Glow-worm Ultracom cxi User Manual

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Ultracom cxi

Installation and Servicing

24cxi

G.C. No. 47-019-01

30cxi

G.C. No. 47-019-02

38cxi

G.C. No. 47-019-03

High Efﬁciency

Condensing Combination

Boilers

www.glow-worm.co.uk

Guarantee Registration

Thank you for installing a new Glow-worm appliance in your home.

Glow-worm appliances are manufactured to the very highest standard so we are pleased to offer

our customers a Comprehensive Guarantee.

This product is guaranteed for 24 months from the date of installation or 30 months from the date

of manufacture, whichever is the shorter, for parts 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 competent

person approved at the time by the Health and Safety Executive,

in accordance with the manufacturer’s recommendations. We strongly recommend regular

servicing of your gas appliance, but where the condition is not met, any chargeable spare parts or

components issued within the applicable guarantee period still benet from a 12 month warranty

from the date of issue by the manufacturer.

We recommend you complete and return as soon as possible your guarantee registration card.

If your guarantee registration card is missing you can obtain a copy or record your registration by

telephoning the Glow-worm Customer Service number 01773 828100.

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

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

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.

CONTENTS DESCRIPTION SECTION PAGE

Warnings 4 Important Information 4

INTRODUCTION

Statutory Requirements 5 Boiler Design 6 Safety Devices 6 Servicing, Maintenance and Spare Parts 6

Boiler Specication 1 7 Boiler Dimensions & Hydraulic Schematic 2 8 Boiler Location, Clearances and Ventilation 3 9 Flue Options and Terminal Clearances 4 10

INSTALLATION

Water System 5 12 Installation Preparation 6 14 Boiler Fixing 7 16 Gas/Water Connections 8 16 Safety Discharge Valve and Condensate Connections 9 18 Flue Length Preparation and Installation 10 20 Electrical Connection 11 36 Commissioning 12 38

MAINTENANCE

Servicing 13 42 Fault Finding 14 46 Replacement of Parts 15 54 Spare Parts 16 64 Manual Handling 17 66 Declaration of Conformity 18 67

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

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 approved at the time by the Health and Safety Executive in accordance with the current issue of these regulations.

Control of Substances Hazardous to Health

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

Insulation Pads

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

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 17 for more information. The handling of the boiler may involve lifting, pushing and pulling, the use of a sack truck may be required. The following handling techniques and precautions should be considered:

- Grip the boiler at its base

- Be physically capable

- Use safety clothing where appropriate, e.g. gloves, safety footwear. Ensure safe lifting techniques are used

- Keep back straight.

- Avoid twisting at the waist.

- Avoid upper body/top heavy bending.

- Always grip using the palm of the hand.

- Use designated hand holds.

- Keep load as close to body as possible.

- Always use assistance if required.

Electrical Supply

The boiler MUST be earthed.

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

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

The boiler MUST be connected to a permanent 230V ac, 50Hz supply. Connection of the whole electrical system of the boiler, including any heating controls, to the electrical supply MUST be through one common isolator and must be fused 3 Amp maximum. Isolation should be by a double pole switched fused spur box, with a minimum gap of 3mm for both poles. The fused spur box should be readily accessible and preferably adjacent to the appliance. It should be identied as to its use. Alternatively connection can be made through an unswitched shuttered socket and 3A fused 3-pin plug both to the current issue of BS 1363, provided they are not used in a room containing a bath or shower. Wiring to the boiler must be PVC 85OC insulated cable, not less than 0.75mm2 (24/0.20mm).

Testing and Certication

This boiler is tested and certicated 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 certication, boiler warranty and may also infringe the current issue of the statutory requirements.

Statutory Requirements

CE Mark

This boiler meets the requirements of Statutory Instrument, No. 3083 The Boiler (Efciency) Regulations, and therefore is deemed to meet the requirements of Directive 92/42/EEC on the efciency requirements for new hot water boilers red with liquid or gaseous fuels. Type test for purposes of Regulation 5 certied by: Notied body 0087. Product/production certied by: Notied 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.

IMPORTANT

Where no British Standards exists, materials and equipment should be t for their purpose and of suitable quality and workmanship. The installation of this boiler must be carried out by a competent person approved at the time by the Health and Safety Executive and in accordance with the rules in force in the countries of destination. Manufacturer’s instructions must not be taken as overriding statutory requirements.

Statutory Requirements

In GB, the installation of the boiler must comply with the

requirements of the current issue of BS6798 and be carried out by a competent person approved at the time by the Health and Safety Executive and as described in the following regulations: The manufacturer’s instructions supplied. The Gas Safety (Installation and Use) Regulations. The appropriate Buildings Regulations either The Building Regulations, The Building Regulations (Scotland), The Building Regulations (Northern Ireland).

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

The Health and Safety at Work Act, Control of Substances Hazardous to Health (COSHH). The Current I.E.E. Wiring Regulations. Where no specic instructions are given, reference should be made to the relevant British Standard Code of Practice.

In IE, the installation must be carried out by a competent person approved at the time by the Health and Safety

Executive and installed in accordance with the current edition of I.S.813 “Domestic Gas Installations”, the current Building Regulations and reference should be made to the current ETCI rules for Electrical Installation. GB: the following Codes of Practice apply: BS4814, BS6798, BS5440 Part 1 and 2, BS5546 Part 1, BS5449, BS6891, BS6700, BS7074 Part 1 and 2, BS7593, BS7671.

IE: I.S.813, BS5546, BS 5449, BS 7074, BS 7593. NOTE: For further information, see the current issue of the

Building Regulations, approved document L1 ( in the UK) and the following current issues of:

1) Central heating system specication (CheSS) and

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

Gas Supply

The gas installation must be in accordance with the relevant standards. In GB, this is BS6891. In IE, this is the current edition of I.S.813 “Domestic Gas Installations”. The supply from the governed meter must be of adequate size to provide a steady inlet working pressure of 20mbar (8in wg) at the boiler. On completion, test the gas installation for tightness using the pressure drop method and suitable leak detection uid, purge in accordance with the above standard.

Domestic Hot Water

All domestic hot water circuits, connections, ttings must be in accordance with the relevant standards and water supply regulations. GB: Guidance G17 to G24 and recommendation R17 to R24 of the Water Regulations Guide. IE: The current edition of I.S.813 “Domestic Gas Installations”.

Heating System

In GB, it is necessary to comply with the Water Supply (Water

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

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

Boiler Design

This boiler is designed for use as part of a sealed water central heating system with fully pumped circulation. The pump, expansion vessel and associated safety devices are all tted within the boiler. The integral programmer is designed for both simple operation and maximum control. Once the controls are set the boiler will operate automatically.

Range Rating

These boilers are fully modulating, it is therefore not necessary to range rate them.

Safety Devices

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 Glow-worm 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 Discharge Valve

A safety discharge valve and discharge pipe are tted to the boiler. This valve must not be touched. Should there be any discharge from the pipe, isolate the boiler electrical supply and call your installer or Glow-worm’s own service organisation using the telephone number on the inside front cover of this booklet.

Condensate Drain

A plastic drain pipe must be tted to allow discharge of condensate to a drain. Condensate should, if possible, be discharged into the internal household draining system. If this is not practical, discharge can be made externally into the household drainage system or a purpose designed soak away, see section 9 for more details.

Pluming from ue terminal

Like all condensing boilers this appliance will produce a plume of condensation from the ue terminal in cool weather. This is due to the high efciency and hence low ue gas temperature of the boiler. This is normal and not an indication of a fault.

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 8OC. 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 10OC or has already reached 35OC. The burner will activate if the boiler temperature does not reach 10OC 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.

Servicing, Maintenance and Spare Parts

Servicing and Maintenance

To ensure the continued efcient and safe operation of the boiler it is recommended that it is checked and serviced as necessary at regular intervals. The frequency of servicing will depend upon the particular installation conditions and usage. If this appliance is installed in a rented property there is a duty of care imposed on the owner of the property by the current issue of the Gas Safety (Installation and Use) Regulations, Section 35. Servicing/maintenance should be carried out by a competent person approved at the time by the Health and Safety Executive in accordance with the rules in force in the countries of destination. To obtain service, please call your installer or Glow-worm’s own service organisation using the telephone number on the inside front cover of this literature.

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 specication 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 information will be on the name badge on the front of the appliance. If in doubt seek advice from the local gas company or Glowworm’s own service organisation using the telephone number.

1 Boiler Specication

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2 Boiler Dimensions & Hydraulic Schematic

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15421

Diagram 2.2

2.1 Boiler Dimensions & Hydraulic Schematic

All dimensions are given in millimetres (except as noted). The general arrangement 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.

Diagram 2.1

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 benecial around the boiler for installation and servicing. For ue installations where external access is not practicable, consideration should be given for the space required to insert the ue internally, which may necessitate clearance larger than those specied in diagram 3.1.

3.3 Timber Frame Buildings

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

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3.4 Combustible Material

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

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

2) The combustible surface and xings 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 efciency and hence low casing temperature of this boiler, cupboard or compartment ventilation is not necessary. Leave existing air vents.

Diagram 3.1

4 Flue Options and Terminal Clearances

Top horizontal telescopic ue (Ø60/100)

Part No. A2043600 - Section 10, page 20

Top horizontal standard ue (Ø60/100) Part No. A2043400 - Section 10, page 24

Ridge Tile Terminal Part No. A2043800 Section 10, page 30

Twin Flue Twin Flue Adapter, concentric ue (Ø80) Part No. A2011000 - Section 10, page 32

Vertical Flue Vertical Flue Adapter, concentric ue (Ø60/100) Part. No. A2024600 - Section 10, page 28 Vertical ue terminal kit, concentric ue (Ø60/100) Part. No. 2000460480 - Section 10, page 28

Plume Management Kit basic set, white, concentric ue (Ø60/100) - Part No. A2044100 for use with Part No. A2043400 and Part No. A2043600 - Section 10, page 35

Multiple Boiler Chimney Flue

Multiple Boiler Chimney

Vertical concentric stack ue

Flue

suitable for use with:-

Vertical concentric stack

Top horizontal telescopic ue,

ue suitable for use with top

Top standard horizontal ue,

horizontal telescopic ue

Twin Flue, as specied by the

and top standard horizontal

manufacturer.

ue as specied by the

Deector Flue Terminal Kit

manufacturer

(Ø60/100) Part No. 0020060582 (black) Part No. 0020060583 (white)

- Section 10, page 34

Diagram 4.1

4 Flue Options and Terminal Clearances

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

* TO A BOUNDARY ALONGSIDE THE

H TERMINAL 300 I ABOVE ADJACENT GROUND OR BALCONY LEVEL 300

* 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

4.1 Flue Options

There are various ue options to choose from as illustrated in diagram 4.1. The ue lengths and installation are described in section 10.

