the water.
After replacement and before fitting the adapter fill the trap with water.
Cleaning
Remove the condense trap as previously described.
Remove the float to clean it.
Remove any solids found.
Flush water through the trap to remove any remaining solids.
Check for any debris in the outlet hose of the condensate drain and clean as necessary.
14.12 Heat Exchanger
Refer to Manual Handling section.
For access, refer to section 14.1.
Refer to section 12.5 for removal of the fan, gas valve and burner assembly.
Drain the boiler.
Remove the securing clip from the heat exchanger adapter then disconnect the adapter and flexible hose.
Undo the two nuts of the flow and return pipes from the heat exchanger.
Move the hoses away from the heat exchanger.
Loosen the three heat exchanger securing screws and clamps (two at the top and one at the bottom) to remove the heat exchanger, see diagram 14.8.
CAUTION: There will be water in the heat exchanger.
Remove condense pipe connector from bottom of heat exchanger.
Carefully ease heat exchanger out.
SECURING SCREWS AND CLAMPS
Diagram 14.6
CONDENSATE TRAP AND SIPHONIC DRAIN
SCREW
FLOAT
ADAPTER
Diagram 14.7
Diagram 14.8
55
14 Replacement of Parts
14.13 Flue Hood
For access, refer to section 14.1.
Remove heat exchanger as described in section 14.12.
Remove the two securing screws and pull the flue hood down and away from the flue hood bracket and flue elbow, see diagram 14.9.
14.14 Heating Flow Thermistor
For access, refer to section 14.1.
Refer to diagram 14.10.
Remove the electrical connections from the thermistor.
Remove the retaining clip from the flow pipe.
NOTE: When reconnecting, the polarity of the wiring to thermistors is not important.
14.15 Heating Return Thermistor
For access, refer to section 14.1.
Refer to diagram 14.10.
Remove the electrical connections from the thermistor.
Remove the retaining clip from the return pipe.
NOTE: When reconnecting, the polarity of the wiring to thermistors is not important.
SECURING SCREWS
FLUE HOOD
FLUE HOOD BRACKET
Diagram 14.9
Diagram 14.10
RETURN THERMISTOR
RETURN PIPE
DRAIN POINT
FLOW PIPE
FLOW THERMISTOR
56
14 Replacement of Parts
14.16 Access User Interface and Main PCB
For access, refer to section 14.1.
Remove control box retaining screw, see diagram 14.11.
Hinge down the control box.
Release the control box cover by carefully pressing the four retaining latches, see diagram 14.11.
14.17 Main PCB
IMPORTANT: When replacing the board refer to instructions
supplied with the replacement.
For access, refer to section 14.16.
Remove the electrical connections to the PCB.
Ease back the four PCB retaining clips and withdraw the PCB from the retaining lugs, see diagram 14.12.
When refitting the rear panel ensure the leads are not trapped.
When replacing the board refer to instructions supplied with the replacement.
14.18 User Interface
IMPORTANT: When replacing the board refer to instructions
supplied with the replacement.
Refer to section 14.16 for access.
Remove main PCB, refer to section 14.17.
Remove electrical connection.
Gently ease back the retaining clips, see diagram 14.13.
Withdraw the board.
14.19 Fuse, Main PCB - Control Box
For access, refer to section 14.16.
The fuse is located at top left hand side of the PCB, see diagram 14.12.
14.20 Control Box
For access, refer to section 14.16.
Remove relevant plugs and connectors, refer to wiring diagram 13.2.
Withdraw grommets and leads so they are hanging loose.
Unthread the retaining cord and remove the control box by drawing it outwards away from its retaining slots, see diagram 14.11.
14.21 Inner Casing Panel Seal
For access, refer to section 14.1.
Refer to diagram 12.9.
Remove the inner casing panel.
To replace remove the old seal, thoroughly clean the casing surfaces. Fit the new seal, it is supplied to the correct length.
Refit the inner casing panel.
NOTE: Ensure the seal is fitted correctly giving an airtight joint.
Diagram 14.12
Diagram 14.13
USER INTERFACE BOARD
RETAINING CLIPS
ELECTRICAL CONNECTION
Diagram 14.11
CHASSIS FRONT
CONTROL BOX SERVICE POSITION
RETAINING LATCHES (4)
RETAINING SCREW
CONTROL BOX COVER
RETAINING CORD
RETAINING
CLIPS (4 OFF)
FUSE
MAIN PCB
RETAINING
LUGS
230V
57
15.1 Spare Parts
When ordering spare parts, contact Glow-worm’s own service organisation using the telephone number on the inside front cover of this booklet. Please quote the name of the appliance and serial number, to be found on the data label. If ordering from British Gas also quote the G.C. number of the part.
15 Spare Parts
Key No. Part No. Description GC Part No.