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 ue terminal positioning must be those detailed in I.S.813 “Domestic Gas Installations”. The terminal must be exposed to the external air, allowing free passage of air across it at all times. Being a condensing boiler some pluming may occur from the ue outlet. This should be taken into consideration when selecting the position for the terminal. Carports or similar extensions of a roof only, or a roof and one wall, require special consideration with respect to any openings, doors, vents or windows under the roof. Care is required to protect the roof if made of plastic sheeting. If the carport comprises of a roof and two or more walls, seek advice from the local gas supply company before installing the boiler. 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. NOTE: If the ue terminal is positioned near a light source insects may enter the ue system. Where safe and practical to do so advise the homeowner to check the ue outlet and clear visible insects from the terminal end.

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 165mm. Part No: CGDK3

15583

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

Diagram 4.3

5 Water System - Heating

5.1 General

5.2 Safety Valve

The safety valve is an integral part of the boiler and it cannot be adjusted. The pipe from the safety discharge valve must not discharge above an entrance, window or any type of public access area.

5.3 Expansion Vessel

The boiler has an integral expansion vessel with a capacity of 8 litres (1.76 gallons), with a charge pressure of 0.5bar. NOTE: The expansion vessel volume depends on the total water system volume and the initial system design pressure. In GB, Guidance on vessel sizing is also given in the current issue of BS5449 and BS7074 Part 1. In IE, current edition of I.S.813 “Domestic Gas Installations”.

5.4 Flow Rate

If it is necessary to alter the ow rate, the system can be tted with a lockable balancing valve in the main ow or return pipes shown as valve “A” in diagram 5.1. The ow rate through the boiler must not be allowed to fall below that given in section 1 - Specication Table.

12800

5.5 Bypass

The boiler is tted with an automatic bypass which can be adjusted to suit your system requirements. Ensure that under no circumstances does the ow rate drop below the gure specied, refer to section 1 - Specication Table.

5.6 Filling the Sealed System

The boiler is supplied with a lling device, see diagram 8.1. This lling device is designed to enable the lling and pressurisation of the system in the event of loss of pressure. NOTE: The water pressure at the boiler must be at least

1.2bar to enable lling the boiler to a minimum pressure. If not pressurisation must be carried out by an alternative lling loop. Suitable external lling systems are shown diagrammatically, see diagram 5.2. The system should be pressurized to 1bar, indicated on the digital display with no heating demand.

5.7 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. Drain points for the appliance are provided at the positions shown in diagram 8.1.

Diagram 5.1

5.8 Water Treatment

Existing system- It is ESSENTIAL that prior to installing the

new boiler the system is thoroughly ushed. New system- For optimum performance after installation, the boiler and its associated central heating system should also be ushed. Flushing should be carried out in accordance with BS7593: 2006 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 ushing, 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.

5 Water System - Domestic Hot Water

5.9 Water Pressure

The minimum working pressure to obtain the maximum domestic ow is:24cxi 1.0bar 30cxi 1.0bar 38cxi 2.5bar The maximum working pressure of the domestic hot water circuit is 10 bar. If the cold water supply pressure exceeds this, then a pressure-reducing valve must be tted in the supply to the boiler.

5.10 ‘Hard’ Water Areas

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

5.11 Domestic Water Flow Rate

The domestic hot water ow has a restrictor, factory tted, which reduces the ow to a maximum of, 8.0 l/min for 24cxi,

12.0 l/min for 30cxi and 15.5 l/min for 38cxi.

12253

Diagram 5.2

6 Installation Preparation

Base Coverplate

A - Wire Retaining Clip B - Union Nut and Sealing Washer

A - Central Heating x 2

C - Tap and Securing Screw

E - Gas Sealing Washer F - O Ring G - Union Nut

B - Domestic Hot Water Outlet

D - Sealing Washers

C - Gas D - Domestic Cold Water Inlet E - Saftey Discharge

Hanging Bracket

Electrical CartridgeGas and Water Isolating Valves 0020036801

Pipe Pack 0020029671 Loose Items Pack

Retaining Screws

stored in cartridge

Documentation Pack (not illustrated)

Wall Template, User Instructions, Installation and Servicing Instructions.

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Diagram 6.1

6 Installation Preparation

6.1 Appliance Pack

Please check the contents of packs as shown in diagram 6.1.

The packs are located in the top polystyrene packing.

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 at.

NOTE: Due to the varied site conditions we do not supply xings and advise that the installer should supply those which are suitable.

6.3 Wall Template

Take the wall template from the document pack located within the top polystyrene packing and place in the desired position

on the wall, giving due consideration to the required boiler clearances, see section 3, and the ue you are tting. Mark the position of the ue centre, if tting a side ue, extend the ue centre line into the corner then 176mm along the adjacent wall, see diagram 6.2. For extended side ues, the ue 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 ue should then be marked at 176mm from the back wall. To allow for the ue passing through the wall at this angle a 125mm hole should be drilled irrespective of internal or external installation. Remove the wall template whilst drilling the ue hole.

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Diagram 6.2

6.4 Flue Hole Cutting

External access ue installation can use a 105mm diameter core drill. Internal access only ue installation will need a 125mm diameter core drill. NOTE: The ue is designed with an internal fall of 44mm/ metre (2.5°), therefore the hole can be drilled horizontally. If ue extension pipes are to be used then a core drill size of 125mm is required. This will allow the extension pieces to slope at 44mm/metre (2.5°) towards the boiler.

7 Boiler Fixing

7.1 Hanging Bracket Fixing

The Wall Hanging Bracket is supplied in the main boiler packaging at the rear of the boiler.

Reposition the wall template over the ue hole and mark the position of the xing holes for the hanging bracket, see diagram 7.1. Drill xing holes and insert suitable wall plugs.

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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.

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Diagram 7.1

8 Gas / Water Connections

8.1 Systems Connection

NOTE: The appliance may contain a small amount of water,

place a water container beneath the boiler connections.

Remove the protective caps from the boiler connections. Assemble and secure the pre formed copper tails to their respective isolation valves making sure of their correct orientation, see diagram 8.1.

Fit the isolation valves/copper tails with seals to the appliance as shown in diagram 8.1

Make sure that all connections are secured in the sequence shown on diagram 8.1. There are ats on the body of the valves for locating a spanner to aid tightening.

Fit the ‘O’ ring seal from the loose items pack to the Double Check Inlet Valve assembly then secure into isolation valve with wire retaining clip, see diagram 8.1.

Diagram 7.2

Fit the Central Heating Isolation Valve handles and secure with screws provided.

Plumb the system pipe work to the copper tails. NOTE: Do not subject the isolation valves to heat and make sure that the test and drain points are accessible, see diagram

8.1.

Flush out the domestic hot water and the heating systems, refer to section 5.8.

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 Gas / Water Connections

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Diagram 8.1

SAFETY DISCHARGE VALVE

VIEW ON UNDERSIDE OF BOILER

UNION NUT AND SEAL

9 Safety Discharge Valve & Condensate Connections

9.1 Safety Discharge Valve

Take the safety discharge pipe, supplied in the pipe pack and the union nut and seal, supplied in the loose items pack and t as shown in diagram 9.1. This must be extended, using not less than 15mm o.d. pipe, to discharge, in a visible position, outside the building, facing downwards, preferably over a drain. To ease future servicing it is advisable to use a compression type tting to extend the safety discharge valve tube. The pipe must have a continuous fall and be routed to a position so that any discharge of water, possibly boiling, or steam cannot create any danger to persons, damage to property or external electrical components and wiring.

9.2 Condensate Trap and Siphonic Drain Connection

A exible condensate outlet pipe is tted and should be used to couple the condensate trap and siphonic drain to a 22mm to 25mm O.D. non corrosive plastic pipe (overow pipe), see diagram 9.2.

IMPORTANT: Please remove the bung from the exible pipe before tting to a drain outlet pipe.

NOTE: the pipe should have a fall of a least 2.5O 44mm/metre away from the boiler. Condensate should, 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 9.3. It is recommended that any external condensate drain pipe is protected 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.

13644

Diagram 9.1

13645

CONDENSATE TRAP AND SYPHONIC DRAIN

FLEXIBLE CONDENSATE OUTLET PIPE

VIEW ON UNDERSIDE OF BOILER

Diagram 9.2

9 Safety Discharge Valve & Condensate Connections

13000

Diagram 9.3

10 Telescopic Flue - Length, Preparation and Installation

10.1 Flue Length

The maximum permissible horizontal ue length is 10 metres plus the ue terminal assembly, this can be achieved by use of the accessories, see diagram 10.3. However should an additional 87.5o or 2 x 45o elbows be used then the length MUST be reduced by 1metre. The diagram 10.1 shows the length achievable by using the kit A2043600. When extension pipes are used the ue system must be designed to have a continuous fall to the boiler of at least 2.5o 44mm/metre to allow condensate to run back into the boiler and out via the condensate drain. The ue can be installed from inside the building, when access to the outside wall face is not practicable.

Horizontal Telescopic Flue - Rear

13558

Multiple Boiler Chimney Flue Length

The ue length must be calculated and installed according to the relevant standards EN 13384-1 and 2 (C43 ue systems only) with reference to the table below and the manufacturers instructions supplied. The appliance maximum ue length must be included when calculating the overall design of the ue system. NOTE: The horizontal ue terminal must be removed, see diagram 10.2.

10.2 Horizontal Telescopic Flue - A2043600

Refer to diagram 10.2 for kit contents.

Horizontal Telescopic Flue - Side

13559

Exhaust mass rate (g/s)

At Min Thermal Load (40C°/30°C)

At Max Thermal Load (80C°/60°C)

Exhaust temperature (ºC)

At Min Thermal Load (40C°/30°C)

At Max Thermal Load (80C°/60°C)

Ultracom

24cxi

Ultracom

30cxi

Ultracom

2.30 2.36 3.20

11.30 14.20 18.55

56.0 63.0 46.0

76.0 75.0 73.0

Diagram 10.1

38cxi

10 Telescopic Flue - Length, Preparation and Installation

14826

Diagram 10.2

15418

Diagram 10.3

10 Telescopic Flue - Length, Preparation and Installation

10.3 REAR Flue

If a wall thickness is between 203mm min. to 413mm max. then the ue can be used without extensions.

With the ue elbow temporarily tted, measure the distance from the outside wall to the butt joint, see diagram 10.4. 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 ue, it can project to a maximum of 600mm, refer to diagram 10.5. If this is not desirable then a Standard ue MUST be used and cut to length.

13223

Diagram 10.4

12979

Diagram 10.5

Diagram 10.6

13224

10 Telescopic Flue - Length, Preparation and Installation

Diagram 10.7

Diagram 10.8

12929

12977

13254

10.4 SIDE Flue

With the ue elbow temporarily tted, measure the distance from the outside wall to the butt joint, see diagram 10.6. 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 ue, it can project to a maximum of 600mm, refer to diagram 10.5. If this is not desirable then a Standard ue MUST be used and cut to length.

10.5 Flue Fitting

IMPORTANT:The ue seals are sensitive to mineral oil based lubricants. Do not grease the seals. If the seals do need to be lubricated use only water.

During the installation of the ue system, ensure that debris such as mortar, lings or swarf are cleared from the ue system before completion. Inspect the ue pipes before tting and do not install damaged or dented ue components. When assembling the ue system, ensure that the inner seals are not damaged, do not install a ue component with a damaged seal. When tting ue elbows ensure that they are tted at the correct angle to avoid strain, this will ensure that the seal ts correctly preventing leakage. With the air duct seams aligned and the ue 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 ue duct. Secure with screw provided and tape the joint, see diagram 10.7. Fit the sealing collar onto the locating ring on the ue terminal, see diagram 10.8. With the ue elbow removed, push the ue 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 ue assembly to be drawn back up to the ue elbow. Secure the ue elbow in position on top of the boiler with the four screws supplied. Draw the ue assembly from wall and engage the ue duct into the elbow and butt t between the air duct and ue elbow. Fit the securing collar into position. Ensuring correct alignment of the ue, 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 ue duct. Fit the securing collar and secure with screws provided, see diagram 10.9. 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 lings and debris removed.

Insert the ue duct into the air duct terminal assembly, remembering to engage the catch within the terminal. Check that the outer rubber sealing collar makes an effective seal against the wall face.

Diagram 10.9

10 Standard Flue - Length, Preparation and Installation

Standard Horizontal Flue

13560

13561

10.6 Flue Length

The maximum permissible horizontal ue length is 10 metres plus the ue terminal assembly, this can be achieved by use of the accessories, see diagram 10.12. However should additional 87.5o or 2 x 45o elbows be used then the length MUST be reduced by 1metre. The diagram 10.10 shows the length achievable by using the kit A2043400. When extension pipes are used the ue system must be designed to have a continuous fall to the boiler of at least 2.5o 44mm/metre to allow condensate to run back into the boiler and out via the condensate drain. The ue can be installed from inside the building, when access to the outside wall face is not practicable.

Multiple Boiler Chimney Flue Length

Diagram 10.10

MODEL 24cxi 30cxi 38cxi

Exhaust mass rate (g/s)

At Min Thermal Load (40C°/30°C)

At Max Thermal Load (80C°/60°C)

Exhaust temperature (ºC)

At Min Thermal Load (40C°/30°C)

At Max Thermal Load (80C°/60°C)

2.30 2.36 3.20

11.30 14.20 18.55

56.0 63.0 46.0

76.0 75.0 73.0

10 Standard Flue - Length, Preparation and Installation

12841

Diagram 10.11

15418

Diagram 10.12

10 Standard Flue - Length, Preparation and Installation

10.7 Standard Horizontal Flue - A2043400

Refer to diagram 10.11 for kit contents.

10.8 REAR Flue

With the ue elbow temporarily tted, measure the distance from the outside wall to the butt joint, see diagram 10.13. 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 ue can project to a maximum of 600mm, refer to diagram 10.14.

10.9 SIDE Flue

With the ue elbow temporarily tted, measure the distance from the outside wall to the butt joint, see diagram 10.15. If the measurement ‘Y’ exceeds 665mm, then the appropriate length of extension pipe is required. The minimum dimension for Lhd is 254 and Rhd 226 to suit a minimum wall thickness of 75mm. The ue can project to a maximum of 600mm, refer to diagram 10.14.

13223

Diagram 10.13

12979

Left Hand illustrated

Diagram 10.14

13224

Diagram 10.15

10 Standard Flue - Length, Preparation and Installation

Diagram 10.16

Diagram 10.17

12847

13254

10.10 Flue Fitting

IMPORTANT:The ue seals are sensitive to mineral oil based lubricants. Do not grease the seals. If the seals do need to be lubricated use only water.

10.16. The air duct should be cut at the opposite end to the terminal The plastic ue duct MUST be cut at the opposite end to the terminal catch. The plastic ue duct extensions MUST be cut at the opposite end to seal. Insert the ue duct into the air duct terminal assembly, remembering to engage the catch within the terminal. Fit the sealing collar behind the locating lugs on the ue terminal, see diagram 10.17. Push the ue 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 ue assembly to be drawn back into the ue elbow. Secure the ue elbow in position on top of the boiler with four torque headed screws supplied. Draw the ue assembly from wall and engage the ue duct into the elbow and butt t between the air duct and ue elbow. Fit the securing collar into position. Ensuring correct alignment of the ue, 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 ue duct. Fit the securing collar and secure with screws provided, see diagram 10.17. 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 ue ducts have been correctly cut to the instructions the sealing collar should t ush with the outside wall.

10 Vertical Flue - Length, Preparation and Installation

10.11 Vertical ue

The vertical ue system is available as an option where the boiler position does not permit the use of the top horizontal ue system. The system is made up from accessories. The accessories include terminal assembly, bends 45º and 87.5º, ue extensions, xing bracket and appropriate weather collar, see diagram 10.19. The maximum permitted straight ue length is 10 metres plus the terminal. For each 87.5º or 2x45o bends tted, the maximum length must be reduced by 1 metre, see diagram

10.18. NOTE: 2x45º bends can replace 1x87.5º bend if necessary. When using 87.5º 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

10.18. Alternatively use 45º bends to avoid horizontal runs, see (b) in diagram 10.18.

The terminal siting should be as shown in diagram 4.2. Measure the distance of ue length required for the installation. The ue must be designed with a continuous fall towards the boiler.

14851

Diagram 10.18

10 Vertical - Flue Length, Preparation and Installation

14849

Flue Installation

IMPORTANT:The ue seals are sensitive to mineral oil based lubricants. Do not grease the seals. If the seals do need to be lubricated use only water.

During the installation of the ue system, ensure that debris such as mortar, lings or swarf are cleared from the ue system before completion. Long lengths of ues must be secured to the walls or ceilings they run against. Use at least one xing bracket for every ue extension that is used. After cutting inner ue tubes ensure that you de-burr and chamfer the male tube end to prevent damage. Inspect the ue pipes before tting and do not install damaged or dented ue components. When assembling the ue system, ensure that the inner seals are not damaged, do not install a ue component with a damaged seal. When tting ue elbows ensure that they are tted at the correct angle to avoid strain, this will ensure that the seal ts correctly preventing leakage. Refer to diagram 10.21 and secure the ue adapter in position on top of the boiler with four screws supplied, making sure the nib ts into the locating slot in the boiler casing to ensure correct orientation. Secure the rst extension pipe to the ue 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 10.22. Fit more extension pipes as required using the collar and screws supplied with each extension pipe. To t 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 screws supplied, see diagram 10.23. The rubber ‘O’ rings of each section should be lubricated prior to assembly. Project the rise of the ue pipe to roof level and cut a 150mm hole in the roof.

Diagram 10.19

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 ashing 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 ue 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 ue terminal ensuring the relationship of ue and air duct lengths are retained.

10 Vertical Flue - Length, Preparation and Installation

Ridge Tile Terminal

A ridge tile terminal is available - part no. A2043800, see diagram 10.20. The installation of a ridge tile will be required. A suitable ridge tile is manufactured by: Aspect East Anglia Limited The Old Mill East Harling NORWICH NR16 2QW Website: www.aspectroong.co.uk Contact: Chris Haythorpe General Manager - Tile Division Tel: 01953 717777 Fax: 01953 717164

14853

Diagram 10.20

10 Vertical Flue - Length, Preparation and Installation

Completion of Installation

With the ue terminal positioned in the roof the length of the nal pipe can be determined. If a telescopic length cannot be used, then a standard ue length can be cut to make the correct length. Cut the ue 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 ue pipe is 10mm longer than the air pipe, see diagram 10.24. Carefully push the terminal assembly upwards to allow room for tting the nal ue piece. Fit a xing bracket to the terminal assembly. Pull the terminal assembly down and join to the ue system. Ensure that the terminal is making a weather tight seal on the weather collar. Secure the xing bracket tted to the terminal to the roong struts or a purpose made batton.

13242

13243

Diagram 10.22

12982

Diagram 10.23

12983

Diagram 10.21

Diagram 10.24

10 Twin Flue - Length, Preparation and Installation

Secure long flue lengths (horizontal & vertical) to walls or ceiling at every joint or on straight flue runs at every joint and every metre flue run.

15406

Diagram 10.25

10 Twin Flue - Length, Preparation and Installation

14869

10.12 Twin ue

The twin ue system is available as an option when the top horizontal or vertical ue system is not appropriate. The system can provide an independent horizontal air inlet and ue outlet, horizontal air inlet and vertical ue outlet or vertical air inlet and ue outlet via a concentric terminal. The system is made up from accessories, see diagram 10.26. NOTE: The air and ue outlets do not have to be equal lengths. 2x45° bends can replace 1x90° bend if necessary. The maximum permitted combined (air inlet + ue outlet) ue length is 40 metres plus terminal assemblies. For each 90° or 45° x 2 bends tted, the maximum ue length must be reduced by 1 metre, see diagram 10.25. 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 ue pipe.