1 2000802463 Burner - 12, 15, 18hxi * 1 2000802662 Burner - 24, 30, 38hxi * 2 801655 Igniter * 3 0020023825 Main P.C.B. * 4 0030037309 Fan * 5 0020038061 User Interface * 6 2000802664 Gas valve - 12, 15, 18, 24, 30hxi * 6 802172 Gas valve - 38hxi * 7 00200220781 NTC * 8 2000802462 Electrode * 9 801635 Burner Door Seal Kit *
1
7
2
6
4
3
5
8
9
Diagram 15.1
58
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
Recommend 2 person lift or 1 person with use of sack truck. If 1 person is performing lift, straddle the load, tilt and place carton into position on truck. Recommend secure appliance onto truck with suitable straps. Ensure safe lifting techniques are used – keep back straight – bend using legs. Keep load as close to body as possible. If 2 persons performing lift, ensure co-ordinated movements during lift. Always use assistance if required.
Carriage of carton from point of delivery to point of installation – ground floor.
Recommend 2 person lift or 1 person with use of sack truck. If 1 person is performing lift, straddle the load, tilt and place carton into position on truck. Recommend secure appliance onto truck with suitable straps. Ensure safe lifting techniques are used – keep back straight – bend using legs. Keep load as close to body as possible. If 2 persons performing lift, ensure co-ordinated
movements during lift. Clear the route before attempting the lift. If removing boiler from truck straddle the load and tilt forwards to facilitate secure grip. Ensure safe lifting techniques are used – keep 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 – first or higher floor, 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/side
­ways. 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, flooring and adequate lighting are pro
­vided 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 flooring, lighting and other factors, and appropriate measures taken.
Unpacking of appliance from carton.
Recommend 2 persons unpack appliance from carton. Always keep working area clear. Cut the carton straps, lift carton up and slide over polystyrene end packs. Remove top polystyrene pack with fittings.
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 firm grip on front and sides of appliance, lift upwards, ensure stable balance achieved and lift upwards to position in place on bracket. Ensure safe lifting techniques are used – keep back straight – bend using legs - when lifting load from floor level. Do not twist – reposi­tion feet instead. Keep boiler as close as possible to body through
­out 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 firm grip on front and sides of appliance, lift upwards, onto worktop if prac
­ticable. Ensure stable balance achieved and lift upwards to position in place on bracket. If 2 persons positioning onto bracket obtain firm grip at front and sides/base of boiler. Ensure co-ordinated movements during 2 person lifts to ensure equal spread of weight of load. Ensure safe lifting techniques are used – keep back straight – bend using legs - when lifting load from floor level. Do not twist – reposition feet instead. Keep boiler as close as possible to body throughout lift to minimise strain on back. Avoid upper body/top heavy bending - do not lean forward/sideways. Always use assistance if required. Rec­ommend wear suitable cut resistant gloves with good grip to protect against sharp edges and ensure good grip when handling appliance.
Positioning of Appliance for Final Installation – within compart
­ment etc. restricting installation.
Recommend 2 persons lift appliance to position into place, space permitting. Fit bracket securely onto wall before lifting appliance into position. Obtain firm grip on front and sides of appliance, lift upwards, onto worktop if practicable. Ensure stable balance achieved and lift upwards to drop into place onto bracket. If 2 persons positioning onto bracket obtain firm grip at front and sides/base of boiler. Ensure co­ordinated movements during 2 person lifts to ensure equal spread of weight of load. If 1 person positioning onto bracket recommend obtain firm grip supporting base of boiler. Ensure safe lifting techniques are used – keep back straight – bend using legs - when lifting load from floor level. Do not twist – reposition feet instead. Keep boiler as close as possible to body throughout lift to minimise strain on back. Always use assistance if required. Recommend wear suitable cut resistant gloves with good grip to protect against sharp edges and ensure good grip when handling appliance.
Positioning of Appliance for Final Installation – in roof space re
­stricting installation.
Recommend 2 persons lift appliance to position into place, space permitting. Fit bracket securely onto wall before lifting appliance into position. Obtain firm grip on front and sides of appliance, lift upwards, ensure stable balance achieved and lift upwards to drop into place onto bracket. If 2 persons positioning onto bracket obtain firm grip at front and sides/base of boiler. Ensure co-ordinated movements dur
­ing 2 person lifts to ensure equal spread of weight of load. If 1 person positioning onto bracket recommend obtain firm grip supporting base of boiler. Ensure safe lifting techniques are used - keep back straight – bend using legs - when lifting load from floor level. Do not twist – reposition feet instead. Keep boiler as close as possible to body throughout lift to minimise strain on back. Always use assistance if re
­quired. Recommend wear suitable cut resistant gloves with good grip to protect against sharp edges and ensure good grip when handling appliance. It is recommended a risk assessment of the roof space area be carried out before moving the appliance into the area to take into account access, stability of flooring, lighting and other factors, and appropriate measures taken.
16 Manual Handling
59
60
Because of our constant endeavour for improvement, details may vary slightly from those shown in these instructions.
0020020819-02 02.07
Glow-worm, Nottingham Road, Belper, Derbyshire. DE56 1JT
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