Multiple Boiler Chimney Flue Length

Terminal Position

The clearances for a ue 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 ue outlet on the same wall or 1200mm from an opposing ue outlet.

Installation Details

The parts available for a twin ue system installation are shown in diagram 10.26.

MODEL 24cxi 30cxi 38cxi

Exhaust mass rate (g/s)

At Min Thermal Load (40C°/30°C)

At Max Thermal Load (80C°/60°C)

Exhaust temperature (ºC)

At Min Thermal Load (40C°/30°C)

At Max Thermal Load (80C°/60°C)

2.30 2.36 3.20

11.30 14.20 18.55

56.0 63.0 46.0

76.0 75.0 73.0

Diagram 10.26

10 Twin Flue - Length, Preparation and Installation

Boiler Connection

IMPORTANT: The ue seals are sensitive to mineral oil based

lubricants. Do not grease the seals. If the seals do need to be lubricated use only water. Place the twin ue adaptor onto the outlet of the boiler with the air inlet to the left hand side, see diagram 10.27. 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 ue pipes can now be built up from the boiler. The ue must be designed with a continuous fall towards the boiler. If using the horizontal ue pipe or 90° bends the pipe must be inclined at 44mm/metre (2.5°) minimum, see diagram

10.25. Alternatively if space allows, use 45° bends in place of 90º bends. To avoid rain ingress to the air Inlet terminal, it is good practice to aim the inlet downwards by approx 2° as rain can damage the boiler. The Flue outlet pipe must always run at 44mm/metre (2.5°) back to the boiler.

IMPORTANT:

Long lengths of ues must be secured to the wall or ceiling it runs against. Use at least one xing bracket on each ue joint used or on straight ue runs every joint and for every metre ue run. Provision must be made in concealed boxing or ductwork that the ue joints can be inspected during annual servicing. The ue seals are sensitive to mineral oil based lubricants. Do

not grease the seals. If the seals do need to be lubricated use only water.

Do not use the ue pipe to attach other pipes or equipment. If visible, advise the householder not to hang or clip items to ue pipes. Do not stress the ue connections during the installation this can damage the ue seals.

Horizontal Terminal Installation

NOTE: The air inlet terminal and the ue outlet terminals

must never be installed on the opposite sides of a property. Termination must only be on the same wall or adjacent walls. When installed close together separated vertically, the air inlet must be tted below the ue outlet terminal (see diagram

10.25). The air terminal must not terminate less than 20mm from an adjacent wall or structure and the ue outlet terminal less than 100mm from any adjacent wall or structure. 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 10.25.

13240

Diagram 10.27

Vertical Terminal Installation

With due consideration to terminal clearances mentioned in Section 4.2, project the rise of the ue pipe to roof level and cut 150mm hole in the roof.

(a) Pitched Roof

(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 nal 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 nal 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 10.25. For installation of (a), attach the twin pipe to concentric ue 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 nal pipe can be determined. Cut the ue 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 tting the nal ue piece(s). Fit a 100mm xing bracket to the terminal assembly Part No2000460486. Pull the terminal assembly down and join to the ue system. Ensure that the terminal is making a weather tight seal on the weather collar. Secure the xing bracket tted to the terminal to the roong struts or a purpose made batton.

10 Plume Management Kit

10.13 Plume Management Kit

12997

The Plume Management Kit: Part No. A2044100 (white) or A2044000 (black) can be used to overcome many site issues. The Plume Management Kit will t to the Top Horizontal Telescopic, Rear Horizontal Telescopic and Standard Horizontal Flue. This enables the ue products to exhaust further away from the boiler, thereby reducing the impact of pluming. NOTE: The ue air inlet can be sited closer to doors, opening windows and air bricks, than stated in section 4.2, see diagram 10.28. The maximum length of the Plume Management Kit must NOT exceed 6m with a horizontal concentric ue 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.

14465

150mm. MIN.

Diagram 10.28

10 Deector Flue Terminal Kit

10.14 Deector Flue Terminal Kit

The terminal kit ts onto the telescopic and standard horizontal ue, see diagram 4.1 for kit contents. The kit is also supplied with installation instructions. NOTE: The deector ue terminal kit can be tted after the boiler and ue have been installed. The deector part of the deector ue terminal can be rotated 45º to allow pluming away from openings, people, cars, windows etc., see diagram 10.29. Should the deector terminal be positioned under a soft or horizontal surface, it is allowed to project the ue 600mm from the wall, to allow the discharge of ue gases produced into free air. IMPORTANT: Do not t the deector ue terminal with the deector positioned downwards.

Diagram 10.29

11 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 identied as to its use.

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

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

11.1 Electrical Wiring

Remove the electrical cartridge from the ttings pack.

Remove the securing screw to open the cartridge, see diagram 11.1. 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 screws of the cable strain relief in the electrical cartridge, see diagram 11.1.

13368

Diagram 11.2

13369

Route the mains supply and system cables through the strain relief and connect to the relevant terminals, refer to the appropriate sections 11.2 or 11.3 .

13302

Diagram 11.1

Diagram 11.3

11 Electrical Connection

11.2 System Controls 24V

WARNING: UNDER NO CIRCUMSTANCES MUST

ANY MAINS VOLTAGE BE APPLIED TO ANY OF THE TERMINALS ON THE 24V CONNECTION PLUG.

Connect the mains supply and system heating controls e.g. room thermostat as diagram 11.2. External controls should be tted in accordance with the rules in force. If tting a proprietary programmer as part of the system controls the internal programmer will need to be disabled as described in section 11.6. If tting the Glow-worm Climapro programmer, the internal programmer will automatically be disabled.

11.3 Mains Voltage System Controls

WARNING: UNDER NO CIRCUMSTANCES MUST

ANY MAINS VOLTAGE BE APPLIED TO ANY OF THE TERMINALS ON THE 24V CONNECTION PLUG.

Connect mains supply and system controls as diagram 11.3. External controls should be tted in accordance with the rules in force. If tting a proprietary programmer as part of the system controls the internal programmer will need to be disabled as described in section 11.4. If tting the Glow-worm Climapro programmer, the internal programmer will automatically be disabled.

11.4 Electrical Cartridge Securing

With the gas service isolation valve closed and with no demand from any external controls, t the electrical cartridge into the interface housing, see diagram 11.4. Secure with the two cartridge retaining screws provided in the cartridge body.

11.5 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 14.

Switch on the power to the appliance. The appliance should display that it is in the “OFF” mode, refer to diagram 12.1. If not, press the “Mode” button repeatedly until the “OFF” symbol is displayed, then continue as follows:

13488

11.6 Disabling the internal Programmer

Fitting an external proprietary Programmer will require that you disable the Internal Programmer, refer to diagram 12.1. a) Press and hold the ‘mode’ button for 5 seconds. The display will change to ashing ‘0’. b) Use the ‘+’ or ‘-’ button to scroll to 96. c) Press ‘MODE’ to conrm. d) The display now shows a ashing ‘d. 0’ Use the ‘+’ or ‘-’ key to scroll to ‘d.92’. e) Press ‘MODE’ to conrm. f) The display now shows a ashing ‘2’ above the ‘d.92’. g) Use the ‘+’ or ‘-’ button to change this value to ‘0’. h) Press ‘MODE’ to conrm, ‘1’ stops ashing and is saved. i) Press and hold ‘MODE’ to exit. The internal Programmer has now been disabled. See the diagnostic menu instructions in the Fault Finding section for further details.

11.7 Internal Programmer Conguration

The internal programmer is factory set in the 24hr. CH mode with the following pre-set timed intervals: Monday - Friday ON 6.00 - OFF 8.00 ON 16:00 - OFF 23.00 Saturday - Sunday ON 8.00 - OFF 23.00

The DHW pre-heat is also factory set with the following preset timed intervals : Monday - Sunday ON 6.00 - OFF 24.00

If required the internal 24 hour Central Heating mode can be changed to the 7 day mode, by following the procedure below:

a) Press and hold the ‘mode’ button for 5 seconds. The display will change to ashing ‘0’. b) Use the ‘+’ or ‘-’ button to scroll to 96. c) Press ‘MODE’ to conrm. d) The display now shows a ashing ‘d. 0’ Use the ‘+’ or ‘-’ key to scroll to ‘d.91’. e) Press ‘MODE’ to conrm. f) The display now shows a ashing ‘0’ above the ‘d.91’. g) Use the ‘+’ button to change this value to ‘1’. h) Press ‘MODE’ to conrm, The value is now saved. i) Press and hold ‘MODE’ to exit.

It is possible to enable a second programmer channel to control the DHW circuit pre-heat function. Follow the same procedure as described above but scroll to ‘d.92’ and change the value to ‘3’. The following two tables outline the conguration options:

Diagram 11.4

Table 1

d.9124 hour / 7 day Operation

0   24 HOUR

1   7 DAY

Table 2

d.92 Enable/disable internal programmer

0  CH OFF / DHW OFF

1  CH OFF / DHW ON

2  CH ON / DHW OFF

3  CH ON / DHW ON

12 Commissioning

MODE

PROG

Ext

SYMBOLS DISPLAYED ON THE LCD AND DESCRIPTIONS

Will be displayed when domestic hot water temperature is less than 50

System Pressure

Max burner display

Glow-worm control (Optional)

Outdoor sensor (if fitted)

Min burner display

Temperature

Appliance OFF

Central Heating Timed Mode

Programmer Adjustment Mode

Domestic Hot Water Function

Central Heating Function

Ext

Eco

LCD

DISPLAY

RESET

BUTTON

DHW CH

TEMPERATURE

ADJUSTMENT

TOGGLE BUTTON

MODE and PROG

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

12.1 Preliminaries - All Systems

Do Not operate the boiler without water. The commissioning should be carried out by a competent person approved at the time by the Health and Safety

Executive and in accordance with the current issue of BS6798. Make sure that the system has been thoroughly ushed out with cold water and that all cleanser if used has been removed. With the gas service isolation valve closed, with no demand from any external controls and the power supply to the boiler switched off. Test for gas soundness and purge air from the gas supply.

12.2 Filling the Heating Circuit

Switch on the power supply to the boiler. The boiler should be in “OFF” mode, this will be indicated on the user interface display, refer to diagram 12.1. If not, press the “Mode” button repeatedly until the “OFF” symbol is displayed, then continue as follows:

1. Connect the exible hose to the double check valve and secure by tightening the knurled nut marked ‘A’, refer diagram 12.2.

2. Open the Central Heating Flow and Return isolation valves marked ‘B’ using a screwdriver or a 4mm allen key

- slot in line with the axis of the isolation valve (shown closed in diagram).

3. Ensure ALL cold water taps are shut off then open the Domestic Cold Water isolation valve marked ‘C’ using a screwdriver or a 3mm allen key - slot in line with the axis of the isolation valve (shown closed in diagram).

4. Open the tap ‘D’, then gradually open tap ‘E’ through 90 to ll the heating system to a pressure of 1.0bar then

close the two lling taps.

5. Vent all air from the system - repeat step 4 as necessary until the system is full and all the air has been vented.

6. To comply with the water regulations the exible hose must be disconnected from the double check valve close the taps ‘E’ and ‘D’ then undo the knurled nut marked ‘A’ and pull the exible hose from the double check valve.

12.3 Domestic Water Circuit

Check that water ows from the hot water taps. Check for water tightness of the complete domestic water system.

The domestic hot water ow has a factory tted restrictor, which reduces the ow to a maximum of, 8.0 l/min for 24cxi,

12.0 l/min for 30cxi and 15.5 l/min for 38cxi.

13176

Diagram 12.1

13577

Diagram 12.2

12 Commissioning

Commissioning should only be carried out by a competent person approved at the time by the Health and Safety

Executive.

12.4 Initial Lighting

NOTE: The combustion for this appliance has been checked, adjusted and preset at the factory for operation on natural gas (G20) as dened on the appliance data label. No measurement of the combustion is necessary. Having checked :

● the appliance has been installed in accordance with the instructions.

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

● the integrity of the appliance combustion circuit and relevant seals.

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

● the gas service isolation valve ‘F’, diagram 12.2, is open.

LPG Conversion: See section 12.9.

Light the appliance by following the procedure below:

Select the “Constant central heating with DHW” function by pressing the “Mode” button repeatedly to scroll through your options until constant central heating with domestic hot water

is shown

, see diagram 12.1

Operational Gas Inlet Pressure

With ALL other gas appliances operating, check the operational supply pressure at the gas service isolation valve test point, see diagram 12.2. The nominal supply pressure for Natural Gas (G20) is 20mbar. The nominal supply pressure for LPG (G31) is 37mbar. Turn the taps and appliances off, then disconnect the pressure gauge. Additionally the safe nominal maximum heat input of the appliance can be achieved at an inlet pressure down to 15mbar.

The BURNER PRESSURE cannot be measured and

NOTE:

is not used to measure the gas rate.

Gas Rate

Make sure that ALL other gas burning appliances and pilot lights are off. Check the gas rate using the gas meter test dial and stop watch, at least 10 minutes after the burner has lit, see table below for approximate rates.

15439

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

● If the burner fails to ignite “F1” will be displayed, initially, this may be due to air in the gas supply line.

● Press the “ “ central heating water temperature button and the factory setting temperature will be displayed. Press “+” (plus) or “-” (minus) buttons to adjust.

● Press the hot water temperature “ ” button and the factory set 40 Press “+” (plus) or “-” (minus) buttons to adjust. Open a hot water tap, the display will indicate the domestic hot water temperature. Check that hot water is available at all taps, then close.

C temperature will be displayed.

12.5 Check the Gas Inlet Pressure and Gas Rate

The supply from the governed meter must be of adequate size to provide a steady inlet working pressure of 20mbar (8in wg) at the boiler. On completion, test the gas installation for tightness using the pressure drop method and suitable leak detection uid, purge as necessary. NOTE: Due to the modulating operation of the boiler and the need to check the gas inlet pressure and measure the gas rate at maximum rate, it will be necessary to force it to maximum. 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 ash between “Hi” and the “default display” this will indicate the boiler has been forced to maximum.

In communal or LPG installations where the gas rate cannot be measured it is acceptable to measure the combustion rate as described in the servicing section. On completion, press the “mode” and “+” buttons simultaneously, this will reset the boiler.

12 Commissioning

12.6 Heating System

Ensure that the external controls and programmer are calling for heat. Fully open all radiator valves, ow control valve, if tted, see diagram 5.1. Press the “MODE” button to change to the CH. Balance the radiators as required and if tted adjust valve 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 ow and return. NOTE: Should the system require that the appliance has to be adjusted, the front casing will need to be removed as described in the servicing section 13 and the control box lowered into its service position. The appliance pump has two speeds and can be adjusted to suit the requirements of the system. The appliance has an inbuilt automatic adjustable bypass valve. The pressure can be adjusted between approx 1.5 and 3.5mH The pressure changes by approx 0.1mH of the bypass screw, see diagram 12.3. Turning clockwise increases the pressure and turning anti-clockwise decreases the pressure. Allow the system to reach maximum temperature then switch off the boiler by isolating from the electrical supply. Drain the entire system rapidly whilst hot, using the drain taps at all the low points of the system. Fill and vent the system as described previously in section 12.2. Lock or remove the handle from control valve, if tted.

Adjust the boiler temperature controls and any system controls to their required settings.

2O but is factory pre-set to approx 2.5mH2O.

C can be achieved across

2O for each full turn

12.7 Completion

Fit the base coverplate, see diagram 12.4. 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.

13234

12.8 Instruct the User

● Demonstrate, then instruct the User about the lighting procedure and heating system controls operation.

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

● Draw attention, if applicable, to the current issue of the Gas Safety (Installation and Use) Regulations, Section 35, which imposes a duty of care on all persons who let out any property containing a gas appliance in the UK.

● The user shall not interfere with or adjust sealed components.

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

● Advise the user that, like all condensing boilers this appliance will produce a plume of condensation from the ue terminal in cool weather. This is due to the high efciency and hence low ue 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, relling and pressurising MUST be carried out by a competent person approved at the time by the Health and Safety Executive.

● Leave these instructions and the ‘Benchmark’ Installation, Commissioning and Service Record with the user.

13539

Diagram 12.4Diagram 12.3

Natural Gas (G20) to LPG (G31) Conversion

OFFSET ADJUSTMENT SCREW

THROTTLE

12.9 LPG CONVERSION - all models

As an option, a chargeable boiler only commissioning service can be provided by Glow-worm Service by calling telephone No. 01773 828100. NOTE: Steps 12.1 and 12.3 will need to be completed before the appliance can be converted. This conversion should only be carried out by a competent person approved at the time by the Health and Safety Executive. During the conversion to Propane use of a suitable ue gas analyser is necessary.

● The person carrying out a combustion measurement should have been assessed as competent in the use of a ue gas analyser and the interpretation of the results.

● The ue gas analyser used should be one meeting the requirements of BS7927 or BS-EN50379-3 and be calibrated in accordance with the analyser manufacturers’ requirements.

● Competence can be demonstrated by satisfactory completion of the CPA1 ACS assessment, which covers the use of electronic portable combustion gas analysers in accordance with BS 7967, parts 1 to 4.

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

● the appliance and system have been installed in accordance with the instructions.

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

● the integrity of the appliance combustion circuit and

relevant seals....

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

● the gas service isolation valve ‘F’, diagram 12.2, is open

(1) Gain access the gas valve, by removing the front and

inner casing panels, see diagram 13.2.

(2) Refer to diagram 12.5 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 13.1.

IMPORTANT: Remember to replace the cap on

completion of the test.

(6) Select the “

function by pressing the “Mode” button repeatedly. The boiler should re automatically.

The appliance will enter a self checking routine, then the

fan will start and the ignition sequence commence.

The boiler, if necessary, will automatically repeat the

ignition sequence a further 4 times.

If the burner fails to ignite the display will show “F1”.

Initially this may be due to air in the gas supply line.

Depress the ‘reset’ button on the fascia to clear the

display and the ignition sequence will be repeated.

If the appliance still does not light & goes “F1”, turn the

throttle anti-clockwise a further turn and press the reset button. The appliance will (after a short delay) again attempt to re. Repeat this procedure, up to a total of 2

extra turns on the throttle screw, until the appliance lights. (7) Check and adjust the burner %CO 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 ash between “Hi” and

the “default display” this will indicate the boiler has been

forced to maximum.

”, constant central heating with DHW

at maximum rate.

(8) If necessary, adjust the burner % CO2 to the value shown

in the “SETTING” column of the table, by turning the throttle screw (anti-clockwise to increase), see diagram

12.5 no more than 1/8 of a turn, waiting a minute to allow for the appliance to stabilise before checking or making further adjustments.

(9) Exit the check sequences press the “mode” and “+”

buttons simultaneously, this will reset the boiler to the default display.

(10) Check the burner % CO

shown in the “SETTING” column of the table.

(11) 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 ash between “Lo” and the “default display” this will indicate the boiler has been forced to minimum.

(12) Adjustment of the %CO

adjust the %CO column of the table with the offset adjustment, see diagram 12.5 (Rotate clockwise to increase).

(13) To exit the function press the “mode” and “+” buttons

simultaneously, this will reset the boiler to the default display.

(14) Repeat (8) and check CO

necessary. Check that the CO/CO value in the table below.

(15) Remove analyser probe from the test point and replace

the cap. Replace the control box and the inner and front panels.

(16) IMPORTANT: Fit the LPG conversion label supplied

in the documentation pack to the inner front panel alongside the data label. Ret the inner door and outer door.

(17) Complete the commissioning, refer to section 12.5 .

to the value shown in the “SETTING”

, at minimum rate, to the value

is very coarse so carefully

at maximum rate - adjust if

ratio is less than the

G31 BURNER % CO2

+ 0.0

- 0.9

+ 0.3

- 0.7

+ 0.2

- 0.8

Throttle TURNS

Diagram 12.5

CO/CO2

0.004

MODEL

24cxi

30cxi

38cxi

15440

CHECK

(case on)

9.2 to 10.2

10.0 to 11.0

9.2 to 10.2

SETTING

(case off)

10.0

10.5

9.8

13869

13 Servicing

IMPORTANT NOTES:

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

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

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 specication 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 14.

6. After servicing, complete the relevant Service Interval Record section of the Benchmark Checklist located in the centre pages of this document.

General Inspection

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

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

● The integrity of the appliance combustion circuit and relevant seals.

● Electrical, gas and water connections.

● System pressure.

● the combustion performance, refer to the following procedure.

● The operational gas inlet pressure and gas rates, refer to the commissioning section paragraph 12.5. Correct any fault before continuing.

COMPETENCY TO CARRY OUT THE CHECK OF COMBUSTION PERFORMANCE

NOTE: BS 6798: 2009 Specication for installation and

maintenance of gas-red boilers of rated input not exceeding 70kW net advises that:

● The person carrying out a combustion measurement must be assessed as competent in the use of a ue gas analyser and the interpretation of the results.

● The ue gas analyser used should be one meeting the requirements of BS7927 or BS-EN50379-3 and be calibrated in accordance with the analyser manufacturers’ requirements.

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

● Select the “ function by pressing the “Mode” button repeatedly, refer to commissioning section. The boiler should re automatically. NOTE: Safe combustion can only be veried by measuring CO/CO2 ratio. This must not exceed the value shown in the table opposite.

COMBUSTION CHECK AND SETTING THE AIR/ GAS RATIO VALVE

● Remove the front casing panel, see diagram 13.2 and hinge down the control box. Taking care not to touch any internal components, proceed as follows:

● Connect the CO2 combustion analyser to the relevant test point, see diagram 13.1.

”, constant central heating with DHW

1. Maximum Rate Check and Adjustment

NOTE: To verify the maximum gas rate CO2 setting the appliance must be checked at the maximum rate rst. 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 ash between “Hi” and the “default display” this will indicate the boiler has been forced to maximum. Wait until the CO2 value is stable and check that the value is within the range specied in table in the “check” column. If the combustion reading is not within the acceptable values AND the integrity of the complete ue system and combustion circuit seals have been veried and the inlet gas pressure (and gas rate) have been veried, then, it will necessary to adjust the combustion rate of the appliance. NOTE: Adjustment is made by turning the gas valve throttle an ⅛ of a turn, waiting 1 minute to allow the appliance to stabilise before checking or making further adjustments.

● Rotate the “throttle”(anti-clockwise to increase), to the required CO2, refer to diagram 12.5 and the “SETTING” column in the table.

● Exit the forced rate function, press the “mode” and “+” buttons simultaneously, this will reset the boiler to the default display. Now proceed to check the minimum rate adjustment.

G31 BURNER % CO2

MODEL CHECK

(case on)

24cxi 9.2 to 10.2 10.0 +0.0

30cxi 10.0 to 11.0 10.5 +0.3

38cxi 9.2 to 10.2 9.8 +0.2

G20 BURNER % CO

MODEL CHECK

(case on)

24cxi 8.5 to 9.6 9.1 +0.2

30cxi 8.5 to 9.6 9.1 +0.2

38cxi 8.5 to 9.3 8.8 +0.2

SETTING

(case off)

- 0.9

- 0.7

- 0.8

SETTING

(case off)

- 0.5

CO/CO2

ratio

0.004

CO/CO2

ratio

0.004

13 Servicing

2. Minimum Rate Check and Adjustment

● Now check the minimum gas rate CO2 setting: Press and release the “reset” button on the controls fascia, then immediately press and hold in either of the “+” buttons. After approximately 5 seconds “Hi” will be displayed. Pressing the “+” or “-” buttons will toggle between “Hi” and “Lo”. Press the mode button when “Lo” is selected, this will force the boiler to minimum rate and the display will ash “Lo”, indicating the boiler is operating at minimum.

● Wait until the CO2 value is stable and check that the value is within the range specied in table in the “check” column. If adjustment is necessary, proceed as follows: NOTE: Adjustment of the CO2 at minimum rate is very coarse and should not be adjusted more than an ⅛ of a turn at a time. Wait 1 minute to allow the appliance to stabilise before checking or making further adjustments.

● Gradually rotate the “offset adjustment” (anti-clockwise to decrease) to the required CO2, refer to diagram 12.5 and the “SETTING” column in the table.

● Exit the minimum rate function, press the “mode” and “+” buttons simultaneously, this will reset the boiler to the default display.

3. Re-Check CO2 and check the CO/CO2 combustion ratio.

● Re-check the maximum and minimum CO2 values to ensure that they are within the “setting” limits in the table then check the CO/CO2 combustion ratio does not exceed the value in the CO/CO2 column of the table. If the CO/CO2 setting exceeds the value in the table, a complete servicing of the appliance will be necessary, refer to section 13.1. If the CO2 and the CO/CO2 ratio falls within the tolerances quoted, exit the function press the “mode” and “+” buttons simultaneously, this will reset the boiler to the default display. Remove the analyser probe and replace the cap on the sampling point, replace the controls fascia, inner and front casing panels. IMPORTANT: Remember to replace the sample point cap on completion of the test.

15442

Diagram 13.1

13649

Diagram 13.2

GAS RATE CHECK

Check the gas rates as described in the commissioning section.

COMPLETION

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

13.1 Servicing

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

checks did not require adjustment then it will not be necessary to complete a full service. All routine servicing requirements can be achieved by the removal of the front panel, see diagram 13.2. Position the control box into the service position, see diagram 13.3. Before commencing with a service or replacement of parts. The boiler should be isolated from the electrical and gas supplies.

13554

Diagram 13.3

13 Servicing

13.2 Spark Electrode

Disconnect the spark electrode plug and earth lead, see diagram 13.5. Remove the two securing screws and withdraw the spark electrode carefully from the combustion chamber, see diagram 13.4. 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.

13515

13.3 Burner

NOTE:

● The following procedure will require that you replace the burner door seal and nyloc nuts.

● Removal of the burner is not necessary during a normal service, but if it is removed it will require a new gasket, see diagram 13.6.

● 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 13.5. Disconnect the electrical plug from the fan. Disconnect the spark electrode plug and earth lead, refer to diagram 13.5. Remove the gas pipe retaining clip. Remove the ve combustion chamber/burner door securing nuts, see diagram 13.7, these should be discarded and replaced with the new nylocs nuts 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 13.7.

Diagram 13.4

13266

13518

Diagram 13.5

Diagram 13.6

13 Servicing

13555

13.4. Combustion Chamber and Heat Exchanger

Remove loose debris from inside the combustion chamber using a soft brush and vacuum cleaner. Carefully ush by spraying water into the heat exchanger, any remaining debris should pass through the condensate trap (Ensure the water is kept away from electrical components).

13.5 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 tting the new seal, see diagram 13.8. Ret the inner casing panel. NOTE: Ensure the seal is tted correctly giving an airtight joint.

13.6 Service Completion

Re-check the combustion as described at the beginning of this section. On completion of the service the “Benchmark” Service Record should be completed.

Diagram 13.7

13272

Diagram 13.8

14 Fault Finding

14.1 Preliminary fault nding

The following checks should be performed before proceeding onto specic 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 11.4 for access and diagram 14.4.

• Check the electrical installation and appliance, carry out tests for earth continuity, polarity, short circuit and resistance to earth, using a suitable multimeter.

An aid to test

Remove the front casing panel, see diagram 13.2 and the control panel securing screw, see diagram 14.1 then lower into service the position. Remove the rear panel by prising the retaining clips, see diagram 14.1. Carry out the tests at connector plug X17, see diagram 14.2. Check chassis earth at a bare metal point on the boiler.

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

service isolation valve is turned on, see diagram 12.2.

• Check pressure at the gas service isolation valve, refer to

section 12.5.

• Check that the heating system pressure indicates at least

1mb, if not, ll and vent the system as described in section

12.2.

• Check that all external controls are on.

• Check the functional ow diagram, 14.5.

13535

Diagram 14.1

13845

14.2 Fault Codes

Fault codes take priority over all other display functions in the event of a fault occurring, refer to diagram 14.6. If multiple faults occur the codes will be displayed for approx. 2 seconds, alternatively.

14.3 Fault Memory

The Fault memory stores details of the ten most recent faults.

To access this menu, refer to diagram 14.3: a) Press and hold ‘MODE’ for 5 seconds. b) When the display shows a ashing ‘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.

14.4 Diagnostic Menu

The Diagnostic Menu provides the ability to view and change certain parameters. See diagram 14.7 for available parameters.

14.5 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 14.8.

Diagram 14.2

13452

Diagram 14.3

14 Fault Finding

13166

Diagram 14.4

14 Fault Finding

CENTRAL HEATING

13012

DHW

13015

Diagram 14.5

14 Fault Finding

Fault Codes

13860

If -9OC is displayed, check that the DHW thermistor wires are unconnected and are not faulty or trapped.

Diagram 14.6

14 Fault Finding

Fault Codes (continued)

13447

Diagram 14.6 continued.

14 Fault Finding

To enter the diagnostic menu: a) Press and hold the ‘MODE’ button for 5 seconds. The display will change to ashing ‘0’. b) Use the ‘+’ or ‘-’ buttons to scroll to 96 (This is the installer level access password). c) Press ‘MODE’ to conrm, see diagnostic display 1. Use the ‘+’ or ‘-’ buttons to view the appropriate diagnostic number, see diagram 14.7. If necessary the values can be changed by: a) Pressing the ‘MODE’ button.

13450

b) The diagnostic value ashes, 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.

13451

14 Fault Finding

Diagnostic Menu - Level 1 Installer Access

13578

(see State Lists table)

Indicates read and write function - all other diagnostics are read only

Diagram 14.7

14 Fault Finding

State list - Accessed through Diagnostic Codes - Level 1, Installer Access d.99

STATE LISTS

Central heating mode 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

Domestic hot water mode

S.10 domestic hot water demand S.11 fan pre-run S.13 ignition

S.14 burner on S.15 pump / fan overrun S.16 fan overrun S.17 pump overrun

NORMAL OPERATING STATE FOR CH MODE

NORMAL OPERATING STATE FOR DHW MODE

13011

Preheat mode

S.20 domestic hot water cycling mode active S.21 fan pre-run S.22 Pump pre run S.23 ignition S.24 burner on S.25 pump / fan overrun S.26 fan overrun S.27 pump overrun S.28 Anticycling period

NORMAL OPERATING STATE FOR PRE-HEAT MODE

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 Antifreeze active – fan speed variation too high Check fan connection. – waiting during blocking function S.34 frost protection active (Priority 4) Temperature below 8 connection if this is not true. S.36 No Heating demand from external controls 24V Check wiring in external controller.

Check wiring at Installer Interface.

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

Check flow & return thermistor connections to pipes. Check harness connection to thermistor. Check harness wires are not trapped between any internal components.

C - check thermistor

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.97 Water pressure sensor check is running, Check connection to pressure sensor. demand (DHW or heating) is blocked Check pump has not seized. S.98 Flow / Return - sensor check is running, demand (DHW or heating) is blocked

Check flow & return thermistor connections to pipes. Check harness connection to thermistor. Check harness wires are not trapped between any internal components.

Diagram 14.8

15 Replacement of Parts

15.1 General

IMPORTANT: The replacement of parts described in sections

15.5 to 15.9 and section 15.12 will require the removal of the burner module assembly and the replacement of 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 tted. Replacement of parts must be carried out by a competent person approved at the time by the Health and Safety Executive. 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 marked ‘F’, see diagram 12.2. Unless stated otherwise parts are replaced in the reverse order to removal. After replacing any parts always test for gas soundness and if necessary carry out functional test of the controls.

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. If the appliance site situation has sufcient side clearances the side panels can be hinged sideways and removed to aid replacement of parts. To remove a side panel undo the three screws securing each side panel to the boiler, two at the front and one at the top.

15.2 Spark Electrode

For access, refer to section 15.1. Refer to section 13.2 for removal.

15.3 Igniter Unit

For access, refer to section 15.1. Remove ignition lead and electrical connections then remove igniter unit by removing two securing screws, see diagram

15.1.

15.4 Ignition Lead

For access, refer to section 15.1. Pull the spark plug style connector off the spark electrode, refer to diagram 13.5. and the spade connector connected to the igniter unit, see diagram 15.1.

13274

Draining of Boiler Heating Circuit

Drain down the Heating Circuit of the boiler only, by closing the heating ow and return isolating valves marked ‘B’, see diagram 12.2. Attach a length of hose to the drain point and open the drain valve, see diagram 8.1. After replacing part, close the drain valve and remove the hose. Open the heating ow and return isolating valves and rell, vent and pressurise the heating circuit. See section 12.2. Check for leaks.

Draining of Boiler Hot Water Circuit

Drain the Domestic Hot Water circuit by closing the cold-water isolation valve on the wall mounting jig. Open one or more hot water taps to drain the hot water circuit. After replacing part open the cold-water isolation valve and slowly open a hot water tap to remove air. Close the hot water tap and check for any leaks.

Diagram 15.1

15 Replacement of Parts

REAR

VENTURI PLATE

SECURING SCREW (3)

15.5 Gas Valve

For access, refer to section 15.1. Refer to section 13.3 for removal of the fan, gas valve and burner assembly. Before removing the gas valve note its orientation in relationship to the fan. Remove the three securing screws, which also secures the plastic swirl plate to the venturi on the fan, see diagram 15.2. Withdraw the gas valve. After assembly test for gas tightness and purge in accordance with the current issue of BS6891or in IE, the current edition of I.S.813 “Domestic Gas Installations”. Check the combustion CO2 and adjust if necessary, see section 13.

15.6 Fan

For access, refer to section 15.1. Refer to section 13.3 for removal of the fan, gas valve and burner assembly. Remove the gas valve as described in section 15.5. Remove the two securing screws, nuts and washers to separate the fan from the gas manifold extension tube and gas manifold, see diagram 15.3. 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”.

13276

Diagram 15.2

13238

15.7 Burner

For access, refer to section 15.1. Refer to section 13.3 for removal of the fan, gas valve and burner assembly. Remove the four screws that secure the burner, see diagram

13.6.

NOTE: The burner will require a new gasket.

15.8 Front Insulation

For access, refer to section 15.1. Refer to section 13.3 for removal of the burner module. Remove burner as described in section 15.7. Remove spark electrode, see section 15.2.

NOTE: The burner will require a new gasket when retted.

15.9 Rear Insulation

For access, refer to section 15.1. Refer to section 13.3 for removal of the burner module. Remove securing screw and washer in the centre of the insulation and withdraw insulation, see diagram 15.4.

WASHER

Diagram 15.3

13277

INSULATION

HEAT EXCHANGER

SECURING SCREW

Diagram 15.4

15 Replacement of Parts

FIBRE WASHER

GLASS

STEEL WASHER

CIRCLIP

15.10 Viewing Window

For access, refer to section 15.1. Refer to diagram 15.5. Remove circlip. Remove steel washer. Remove glass. Remove bre washer.

15.11 Expansion Vessel

For access, refer to section 15.1. Drain the boiler heating circuit as described in the appropriate section of 15.1. Undo the coupling at the base of the vessel, see diagram

15.6.

While holding the vessel remove the securing bolt on the top panel of the boiler. Remove upper support bracket. Fit a new gasket between the expansion vessel and coupling. Rell, vent and pressurise the boiler.

13278

Diagram 15.5

13279

Diagram 15.6

15 Replacement of Parts

15.12 Heat Exchanger

Refer to Manual Handling section. For access, refer to section 15.1. Refer to section 13.3 for removal of the fan, gas valve and burner assembly. Drain the boiler heating circuit as described in the appropriate section of 15.1. Drain the boiler hot water circuit as described in the appropriate section of 15.1. Remove the clip securing the condense hose adapter to heat exchanger, refer to diagram 15.7. Pull the condense hose adapter off the heat exchanger connection. Disconnect the central heating ow and return pipes from the heat exchanger. Move the pipes away from the heat exchanger. Slacken the three heat exchanger securing screws and clamps (two at the top and one at the bottom) to remove the heat exchanger, see diagram 15.8. CAUTION: There will be water in the heat exchanger. Carefully ease heat exchanger out.

15.13 Flue Hood

For access, refer to section 15.1. Remove heat exchanger as described in section 15.12. Remove the two securing screws and pull the ue hood down and away from the ue hood bracket and ue elbow, see diagram 15.9.

13257

Diagram 15.7

13522

Diagram 15.8

Diagram 15.9

13281

15 Replacement of Parts

15.14 Heating Flow Thermistor

For access, refer to section 15.1. Refer to diagram 15.10. Remove the electrical connections from the thermistor. Remove the retaining clip from the ow pipe. NOTE: When reconnecting, the polarity of the wiring to thermistors is not important.

15.15 Heating Return Thermistor

For access, refer to section 15.1. Refer to diagram 15.10. 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.

15.16 Condense Trap and Siphonic Drain

For access, refer to section 15.1. Refer to diagram 15.11. Remove the igniter unit as described in section 15.3 to improve accessibility. Remove the securing clip from the heat exchanger adapter, then disconnect the adapter and exible hose. Lift the siphon adapter and hose out of the condensate trap and siphonic drain, do not disconnect the hose. Disconnect the drain connection. Slacken to disengage but do not remove the two securing screws. The condense trap will contain water, lift taking care not to spill the water. After replacement and before tting the adapter ll the trap with water.

Cleaning

Remove the condense trap as previously described. Remove the oat 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.

13316

Diagram 15.10

13544

Diagram 15.11

15 Replacement of Parts

15.17 Pump (head only)

For access, refer to section 15.1. Drain the boiler heating circuit as described in the appropriate section of 15.1. Refer to diagram 15.12. Remove the four cap head screws. Carefully remove the pump head together with cable. Do not strain cable. Support the pump head, unscrew cable cover at the side of pump head and take off. Disconnect wiring from pump head. Reconnect wiring to new pump head and t cover. Fit the new pump head with ‘O’ ring.

Complete pump replacement

For access, refer to section 15.1. Drain the boiler heating circuit as described in the appropriate section of 15.1. Refer to diagram 15.12, 15.13. Remove the pump head as described in section 15.17. Remove the safety discharge valve as described in section

15.18. Disconnect the expansion vessel pipe at the coupling, see diagram 15.6 and at the pump housing by removing the securing clip, see diagram 15.12. Disconnect the central heating ow pipe union connection and withdraw the pump securing clip. Spring back the rear location bracket to release the pump housing and gently rotate backwards and forwards whilst easing the pump to the right to disengage from the 3 way valve.

13257

13589

15.18 Safety Discharge Valve

For access, refer to section 15.1. Drain the boiler heating circuit as described in the appropriate section of 15.1. Refer to diagram 15.13. Undo the safety discharge valve union and remove from the pipework. Remove the securing clip and withdraw the safety discharge valve. Fit new ‘O’ ring. Rell, vent and pressurise the boiler.

Diagram 15.12

13256

Diagram 15.13

15 Replacement of Parts

MAINTENANCE

15.19 Domestic Hot Water Thermistor

For access, refer to section 15.1. Refer to diagram 15.14. Disconnect the domestic hot water thermistor electrical connections Remove hot water thermistor and retaining clip. Remove domestic hot water thermistor from clip. NOTE: When reconnecting electrical connections, polarity is not important. Carry out a functional test of the controls.

15.20 Automatic Air Vent

For access, refer to section 15.1. Drain the boiler heating circuit as described in the appropriate section of 15.1. Refer to diagram 15.15 and gain access through the plastic maintenance cover. Unscrew the automatic air vent. Fit the new automatic air vent and ‘O’ ring ensuring the vent cap is left loose. Rell, vent and pressurise the boiler.

15.21 Low Water Pressure Sensor

For access, refer to section 15.1. Drain the boiler heating circuit as described in the appropriate section of 15.1. Refer to diagram 15.16. Disconnect the electrical lead. Remove the retaining clip, remove the low water pressure sensor. Fit new ‘O’ ring. Fit the new low water pressure sensor. Rell vent and pressurise the boiler.

RETAINING CLIP

13550

Diagram 15.14

13258

COVER

AUTOMATIC AIR VENT

Diagram 15.15

13315

Diagram 15.16

15 Replacement of Parts

15.22 Flow Sensor

For access, refer to section 15.1. Drain the boiler hot water circuit as described in the appropriate section of 15.1. Refer to diagram 15.17. Remove the front securing clip. Disconnect the domestic cold water pipe at the bulkhead connection and remove the pipe. Remove the rear securing clip. Disengage the ow sensor housing. Remove the electrical connection. Fit new ‘O’ rings. After replacing the ow sensor, open the cold-water isolation valve and slowly open a hot water tap to remove air.

15.23 Bypass

For access, refer to section 15.1. Drain the boiler heating circuit as described in the appropriate section of 15.1. Refer to diagram 15.18. Remove the retaining clip to remove the bypass screw. Fit new ‘O’ rings. After replacing the bypass, rell, vent and pressurise the boiler.

15.24 Three Way Valve

For access, refer to section 15.1. Drain the boiler heating circuit as described in the appropriate section of 15.1. Refer to diagram 15.18. Remove the retaining clips and three securing screws to remove the three way valve. Undo the securing nut to check the solenoid actuator, spindle and shaft. Fit new ‘O’ rings before replacing the three way valve assembly. Rell, vent and pressurise the boiler.

13282

Diagram 15.17

13259

15.25 Plate-to-Plate Heat Exchanger

For access, refer to section 15.1. Drain the boiler heating and domestic hot water circuits as described in the appropriate sections of 15.1. Refer to diagram 15.19. Remove the 4 securing screws. Remove the plate-to-plate heat exchanger by lifting it up and over the top of the left hand hydroblock. When replacing the plate-to-plate heat exchanger ensure that the four rubber sealing washers are tted into the hydroblock. NOTE: The plate-to-plate heat exchanger only ts one way. Rell, vent and pressurise the boiler.

Diagram 15.18

15 Replacement of Parts

PLATE TO PLATE

15.26 Hydroblock and Bypass Tube

For access, refer to section 15.1. IMPORTANT: To replace the bypass tube and seals the LH and RH hydroblocks will need to be removed. The following procedure must also be used for the replacement of either the LH or RH hydroblock. Refer to section 15.1 and drain the boiler heating circuit and the boiler domestic water circuit.

13331

Disconnect the CH ow, return and DHW inlet pipes at the bulkhead connectors, then the retaining clips, remove the pipes and “o” ring seals. Remove the low water pressure sensor as described in section 15.21. Remove the ow sensor as described in section 15.22. Remove the 3 way valve as described in section 15.24. Remove the pump as described in section 15.17. Remove the plate to plate heat exchanger, refer to section

15.25. Disconnect the central heating ow at the heat exchanger connector then remove the retaining clip at the hydroblock. Disconnect the pipe and “O” ring. Remove clips from the plastic LH and RH hydroblocks retaining the DHW, DCW and heating ow pipes, see diagram

15.20. Remove the CH lter from the heating ow pipe port in the LH hydroblock. The lter is a push-t in the hydroblock port. Grip the LH and RH hydroblocks simultaneously and lift clear of the spigots on the mounting bracket. NOTE: Before removing the bypass tube from the hydroblocks, take note of the tube position and orientation. Fit the new bypass tube with new ‘O’ ring seals and reassemble to hydroblocks. Before retting the plate to plate heat exchanger ensure that the four rubber seals are in place, two in the LH and two in the RH hydroblock. Fit new ‘O’ rings to pipes. Rell system, vent and pressurise the boiler.

CH FLOW (from heat exchanger)

LH HYDROBLOCK DHW OUTLET RETAINING CLIP

RETAINING CLIP

Diagram 15.19

MOUNTING BRACKET

RH HYDROBLOCK DCW INLET RETAINING CLIP

BYPASS TUBE

13588

RUBBER SEAL (4 OFF)

SPIGOT (4 OFF)

3 WAY VALVE SEALS

DCW INLET

FILTER

(in Hydroblock)

DHW OUTLET

CH FLOW

Diagram 15.20

15 Replacement of Parts

15.27 Access User Interface and Main PCB

For access, refer to section 15.1. Remove control box retaining screw, see diagram 15.21. Hinge down the control box. Release the control box cover by carefully pressing the four retaining latches, see diagram 15.21.

15.28 Main PCB

IMPORTANT: When replacing the board refer to instructions

supplied with the replacement. For access, refer to section 15.27. Remove the electrical connections to the PCB. Ease back the four PCB retaining clips and withdraw the PCB from the retaining lugs, see diagram 15.22. When retting the rear panel ensure the leads are not trapped.

15.29 User Interface

IMPORTANT: When replacing the board refer to instructions

supplied with the replacement. Refer to section 15.27 for access. Remove main PCB, refer to section 15.28. Remove electrical connection. Gently ease back the retaining clips, see diagram 15.23. Withdraw the board.

13535

Diagram 15.21

13313

15.30 Fuse, Main PCB - Control Box

For access, refer to section 15.27. The fuse is located at top left hand side of the PCB, see diagram 15.22.

15.31 Control Box

For access, refer to section 15.27. Remove relevant plugs and connectors, refer to wiring diagram 14.4. 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

15.21.

15.32 Inner Casing Panel Seal

For access, refer to section 15.1. Refer to diagram 13.8. 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. Ret the inner casing panel. NOTE: Ensure the seal is tted correctly giving an airtight joint.

Diagram 15.22

13355

Diagram 15.23

16 Spare Parts

16.1 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.

Key No. Part No. Description GC Part No.

1 2000802463 Burner - 24cxi E84021 1 2000801840 Burner - 30cxi E88867 1 2000802662 Burner - 38cxi H36356 2 0020014173 Pressure Relief Valve H42758 3 0020014161 Automatic Air Vent H42754 4 0020014171 Pump H42760 5 801655 Igniter E84015 6 0020038061 User Interface H52596 7 0020023825 Main PCB H42783 8 0020037309 Fan H53083 9 2000802664 Gas Valve - 24, 30cxi E84004 9 802172 Gas Valve - 38cxi E99505 10 0020014174 Flow Sensor H43155 11 0020014169 Bypass H42768 12 0020014168 3 Way Valve H42766 13 0020014160 Domestic Hot Water Thermistor H36325 14 0020020781 NTC 720340 15 0020014402 Plate to Plate Heat Exchanger H43160 16 2000802462 Electrode H53089 17 801635 Burner Door Seal Kit E85008

16 Spare Parts

13740

Diagram 16.1

17 Manual Handling

IMPORTANT. With regards to the Manual Handling Operations, 1992

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

General recommendations when handling

Clear the route before attempting the lift. Ensure safe lifting techniques are used – keep back straight – bend using legs. Keep load as close to body as possible. Do not twist – reposition feet instead. If 2 persons performing lift, ensure co-ordinated movements during lift. Avoid upper body/top heavy bending - do not lean forward/sideways. Recommend wear suitable cut resistant gloves with good grip to protect against sharp edges and ensure good grip. Always use assistance if required.

Removal of carton from delivery van

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

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

Carriage of carton from point of delivery to point of installation – rst or higher oor, cellar.

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

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

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

Positioning of Appliance for Final Installation – no obstructions.

Recommend 2 persons lift appliance to position into place. Fit bracket securely onto wall before lifting appliance into position. Obtain rm grip on front and sides of appliance, lift upwards, ensure stable balance achieved and lift upwards to position in place on bracket. Ensure safe lifting techniques are used – keep back straight – bend using legs - when lifting load from oor level. Do not twist – reposition feet instead. Keep boiler as close as possible to body throughout lift to minimise strain on back. Ensure co-ordinated movements to ensure equal spread of weight of load. Always use assistance if required. Recommend wear suitable cut resistant gloves with good grip to protect against sharp edges and ensure good grip when handling appliance.

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

Recommend 2 persons lift appliance to position into place. Fit bracket securely onto wall before lifting appliance into position. Obtain rm grip on front and sides of appliance, lift upwards, onto worktop if practicable. Ensure stable balance achieved and lift upwards to position in place on bracket. If 2 persons positioning onto bracket obtain rm grip at front and sides/base of boiler. Ensure co-ordinated movements during 2 person lifts to ensure equal spread of weight of load. Ensure safe lifting techniques are used – keep back straight – bend using legs - when lifting load from oor level. Do not twist – reposition feet instead. Keep boiler as close as possible to body throughout lift to minimise strain on back. Avoid upper body/top heavy bending - do not lean forward/sideways. Always use assistance if required. Recommend wear suitable cut resistant gloves with good grip to protect against sharp edges and ensure good grip when handling appliance.

Positioning of Appliance for Final Installation – within compartment etc. restricting installation.

Recommend 2 persons lift appliance to position into place, space permitting. Fit bracket securely onto wall before lifting appliance into position. Obtain rm grip on front and sides of appliance, lift upwards, onto worktop if practicable. Ensure stable balance achieved and lift upwards to drop into place onto bracket. If 2 persons positioning onto bracket obtain rm grip at front and sides/base of boiler. Ensure coordinated movements during 2 person lifts to ensure equal spread of weight of load. If 1 person positioning onto bracket recommend obtain rm grip supporting base of boiler. Ensure safe lifting techniques are used – keep back straight – bend using legs - when lifting load from oor level. Do not twist – reposition feet instead. Keep boiler as close as possible to body throughout lift to minimise strain on back. Always use assistance if required. Recommend wear suitable cut resistant gloves with good grip to protect against sharp edges and ensure good grip when handling appliance.

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

Recommend 2 persons lift appliance to position into place, space permitting. Fit bracket securely onto wall before lifting appliance into position. Obtain rm grip on front and sides of appliance, lift upwards, ensure stable balance achieved and lift upwards to drop into place onto bracket. If 2 persons positioning onto bracket obtain rm grip at front and sides/base of boiler. Ensure co-ordinated movements during 2 person lifts to ensure equal spread of weight of load. If 1 person positioning onto bracket recommend obtain rm grip supporting base of boiler. Ensure safe lifting techniques are used - keep back straight – bend using legs - when lifting load from oor level. Do not twist – reposition feet instead. Keep boiler as close as possible to body throughout lift to minimise strain on back. Always use assistance if required. Recommend wear suitable cut resistant gloves with good grip to protect against sharp edges and ensure good grip when handling appliance. It is recommended a risk assessment of the roof space area be carried out before moving the appliance into the area to take into account access, stability of ooring, lighting and other factors, and appropriate measures taken.

Unpacking of appliance from carton.

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

18 Declaration of Conformity

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

0020020820-04 09.09

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

www.high-efciency.info

Glow-worm Ultracom cxi User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual