Glow-worm ULTRACON 18SXI, ULTRACON 30SXI Installation And Servicing Manual

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Installation and Servicing

High Efﬁciency

Condensing Combination

Boilers

Ultracom

www.glow-worm.co.uk

30sxi

G.C. No. 41-019-08

18sxi

G.C. No. 41-019-07

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. In addition this product is guaranteed for 12

months from the date of installation or 18 months from the date of manufacture, whichever is the

shorter, for labour.

The second year of the parts guarantee, from the beginning of the 13th month onwards after

installation or manufacture, is conditional upon the boiler having been serviced by a CORGI

registered gas installer,

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

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

components issued within the applicable guarantee period still beneﬁt from a 12 month warranty

from the date of issue by the manufacturer.

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

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

telephoning the Glow-worm Customer Service number 01773 828100.

Guarantee Registration

Customer Service:

Tel. 01773 828100

Technical Helpline:

Tel. 01773 828300

General and Sales enquiries:

Tel. 01773 824639

Fax: 01773 820569

Tel. 0800 0732142

CONTENTS DESCRIPTION SECTION PAGE

Warnings 4 Important Information 4 Statutory Requirements 5 Boiler Design 6 Safety Devices 6 Servicing, Maintenance and Spare Parts 6

Boiler Speciﬁcation 1 7 Boiler Dimensions & Hydraulic Schematic 2 8 Boiler Location, Clearances and Ventilation 3 9 Flue Options and Terminal Clearances 4 10 Water System 5 12 Installation Preparation 6 14 Boiler Fixing 7 15 Gas/Water Connection 8 16 Safety Discharge Valve and Condensate Connections 9 17 Flue Length Preparation and Installation 10 19 Electrical Connection 11 34 Commissioning 12 36

Servicing 13 40 Fault Finding 14 44 Replacement of Parts 15 52 Spare Parts 16 60 Manual Handling 17 62 Declaration of Conformity - 63

INTRODUCTION

INSTALLATION

MAINTENANCE

These instructions consist of, Installation, Servicing, Fault Finding, Replacement of Parts

and Spares. The instructions are an integral part of the appliance and must, to comply

with the current issue of the Gas Safety (Installation and Use) Regulations, be handed to

the user on completion of the installation.

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 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 identiﬁed as to its use.

Alternatively connection can be made through an unswitched shuttered socket and 3A fused 3-pin plug both to the current issue of BS 1363, provided they are not used in a room containing a bath or shower.

Wiring to the boiler must be PVC 85OC insulated cable, not less than 0.75mm2 (24/0.20mm).

Testing and Certification

This boiler is tested and certiﬁcated for safety and performance. It is, therefore, important that no alteration is made to the boiler, without permission, in writing, by Glowworm.

Any alteration not approved by Glow-worm, could invalidate the certiﬁcation, boiler warranty and may also infringe the current issue of the statutory requirements.

Statutory Requirements

CE Mark

This boiler meets the requirements of Statutory Instrument, No. 3083 The Boiler (Efﬁciency) Regulations, and therefore is deemed to meet the requirements of Directive 92/42/EEC on the efﬁciency requirements for new hot water boilers ﬁred with liquid or gaseous fuels.

Type test for purposes of Regulation 5 certiﬁed by: Notiﬁed body 0087.

Product/production certiﬁed by: Notiﬁed body

0086.

The CE mark on this appliance shows compliance with:

1. Directive 90/396/EEC on the approximation of the laws of the Member States relating to appliances burning gaseous fuels.

2. Directive 73/23/EEC on the harmonisation of the Laws of the Member States relating to electrical equipment designed for use within certain voltage limits.

3. Directive 89/336/EEC on the approximation of the Laws of the Member States relating to electromagnetic compatibility.

IMPORTANT

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

The installation of this boiler must be carried out by a competent person in accordance the rules in force in the countries of destination.

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

Statutory Requirements

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

requirements of the current issue of BS6798 and be carried out by a competent person as described in the following regulations:

The manufacturer’s instructions supplied.

The Gas Safety (Installation and Use) Regulations.

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

The Water Fittings Regulations or Water byelaws in Scotland.

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

The Current I.E.E. Wiring Regulations.

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

In IE, the installation must be carried out by a competent person and installed in accordance with the current edition

of I.S.813 “Domestic Gas Installations”, the current Building Regulations and reference should be made to the current ETCI rules for Electrical Installation.

GB: the following Codes of Practice apply:

BS4814, BS6798, BS5440 Part 1 and 2, BS5546 Part 1, BS5449, BS6891, BS6700, BS7074 Part 1 and 2, BS7593, BS7671.

IE: I.S.813, BS5546, BS 5449, BS 7074, BS 7593.

NOTE: For further information, see the current issue of the

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

1) Central heating system speciﬁcation (CheSS)

and

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

Gas Supply

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

In GB, this is BS6891.

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

Installations”.

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

On completion, test the gas installation for tightness using the pressure drop method and suitable leak detection ﬂuid, purge in accordance with the above standard.

Domestic Hot Water

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

GB: Guidance G17 to G24 and recommendation R17 to R24 of the Water Regulations Guide.

IE: The current edition of I.S.813 “Domestic Gas Installations”.

Heating System

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

Fittings) Regulations 1999 (for Scotland, the Water Byelaws 2000, Scotland).

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

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

Boiler Design

This boiler is designed to provide central heating from a sealed water system with a fully indirect cylinder, pumped circulation. The pump, expansion vessel and associated safety devices are all ﬁtted 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.

Condensate Drain

A plastic drain pipe must be ﬁtted to allow discharge of condensate to a drain.

Electrical Supply Failure

The boiler will not work without an electrical supply.

Normal operation of the boiler should resume when the electrical supply is restored.

Reset any external controls, to resume normal operation of the central heating.

If the boiler does not resume normal operation press the reset button. If the boiler does not resume normal operation after this call your Installation/Servicing company or Glowworm service.

Overheating Safety

The boiler software is designed to recognise the potential for an overheat lockout and will shutdown before this happens. To restart the boiler, press the reset button on the controls fascia.

If the boiler fails to resume normal operation and all external controls are calling for heat, then call your Installation/ Servicing company or Glow-worm service.

Safety Discharge Valve

A safety discharge valve and discharge pipe are ﬁtted 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.

Safety Devices

Frost protection

The appliance has a built in frost protection device that protects the boiler from freezing. With the gas and electric supplies ON and irrespective of any room thermostat setting, the frost protection device will operate the pump when the temperature of the boiler water falls below 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 10

C 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.

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 flue terminal

Like all condensing boilers this appliance will produce a plume of condensation from the ﬂue terminal in cool weather. This is due to the high efﬁciency and hence low ﬂue gas temperature of the boiler.

This is normal and not an indication of a fault.

Servicing, Maintenance and Spare Parts

Servicing and Maintenance

To ensure the continued efﬁcient and safe operation of the boiler it is recommended that it is checked and serviced as necessary at regular intervals. The frequency of servicing will depend upon the particular installation conditions and usage. If this appliance is installed in a rented property there is a duty

of care imposed on the owner of the property by the current issue of the Gas Safety (Installation and Use) Regulations,

Section 35. Servicing/maintenance should be carried out by a competent person in accordance with the rules in force in the countries of destination. To obtain service, please call your installer or Glow-worm’s own service organisation using the telephone number on the inside front cover of this literature.

“Benchmark” scheme

Glow-worm support the Benchmark initiative. It is very important that the Installation, Commissioning and Service Record is completed by the installation engineer and handed over to the user.

Spare Parts

Remember, when replacing a part on this appliance, use only spare parts that you can be assured conform to the safety and performance speciﬁcation that we require. Do not use reconditioned or copy parts that have not been clearly authorised by Glow-worm.

If a part is required contact Glow-worm’s own service organisation.

Please quote the name of the boiler this infomation will be on the name badge on the front of the appliance.

If in doubt seek advice from the local gas company or Glowworm’s own service organisation using the telephone number on the inside front cover of this booklet.

1 Boiler Speciﬁcation

13498

Table 1. Flow Rate

MODEL MINIMUM FLOW RATE

18sxi 774 litres/hr.

30sxi 1289 litres/hr.

This is equal to 20

C differential at maximum heat input.

BOILER SPECIFICATION 18sxi 30sxi

Lift weight 36kg (80Ib) 39kg (86Ib)

Total weight (installed) 41kg (90Ib) 44.5kg (98Ib)

Gas connection 15mm copper 15mm copper

Heating flow & return connection Ø O.D. 22mm. copper 22mm. copper

Condensate connection Ø I.D. 21.5mm. plastic 21.5mm. plastic

Safety valve 3 bar (43/5Ibf/in2) 3 bar (43/5Ibf/in2)

Safety valve discharge 15mm. copper 15mm. copper

Expansion vessel capacity 8 litres (1.76 gallons) 8 litres (1.76 gallons)

Expansion vessel charge pressure 0.5bar (7,3Ibf/in2) 0.5bar (7,3Ibf/in2)

Electrical supply 230V~50Hz fused 3A 230V~50Hz fused 3A

Electrical rating 180W fused 3A 180W fused 3A

EN60529 IP clasification IPX4D IPX4D

Internal fuse rating on main PCB 2A 2A

Gas supply (governed meter only) II

2H3P

G20 natural gas II

2H3P

G20 natural gas

Inlet gas working pressure 20mbar 20mbar

Burner % CO2 case on 9.3 nominal 9.3 nominal

Burner % CO2 case off 9.1 nominal 9.1 nominal

2.0 m3/h 3.0 m3/h

71 ft3/h 107 ft3/h

0.53 m3/h 0.53 m3/h

18.7 ft3/h 18.7 ft3/h

Flue type C13, C33, C53 C13, C33, C53

NOx Class 5 Class 5

Heat output condensing mode 20.02kW 30.58kW

Heat input Nett Q = kW max. 18.9 min. 5 max. 28.6 min. 5.3

Heat output P = kW max. 18.57 min. 4.95 max. 28.17 min. 5.25

SEDBUK rating Band A 90.4% Band A 90.6%

Approximate max. gas rate after 10 mins. from cold

Approximate min. gas rate after 10 mins. from cold

2 Boiler Dimensions and Hydraulic Schematic

13482

Diagram 2.2

Diagram 2.1

13642

120

CONDENSATE CONNECTION

SDV

outlet

100100

140

176

450

726

BOILER

334

127

130 130

2.1 Boiler Dimensions & Hydraulic Schematic

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

The general arrangment of the boiler is shown in diagram 2.1. and the hydraulic and gas schematic, diagram 2.2.

The data label is positioned on the front of the inner casing panel.

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

In GB, this is the current I.E.E. WIRING REGULATIONS and BUILDING REGULATIONS.

In IE, reference should be made to the current edition of I.S.813 “Domestic Gas Installations” and the current ETCI rules.

3.2 Clearances

The boiler should be positioned so that at least the minimum operational and servicing clearances are provided, see diagram 3.1.

Additional clearances may be beneﬁcial around the boiler for installation and servicing.

For ﬂue installations where external access is not practicable, consideration should be given for the space required to insert the ﬂue internally, which may necessitate clearance larger than those speciﬁed in diagram 3.1.

3.3 Timber Frame Buildings

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

3.4 Combustible Material

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

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

2) The combustible surface and ﬁxings are suitable for supporting the load.

3) The minimum clearances from the boiler case are maintained.

3.5 Room Ventilation

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

3.6 Cupboard or Compartment Ventilation

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

Leave existing air vents.

Diagram 3.1

150

200

*5 600

CLEARANCES

mm clearance to combustible material

13208

4 Flue Options and Terminal Clearances

Diagram 4.1

Top horizontal telescopic ﬂue (Ø60/100) Part No. A2043600 - Section 10, page 20

Top horizontal standard ﬂue

(Ø60/100)

Part No. A2043400 - Section 10, page 24

Twin Flue Twin Flue Adapter, concentric ﬂue (Ø80) Part No. A2011000 - Section 10, page 31

Plume Management Kit basic set, white, concentric ﬂue (Ø60/100) - Part No. A2044100 for use with Part No. A2043400 and Part No. A2043600 - Section 10, page 34

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

HORIZONTAL FLUES

A DIRECTLY BELOW AN OPENING, AIR BRICK, OPENING WINDOWS 300 B ABOVE AN OPENING, AIR BRICK, OPENING WINDOWS 300 C HORIZONTALLY TO AN OPENING, AIR BRICK, OPENING WINDOWS 300 D BELOW GUTTER, DRAIN/SOIL PIPE 25 E BELOW EAVES 25 F BELOW A BALCONY OR CAR PORT 25 G FROM VERTICAL DRAIN PIPES AND SOIL PIPES 25 H FROM INTERNAL/EXTERNAL CORNERS 25

H* TO A BOUNDARY ALONGSIDE THE TERMINAL 300 I ABOVE ADJACENT GROUND OR BALCONY LEVEL 300

J* FROM SURFACE OR A BOUNDARY FACING THE TERMINAL 600 K FACING TERMINALS 1200 L FROM OPENING (DOOR/WINDOW) IN CAR PORT INTO DWELLING 1200 M VERTICAL FROM A TERMINAL 1500 N HORIZONTALLY FROM A TERMINAL 300

VERTICAL FLUES

P FROM ANOTHER TERMINAL 600 Q ABOVE ROOF LEVEL 300 R FROM ADJACENT OPENING WINDOW 1000 S FROM ADJACENT WALL TO FLUE 300

Diagram 4.2

4 Flue Options and Terminal Clearances

Diagram 4.3

12325

4.1 Flue Options

There are various ﬂue options to choose from as illustrated in diagram 4.1. The ﬂue lengths and installation are described in section 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 ﬂue terminal positioning must be those detailed in I.S.813 “Domestic Gas Installations”.

The terminal must be exposed to the external air, allowing free passage of air across it at all times.

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

Carports or similar extensions of a roof only, or a roof and one wall, require special consideration with respect to any openings, doors, vents or windows under the roof. Care is required to protect the roof if made of plastic sheeting. If the carport comprises of a roof and two or more walls, seek advice from the local gas supply company before installing the boiler.

H* and J* See diagram 4.2 . These dimensions comply with the building regulations, but they may need to be increased to avoid wall staining and nuisance from pluming depending on site conditions.

4.3 Terminal Guard

A terminal guard is required if persons could come into contact with the terminal or the terminal could be subject to damage.

If a terminal guard is required, it must be positioned to provide minimum of 50mm clearance from any part of the terminal and be central over the terminal.

The guard should be similar to that shown in diagram 4.3.

A suitable guard is manufactured by: -

Tower Flue Components Morley Rd. Tonbridge Kent TN9 1RA. Size: 280mm x 280mm x 270mm.

5 Water System

5.1 General

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

An options board accessory is available to link the internal programmer with a Honeywell S or Y plan system.

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 ﬂow rate, the system can be ﬁtted with a lockable balancing valve in the main ﬂow or return pipes shown as valve “A” in diagram 5.1. The ﬂow rate through the boiler must not be allowed to fall below that given in section 1 - Speciﬁcation Table.

5.5 Bypass

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

Ensure that under no circumstances does the ﬂow rate drop below the ﬁgure speciﬁed, refer to section 1 - Speciﬁcation Table.

5.6 Filling the Sealed System

Provision for ﬁlling the system at low level must be made, see diagram 5.2. There must be no permanent connection to the mains water supply, even through a non-return valve.

NOTE: It is important that ﬁttings used for connection to potable water comply with the water undertakings requirements.

5.7 Draining Points

Draining taps must be provided at all the 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.

5.8 Domestic Hot Water Cylinder

SINGLE FEED INDIRECT CYLINDERS ARE NOT SUITABLE AND SHOULD NOT BE USED.The domestic hot water cylinder must be of the double feed indirect coil type. It must be suitable for working at a gauge pressure of 0.35bar above the safety valve setting.

13486

5.9 Water Treatment

Existing system- It is ESSENTIAL that prior to installing the

new boiler the system is thoroughly ﬂushed.

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

Flushing should be carried out in accordance with BS7593: 1992 using a cleanser such as Sentinel X300 or X400, Fernox Restorer or Salamander corrosion guard cleaner.

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

For long-term corrosion protection, after ﬂushing, an inhibitor suitable for stainless steel exchangers should be used, refer to the current issue of BS 5449 and BS 7593 on the use of inhibitors in central heating systems. Examples are Sentinel X100 Fernox Protector or Salamander corrosion guard inhibitor.

Diagram 5.1

5 Water System

13801

Diagram 5.2

TEMPORARY CONNECTION

HOSE

UNION

HOSE

UNION

SUPPLY

PIPE

CONTROL

VALVE

CONTROL

VALVE

DOUBLE

CHECK

VALVE

BOILER

RETURNFLOW

HEATING CIRCUIT

DRAIN POINT

SUPPLY

PIPE

AIR GAP

TUNDISH

CONTROL

VALVE

CONTROL

VALVE

TYPE CA BACKFLOW

PREVENTION DEVICE

BOILER

RETURNFLOW

HEATING CIRCUIT

DRAIN POINT

Method 1

Method

Diagram 6.1

13647

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 ﬂat.

NOTE: Due to the varied site conditions we do not supply

ﬁxings and advise that the installer should supply those

which are suitable.

6 Installation Preparation

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 ﬂue you are ﬁtting.

Mark the position of the ﬂue centre, if ﬁtting a side ﬂue, extend the ﬂue centre line into the corner then 176mm along the adjacent wall, see diagram 6.2.

For extended side ﬂues, the ﬂue hole centre should be determined by extending the dashed inclined line on the template to the side wall. This dashed line is drawn at 44mm/ metre (2.5°) rise from the boiler. Where this line reaches the side wall, a horizontal line should be marked. The vertical centre line of the ﬂue should then be marked at 156mm from the back wall.

To allow for the ﬂue passing through the wall at this angle a 125mm hole should be drilled irrespective of internal or external installation.

Remove the wall template whilst drilling the ﬂue hole.

B - Union Nut and Sealing Washer

A - Central Heating x 2 B - Gas

A - Large Sealing Washers

C - Gas

C - Saftey Discharge

Electrical Cartridge

Gas and Water Isolating Valves 0020036801

Pipe Pack 0020029672

Loose Items Pack (discard addtional items within this pack)

Documentation Pack

(not illustrated)

Wall Template, User Instructions,

Installation and Servicing Instructions.

Hanging Bracket

Retaining Screws

Stored in cartridge

Base Coverplate

WALL PLUG

SCREW NO 12 x 50mm

TEMPLATE

Preferred

fixing points

HANGING BRACKET

Diagram 7.1

13490

6 Installation Preparation

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 ﬂue hole and mark the position of the ﬁxing holes for the hanging bracket, see diagram 7.1.

Drill ﬁxing holes and insert suitable wall plugs.

Diagram 7.2

13479

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.

7 Boiler Fixing

WALL TEMPLATE

Preferred

fixing points

176

2.5o 44mm/metre inclined extended flue length

Standard flue length Horizontal

13853

Diagram 6.2

6.4 Flue Hole Cutting

External access ﬂue installation can use a 105mm diameter core drill.

Internal access only ﬂue installation will need a 125mm diameter core drill.

NOTE: The ﬂue is designed with an internal fall of 44mm/ metre (2.5°), therefore the hole can be drilled horizontally.

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

8 Gas / Water Connection

8.1 Systems Connection

Remove the protective caps from the boiler connections.

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

There are ﬂats on the body of the valves for locating a spanner to aid tightening to copper tails.

NOTE: Make sure that the test and drain points are accessible, refer diagram 8.1.

Plumb the system pipe work to the copper tails.

NOTE: Do not subject the isolation valves to heat.

Flush out the heating system before connecting to the boiler, refer to section 5.9.

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”.

Diagram 8.1

13477

OLIVE

PIPE

OLIVE

NUT

WASHER

WATER ISOLATION VALV

E (2 OFF)

GAS ISOLATION VALV

DRAIN POINT

SAFETY DISCHARGE VALVE

VIEW ON UNDERSIDE OF BOILER

UNION NUT AND SEAL

9 Safety Discharge Valve and Condensate Connections

Diagram 9.1

13491

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 ﬁt 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.

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.

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

9.2 Condensate Trap and Siphonic Drain Connection

The condensate drain connection is behind the pump at the rear of the boiler, see diagram 9.2. A ﬂexible condensate outlet pipe is ﬁtted and should be used to couple the condensate trap and siphonic drain to a 22mm to 25mm O.D. non corrosive plastic pipe (overﬂow pipe), see diagram 9.2.

IMPORTANT: Please remove the bung from the ﬂexible pipe before ﬁtting 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 insulated and also preferably of 32mm diameter, to prevent freezing in adverse weather conditions.

The condensate is discharged periodically in ‘slugs’ by siphonic action.

It is not necessary to provide air breaks or extra traps in the discharge pipe as there is already a 75mm high trap inside the boiler. Fitting an extra trap may cause the boiler siphon to work incorrectly.

Refer to BS5546 or BS6798 for advice on disposal of boiler condensate.

Diagram 9.2

13492

FLEXIBLE CONDENSATE OUTLET PIPE

CONDENSATE TRAP AND SYPHONIC DRAIN

VIEW ON UNDERSIDE OF BOILER

FLEXIBLE CONDENSATE OUTLET PIPE

INTERNAL SOIL AND VENT STACK

BOILER

MIN. DIA. 21mm NO RESTRICTION ON LENGTH

EXTERNAL SOIL AND VENT STACK

MIN. DIA. 21mm NO RESTRICTION ON LENGTH

BOILER

MIN. DIA. 21mm

EXTERNAL LENGTH OF PIPE 3M MAX.

OPEN END OF PIPE DIRECT INTO GULLEY BELOW GROUND BUT ABOVE WATER LEVEL

MIN. DIA. 21mm NO RESTRICTION ON LENGTH

BOILER

SINK (CONSTITUTES AIR

BREAK)

BOILER

MIN. DIA. 21mm NO RESTRICTION ON LENGTH

SINK

OPEN END OF PIPE DIRECT INTO GULLEY BELOW GROUND LEVEL BUT ABOVE WATER LEVEL.

Ø22mm MIN. TERMINATION FROM APPLIANCE

EXTERNAL LENGTH OF PIPE 3M MAX.

25mm MIN.

SEAL

BOTTOM OF TUBE SEALED

Ø100mm PLASTIC

TUBE

300mm MIN.

GROUND (either/or)

500mm MIN.

HOLE

DEPTH

400mm MIN.

LIMESTONE CHIPPINGS

2 ROWS OF 3 x 12mm HOLES AT 25mm CENTRES 50mm FROM BOTTOM OF TUBE. HOLES TO FACE AWAY FROM HOUSE.

External Soil and Vent Pipe or Rainwater Pipe

Internal Soil and Vent Pipe

External Termination into Soakaway

Internal Termination Downstream of Sink Waste

Internal Termination into Combined Sink Waste

External Termination to a Gulley or Hopper

NOTE: PIPEWORK SHOULD ALWAYS FALL AWAY FROM BOILER BY AT LEAST 2.5

44mm FOR EVERY 1M.

EXTERNAL MAX.

*NOTE: FOR EXTENDED PIPE RUNS 32mm DIA. PIPE SHOULD BE USED.

9 Safety Discharge Valve and Condensate Connections

Diagram 9.3

13000

10.1 Flue Length

The maximum permissable horizontal ﬂue length is 10 metres plus the ﬂue terminal assembly, this can be achieved by use of the accessories, see diagram 10.3.

However should an additional 90o 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.

10 Telescopic Flue - Length, Preparation and Installation

When extension pipes are used the ﬂue system must be designed to have a continuous fall to the boiler of at least

2.5

44mm/metre to allow condensate to run back into the

boiler and out via the condensate drain.

The ﬂue can be installed from inside the building, when access to the outside wall face is not practicable.

Horizontal Telescopic Flue

Diagram 10.1

380 min. to 590 max.

WALL THICKNESS

BOILER MOUNTING WALL

OUTSIDE WA

LL FACE

203 min. to 413 max.

87min

112

176

NOTE. If necessary, it is permitted to increase this dimension to 600mm max.

FLUE LENGTH

13558

FLUE

Min flue length 380mm

Max flue length 590mm

211

239

5mm min. clearance

Max. distance from outside

wall face to min clearance. LH - 346mm RH - 374mm

Min. distance from outside wall face to min clearance. LH - 136mm RH - 164mm

OUTSIDE WA

LL FACE

87min

NOTE. If necessary, it is permitted to increase this dimension to 600mm max.

INTERNAL SURFACE

13559

TELESCOPIC TERMINAL ASSEMBLY

SEALING COLLAR

TRIM RING

SECURING COLLAR

FLUE ELBOW

GASKET (fitted)

SEALING TA

PE (telescopic only)

A2043600 Top Outlet Horizontal telescopic flue pack

SCREW x 1

SCREW x 2

SCREW x 4

13221

Diagram 10.3

13765

10 Telescopic Flue - Length, Preparation and Installation

Diagram 10.2

BUTT JOINT

10.2 Horizontal Telescopic Flue - A2043600

Refer to diagram 10.2 for kit contents.

10.3 REAR Flue

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

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

10.4 SIDE Flue

With the ﬂue elbow temporarily ﬁtted, 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 ﬂue, it can project to a maximum of 600mm, refer to diagram 9.5, if this is not desirable then a Standard ﬂue MUST be used, and cut to length.

Diagram 10.4

13223

Diagram 10.5

12979

10 Telescopic Flue - Length, Preparation and Installation

Diagram 10.6

13224

Diagram 10.7

12929

Diagram 10.8

12977

Diagram 10.9

13254

10 Telescopic Flue - Length, Preparation and Installation

10.5 Flue Fitting

With the air duct seams aligned and the ﬂue set to the required length ‘Y’, mark the securing hole position in the air duct. Drill a 3mm diameter hole at this position, take care not to pierce the inner ﬂue duct. Secure with screw provided and tape the joint, see diagram 10.7.

Fit the sealing collar onto the locating ring on the ﬂue terminal, see diagram 10.8.

With the ﬂue elbow removed, push the ﬂue assembly into the wall, externally or internally, until the end of the assembly protrudes a short way from the inside face of the wall. This will enable the internal trim ring (if required) to be positioned and allow the ﬂue assembly to be drawn back up to the ﬂue elbow.

Secure the ﬂue elbow in position on top of the boiler with four screws supplied.

Draw the ﬂue assembly from wall and engage the ﬂue duct into the elbow and butt ﬁt between the air duct and ﬂue elbow.

Check the correct alignment of the ﬂue.

Fit the securing collar in position, mark through two of the pre drilled holes in the securing collar. Remove securing collar and drill two 3mm diameter holes one in the elbow and one in the air duct, take care not to pierce the inner ﬂue duct. Fit the securing collar and secure with screws provided, see diagram

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 ﬁlings and debris removed.

Insert the ﬂue duct into the air duct terminal assembly, remembering to engage the catch within the terminal.

NOTE: If the seals require lubricant to ease installation, do not use mineral oils or grease, only silicon grease or water is recommended.

13561

Standard Horizontal Flue

10.6 Flue Length

The maximum permissable horizontal ﬂue length is 10 metres plus the ﬂue terminal assembly, this can be achieved by use of the accessories, see diagram 10.12.

However should additional 90o 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 ﬂue system must be designed to have a continuous fall to the boiler of at least

2.5

44mm/metre to allow condensate to run back into the

boiler and out via the condensate drain.

The ﬂue can be installed from inside the building, when access to the outside wall face is not practicable.

10 Standard Flue - Length, Preparation and Installation

Diagram 10.10

FLUE

Max flue length 730mm

211

239

5mm min. clearance

Max. distance from outside

wall face to min clearance. LH - 486mm RH - 514mm

Min. distance from outside wall face to min clearance. LH/RH - 75mm

OUTSIDE WA

LL FACE

87min

NOTE. If necessary, it is permitted to increase this dimension to 600mm max.

INTERNAL SURFACE

WALL THICKNESS

BOILER MOUNTING WALL

OUTSIDE WALL FACE

75 min. to 554 max.

87min

112

176

NOTE. If necessary, it is permitted to increase this dimension to 600mm max.

13560

SEALING COLLAR

SECURING COLLAR

FLUE ELBOW

GASKET (fitted)

A2043400 Top Outlet Standard Horizontal Concentric Flue Pack

STANDARD TERMINAL ASSEMBLY

SCREW x 2

SCREW x 4

TRIM RING

Diagram 10.11

13222 13765

10 Standard Flue - Length, Preparation and Installation

Diagram 10.12

BUTT JOINT

10.7 Standard Horizontal Flue - A2043400

Refer to diagram 10.11 for kit contents.

10.8 REAR Flue

With the ﬂue elbow temporarily ﬁtted, 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 ﬂue can project to a maximum of 600mm, if this is desirable, refer to diagram 10.14.

10.9 SIDE Flue

With the ﬂue elbow temporarily ﬁtted, 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 ﬂue can project to a maximum of 600mm, if this is desirable, refer to diagram 10.14.

13224

Diagram 10.15

Left Hand illustrated

Diagram 10.13

13223

Diagram 10.14

12979

10 Standard Flue - Length, Preparation and Installation

AIR DUCT

FLUE DUCT

13mm

L + 11mm

TERMINAL CATCH

Diagram 10.16

12847

Diagram 10.17

13254

10 Standard Flue - Length, Preparation and Installation

10.10 Flue Fitting

Remove the ﬂue elbow.

Separate the ﬂue duct from the terminal by twisting to release the terminal catch, then pull out of the retaining seal, refer to diagram 10.16.

The ﬂue duct cutting length (L + 11mm.) is shown in diagram

10.16.

The air duct should be cut at the opposite end to the terminal

The plastic ﬂue duct MUST be cut at the opposite end to the terminal catch.

The plastic ﬂue duct extensions MUST be cut at the opposite end to seal.

The cut ducts must be de-burred and all ﬁlings and debris removed.

Insert the ﬂue duct into the air duct terminal assembly, remembering to engage the catch within the terminal.

NOTE: If the seals require lubricant to ease installation, do not use mineral oils or grease, only silicon grease or water is recommended.

Fit the sealing collar behind the locating lugs on the ﬂue terminal, see diagram 10.17.

Push the ﬂue assembly into the wall, externally or internally, initially until the end of the assembly protrudes a short way from the inside face of the wall. This will enable the internal trim ring (if required) to be positioned and allow the ﬂue assembly to be drawn back into the ﬂue elbow.

Secure the ﬂue elbow in position on top of the boiler with four torque headed screws supplied.

Draw the ﬂue assembly from wall and engage the ﬂue duct into the elbow and butt ﬁt between the air duct and ﬂue elbow.

Ensuring the correct alignment of the terminal.

Fit the securing collar into position, mark through two of the pre drilled holes in the securing collar. Remove securing collar and drill two 3mm diameter holes one in the elbow and one in the air duct, take care not to pierce the inner ﬂue duct. Fit the securing collar and secure with screws provided, see diagram 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 ﬂue ducts have been correctly cut to the instructions the sealing collar should ﬁt ﬂush with the outside wall, check this.

Diagram 10.18

13225

10 Vertical Flue - Length, Preparation and Installation

10.11 Vertical flue

The vertical ﬂue system is available as an option where the boiler position does not permit the use of the top horizontal ﬂue system.

The system is made up from accessories. The accessories include terminal assembly, bends 45º and 90º, ﬂue extensions, ﬁxing bracket and appropriate weather collar, see diagram 10.19.

The maximum permitted straight ﬂue length is 10 metres plus the terminal. for each 90o or 2x45o bends ﬁtted, the maximum length must be reduced by 1 metre, see diagram 10.18.

NOTE: 2x45º bends can replace 1x90º bend if necessary. When using 90º bends any horizontal extension pipe should be inclined by a minimum of 44mm/metre (2.5°) towards the boiler to facilitate condense removal, see (a) in diagram

10.18.

Alternatively use 45º bends to avoid horizontal runs, see (b) in diagram10.18.

The terminal siting should be as shown in diagram 4.2.

Measure the distance of ﬂue length required for the installation.

The ﬂue must be designed with a continuous fall towards the boiler.

10 Vertical - Flue Length, Preparation and Installation

12969

Diagram 10.19

Flue Installation

Refer to diagram 10.20 and secure the ﬂue adapter in position on top of the boiler with four screws supplied, making sure the nib ﬁts into the locating slot in the boiler casing to ensure correct orientation.

NOTE: The rubber ‘O’ rings of each section should be lubricated prior to assembly. Do not use mineral oils or grease, silicon grease or water is recommended.

Secure the ﬁrst extension pipe to the ﬂue adapter with the securing collar supplied by positioning the collar centrally over the joint, then tighten the two screws on the securing collar, see diagram 10.21.

Fit more extension pipes as required using the collar and screws supplied with each extension pipe. To ﬁt position the collar centrally over the joint, tighten the two screws on the securing collar. Using the holes provided in the securing collar drill and insert the two self tapping srews supplied, see diagram 10.22.

When installing the ﬂue it is recommended that it is supported every 2 metres and at every bend by a ﬁxing bracket.

Project the rise of the ﬂue pipe to roof level and cut a 150mm hole in the roof.

Flue Terminal Installation

(a) Pitched Roof

Fit the required pitched roof weather collar over the 150mm hole in the roof. Make good the tiling or slating around the collar incorporating the ﬂashing of the weather collar. Position the angle cap over the weather collar in the correct orientation to attain the correct angle for your roof.

(b) Flat Roof

Fit the aluminium weather collar over the 150mm hole in the roof ensuring a weather tight seal.

From above carefully place the ﬂue terminal through the weather collar.

Flue Terminal to Boiler Connection

Should the clearances above the boiler to roof not allow for extensions, it is permitted to cut the ﬂue terminal ensuring the relationship of ﬂue and air duct lengths are retained.

10 Vertical Flue - Length, Preparation and Installation

Diagram 10.20

13243

Diagram 10.21

13242

Diagram 10.22

12982

Completion of Installation

With the ﬂue terminal positioned in the roof the length of the ﬁnal pipe can be determined. If a telescopic length cannot be used, then a standard ﬂue length can be cut to make the correct length. Cut the ﬂue to the desired length measuring from the ‘O’ ring end and discard the plain end of the tube. The cuts must be square and made free of burrs to allow correct assembly. (NOTE: The ﬂue pipe is 10mm longer than the air pipe), see diagram 10.23. Carefully push the terminal assembly upwards to allow room for ﬁtting the ﬁnal ﬂue piece. Fit a ﬁxing bracket to the terminal assembly. Pull the terminal assembly down and join to the ﬂue system. Ensure that the terminal is making a weather tight seal on the weather collar. Secure the ﬁxing bracket ﬁtted to the terminal to the rooﬁng struts or a purpose made batton.

Diagram 10.23

12983

10 Twin Flue - Length, Preparation and Installation

Diagram 10.24

13226

10 Twin Flue - Length, Preparation and Installation

10.12 Twin flue

The twin ﬂue system is available as an option when the top horizontal or vertical ﬂue system is not appropriate.

The system can provide an independent horizontal air inlet and ﬂue outlet, horizontal air inlet and vertical ﬂue outlet or vertical air inlet and ﬂue outlet via a concentric terminal.

The system is made up from accessories, see diagram 10.25.

NOTE: The air and ﬂue outlets do not have to be equal lengths. 2x45° bends can replace 1x90° bend if necessary.

The maximum permitted combined (air inlet + ﬂue outlet) ﬂue length is 40 metres plus terminal assemblies, for each 90° or 45° x 2 bends ﬁtted, the maximum length must be reduced by 1 metre, see diagram 10.24.

NOTE: When using 90° bends any horizontal run should be inclined by a minimum of 44mm/metre (2.5°) towards the boiler to facilitate condense removal.

Alternatively use 45° bends to avoid horizontal runs in the ﬂue pipe.

Terminal Position

The clearances for a ﬂue outlet are given in the "Flue Location and Ventilation" section.

In addition the horizontal air inlet must not be closer than 300 mm from a ﬂue outlet on the same wall or 1200mm from an opposing ﬂue outlet.

Diagram 10.25

12970

10 Twin Flue - Length, Preparation and Installation

Diagram 10.26

13240

Installation Details

The parts available for a twin ﬂue system installation are shown in diagram 10.25.

Boiler Connection

Push the twin ﬂue adaptor onto the outlet of the boiler with the air inlet to the left hand side, see diagram 10.26. Secure the adaptor to the top panel with the screws provided. Care should be taken when inserting the screw through the hole in adaptor top.

To facilitate engagement, it is recommended that the rubber ‘O’ rings are lubricated with silicone grease or water prior to assembly.

Air and Flue Pipe Installation

The air and ﬂue pipes can now be built up from the boiler.

The ﬂue must be designed with a continuous fall towards the boiler. If using the horizontal ﬂue pipe or 90° bends the pipe must be inclined at 44mm/metre (2.5°)

minimum, see diagram

10.25.

Alternatively if space allows, use 45° bends in place of 90º bends.

The rubber ‘O’ rings of each section should be lubricated prior to assembly with silicone grease.

When building the ﬂue up it is recommended that it is supported every 2 metres and at every bend by a ﬁxing bracket.

Horizontal Terminal Installation

With due consideration to terminal clearances mentioned in Section 4.2 drill the one or two holes as required with a 90mm core drill.

Push the horizontal terminal through the wall allowing approx. 100mm to protrude outside.

Push a grey rubber wall seal onto either side of the wall ensuring that both wall seals are pushed up to the wall surface, see examples (b) and (c) diagram 10.24.

Vertical Terminal Installation

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

(a) Pitched Roof

(b) Flat Roof

Fit the aluminium weather collar over the 150mm hole in the roof ensuring a weather tight seal.

Horizontal Pipes-Completion of Installation

Having built the pipe(s) from the boiler to the terminal(s), the length of the ﬁnal pipe piece can be determined. Cut pipes at the opposite end to the ‘O’ ring seal making square and free from burrs. Push the horizontal terminal through the wall to engage the ﬁnal pipe piece and pull back ensuring the grey wall seals are fully pulled up to the outside and inside wall faces.

Vertical Pipes-Completion of Installation

Refer to diagram 10.24.

For installation of (a), attach the twin pipe to concentric ﬂue adaptor, part number A2011600, to the base of vertical terminal assembly. For installation of (b), attach the single pipe to concentric adaptor, part number A2011500, to the base of vertical terminal assembly.

With the vertical terminal assembly positioned in the roof, the length of the ﬁnal pipe can be determined. Cut the ﬂue to the desired length measuring from the ‘O’ ring seal end and discard the plain end of the tube. The cut end should be square and free from burrs. Carefully push the terminal assembly upwards to allow room for ﬁtting the ﬁnal ﬂue piece(s). Fit a 100mm ﬁxing bracket to the terminal assembly Part No 2000460486. Pull the terminal assembly down and join to the ﬂue system. Ensure that the terminal is making a weather tight seal on the weather collar. Secure the ﬁxing bracket ﬁtted to the terminal to the rooﬁng struts or a purpose made batton.

10 Plume Management Kit

10.13 Plume Management Kit

The Plume Management Kit: Part No. A2044100 (white) or A2044000 (black) can be used to overcome many site issues.

The Plume Management Kit will ﬁt to the Top Horizontal Telescopic, Rear Horizontal Telescopic and Standard Horizontal Flue. This enables the ﬂue products to exhaust further away from the boiler, thereby reducing the impact of pluming.

NOTE: The ﬂue air inlet can be sited closer to doors, opening windows and air bricks, than stated in section 4.2, see diagram 10.27.

The maximum length of the Plume Management Kit must NOT exceed 6m with a horizontal concentric ﬂue length of 2m max.

For each 90o bend or 2 x 45o bends the maximum length of the Plume Management Kit must be reduced by 1m.

For more information contact Glow-worm, refer to page 2.

The Plume Management Kit is supplied with installation instructions.

Refer to BS5546 or BS6798 for advice on disposal of boiler condensate.

Diagram 10.27

FLUE OUTLET

FLUE PRODUCTS

AIR INLET

PLUME MANAGEMENT KIT

75mm. MIN.

AIR BRICK

OPENING WINDOW OR DOOR

100mm. MIN.

IMPORTANT: The flue outlet must not be positioned within 300mm from an opening, air brick or opening windows.

12997

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 identiﬁed as to its use.

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

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

11.1 Electrical Wiring

If you are ﬁtting the Glow-worm Options Board Kit, please refer to the instructions supplied with the kit for the system wiring.

Remove the electrical cartridge from the ﬁttings pack.

Remove the securing screw to open the cartridge.

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.

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

13302

Diagram 11.1

Diagram 11.3

13369

Diagram 11.2

13368

24V SYSTEM CONTROLS

NOTE: This appliance will not operate without a link or system

controls fitted.

NOTE: ALL CABLES CONNECTED TO THE APPLIANCE SHOULD BE PERMANENTLY FIXED TO THE WALL

NOTE: This appliance will not operate without a link or system

controls fitted.

11 Electrical Connection

Diagram 11.4

13488

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 ﬁtted in accordance with the rules in force.

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 ﬁtted in accordance with the rules in force.

11.4 Electrical Cartridge Securing

Fit electrical cartridge into the interface housing on completion of the wiring, 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.

ELECTRICAL CARTRIDGE

SECURING SCREW (2 OFF)

12 Commissioning

Diagram 12.2

CENTRAL HEATING ISOLATION VALVES

GAS SERVICE ISOLATION VALVE

ALL SHOWN CLOSED

DRAIN POINTS

UNDERSIDE VIEW OF BOILER

PRESSURE TEST POINT

13476

12.1 Preliminaries - All Systems

The commissioning should be carried out by a competent person in accordance with the current issue of BS6798.

DO NOT operate the boiler without water.

Make sure that the system has been thoroughly ﬂushed out with cold water and that all cleanser, if used, has been removed.

Isolate the boiler from the mains electrical supply and test for gas tightness and purge air from the gas supply.

12.2 LPG Conversion

All models can be converted to run on LPG-Propane (G31). This conversion should be carried out by a competent person as described in section 12.10.

12.3 Filling the Heating Circuit

With the gas isolation valve closed and with no demand from any external controls 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. Open the Central Heating Flow and Return isolating valves marked ‘A’ using a screwdriver or a 4mm allen key - slot in line with the axis of the valve (shown closed in diagram).

2. Fill the heating system to a pressure of 1.0bar. The system pressure will be displayed on the user interface.

3. Vent all air from the system - repeat as neccessary until the system is full and all the air has been vented.

12.4 Initial Lighting

NOTE: If you have ﬁtted a Glow-worm Options Board

Kit, please refer to the instructions supplied with the kit for completion of commissioning.

Do not operate the boiler without water.

Refer to diagram 12.1

1. With no demand from any external controls, switch on the electrical supply to the boiler.

2. Open the gas service isolation valve, see diagram 12.2.

3. Select your required function by pressing “ Mode”, scroll through your options and select one of the following:-

Central heating.

Boiler functions ALL swicthed off.

“OFF”

4. Turn ON your external controls and select the room temperature required.

The boiler will operate automatically.

NOTE: The display will indicate the Heating system water

temperature or a fault code if in a fault condition.

Diagram 12.1

MODE

PROG

SYMBOLS DISPLAYED ON THE LCD AND DESCRIPTIONS

System Pressure

Max burner display

Min burner display

Temperature

Appliance OFF

Central Heating Functio

LCD

DISPLAY

RESET

BUTTON

NOT USED

CH TEMPERATURE

ADJUSTMENT

GGLE BUTTON

MODE and PROG

Glow-worm control (Optional)

Ext

13473

12.5 Gas Inlet Pressure

Check the supply pressure at the gas service isolation valve test point, see diagram 12.2.

The nominal supply pressure should be 20mbar when the appliance is operating at the maximum heat input. This can be achieved by turning on several hot water taps.

NOTE: There is a pressure drop over the gas service isolation valve prior to the inlet pressure test point, this is normal and the inlet pressure to the main gas valve can be up to 2mbar less than the supply pressure to the boiler at the maximum heat input. Additionally the safe nominal maximum heat input of the appliance can be achieved at an inlet pressure down to 15mbar.

12 Commissioning

12.6 Gas Rate

The gas valve is factory set for natural gas (G20) and should need no adjustment.

Should any doubt exist about the gas rate, check it using the gas meter test dial and stop watch, at least 10 minutes after the burner has lit, see diagram 12.3 for approximate rates. Make sure that all other gas burning appliances and pilot lights are off.

It should be noted that this appliance will modulate the heat input according to demand. This may affect the gas rates measured if the appliance reaches its operating temperature during the measurement.

Disconnect the pressure gauge and close the screw.

NOTE: The burner pressure cannot be measured at the gas valve as it is altered by the suction of the fan and modulated according to demand.

Adjusting the gas valve requires a combustion analyser and should only be carried out by a competent person, but in the unlikely event that the gas valve needs adjusting, refer to section 13.7.

Flue Gases: If any doubt exists that the ﬂue products are not exhausting correctly, investigate by use of a ﬂue gas analyser (FGA).

12.7 Heating Systems

Ensure that the external controls are calling for heat.

Fully open all radiator valves, ﬂow control valve, if ﬁtted, see diagram 5.1.

Switch on the appliance and ensure that the central heating is calling for heat.

Balance the radiators as required and if ﬁtted 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

C can be achieved across

ﬂow and return.

NOTE: Should the system require that the appliance has to be adjusted, the front 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 depending on the requirements of the system.

The appliance has an inbuilt automatic adjustable bypass valve. The pressure can be adjusted between approx 1.5 and 3.5mH2O but is factory pre-set to approx 2.5mH2O. The pressure changes by approx 0.1mH

2O for each full turn

of the bypass screw, see diagram 12.4. 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.

Lock or remove the handle from control valve, if ﬁtted.

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

AUTOMATIC BYPASS VALVE

BYPASS SCREW

13234

Diagram 12.4

13866

Diagram 12.3

sxi

0.53

18.7

2.0

71.0

107.0

0.39

0.41

1.47

2.22

12 Commissioning

12.8 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.

12.9 Instruct the User

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

Advise the user on the use and maintenance of any scale reducer and pass on any relevant instructional documents.

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

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

The user shall not interfere with or adjust sealed components.

It is the Law that any servicing is carried out by a competent person.

Advise the user that, like all condensing boilers this appliance will produce a plume of condensation from the ﬂue terminal in cool weather. This is due to the high efﬁciency and hence low ﬂue gas temperature of the boiler.

Advise the user of the precautions necessary to prevent damage to the system, boiler and the building, in the event of the heating system being out of use during frost or freezing conditions.

Advise the user that the permanent mains electrical supply SHOULD NOT be switched off, as the built in frost protection and pump/valve 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: Contact your installation/servicing company as

draining, reﬁlling and pressurising MUST be carried out by a

competent person.

Leave these instructions and the ‘Benchmark’ service record with the user.

Diagram 12.4

COVER PLATE

13538

12.11 LPG CONVERSION - all models

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.

During the conversion to Propane use of a suitable ﬂue gas analyser is necessary.

As an option a chargeable boiler only commissioning service can be provided by Glow-worm Service by calling telephone No. 01773 828100.

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

Ensure that the appliance supply pressure = 37mbar.

(1) Access the gas valve.

(2) Refer to diagram 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 13.9.

IMPORTANT: Remember to replace the cap on completion of the test.

(6) Turn on the mains electrical supply and turn on the gas service isolation valve. Switch the boiler on.

(7) Ensure external controls are calling for heat (i.e, generate a hot water demand by fully opening a hot water tap. The boiler should ﬁre automatically.

NOTE: If the appliance does not light & goes to lockout (F1) turn the throttle anti-clockwise a further turn and press the reset button. The appliance will (after a short delay) again attempt to ﬁre. Repeat this procedure (up to a total of 2 extra turns on the throttle screw) until the appliance lights. PLEASE NOTE several ignition attempts may be needed, to purge gas through the appliance, before a successful ignition is achieved.

(8) Check and adjust the burner %CO

at maximum rate.

Press the “reset” button on the controls fascia, release and immediately press and hold in the “+” button. After approximately 5 seconds “Hi” will be displayed. Pressing the mode button when “Hi” is selected will force the boiler to maximum rate, the display will ﬂash between “Hi” and the “default display” this will indicate the boiler has been forced to maximum.

(9) Adjust, if necessary, the burner % CO2 to the value shown in the “SETTING” column of the table, with the throttle screw, see diagram 12.5(rotate anti-clockwise to increase).

(10) To exit the check sequences press the “mode” and “+” buttons simultaneously, this will reset the boiler to the default display.

(11) Check the burner % CO

, at minimum rate, to the value

shown in the “SETTING” column of the table.

(12) If adjustment is required, press the “reset” button on the controls fascia, release and immediately press and hold in the “+” button. After approximately 5 seconds “Hi” will be displayed. Pressing the “+” or “-” buttons will cycle between “Hi” and “Lo”. Pressing the mode button when “Lo” is selected will force the boiler to minimum rate, the display will ﬂash between “Lo” and the “default display” this willindicate the boiler has been forced to minimum.

12 Commissioning - Nat. Gas (G20) to LPG (G31) Conversion

OFFSET ADJUSTMENT

THROTTLE

ELECTRICAL PLUG

GAS PIPE RETAINING CLIP

SEALING GROMMET

13553

Diagram 12.5

13870

(13) Adjustment of the %CO2 is very coarse so carefully adjust the %CO

to the value shown in the “SETTING” column of the table with the offset adjustment, see diagram 12.5 and %CO

Table (Rotate clockwise to

increase).

(14) To exit the function press the “mode” and “+” buttons simultaneously, this will reset the boiler to the default display.

(15) Repeat (8) and check CO2 at maximum rate - adjust if necessary.

Please remember after ﬁnishing this procedure to turn off the hot water tap.

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

the cap. Reﬁt the control panel.

(17) IMPORTANT: Fit the LPG conversion label supplied

in the documentation pack to the inner front panel alongside the data label. Reﬁt the inner door and outer door.

(18) Continue commissioning from 12.7.

MODEL

18sxi

30sxi

G31 BURNER % CO2

CHECK

(case on)

SETTING

(case off)

9.2 to 10.2

10.0 to 11.0

10.0

10.5

+ 0.0

- 1.0

+ 0.3

- 0.8

Throttle

TURNS

13 Servicing

13.1 General Inspection

Before servicing inspect the following:

1. condition of case and ﬂue.

2. ﬂue terminal for obstructions.

3. electrical supply connections.

4. water connections.

5. gas connection.

6. system pressure.

correct any fault before continuing.

13.2 Functional Checks

With the appliance operational carry out the following:

COMBUSTION

CHECK - with a ﬂue gas analyser as described in section 13.7.

NO ﬂue gas analyser is available, it will be necessary

to remove the front and inner casing panels, diagram

13.1 and taking care not to touch any internal components, check the ﬂame picture through the viewing window, diagram 13.2.

If the ﬂame shows signs of lift, sooting or appears yellow, it will be necessary to service the burner and heat exchanger as described in paragraphs 13.5 and

13.6.

If the servicing does not correct the condition a ﬂue gas analyser will have to be used as described in paragraph

13.7.

However should the ﬂame indicate correct combustion it will not be necessary to service the heat exchanger and burner.

GAS RATE

CHECK - the gas rates, see table on page 37.

If you cannot measure the gas rate it is acceptible to measure the combustion rate as described in section

13.7. However if you do not have either facility then the appliance MUST be turned off and disconnected until such equipment is available.

If the gas rate requires adjustment you MUST NOT adjust the gas valve without a gas analyser, refer to section 13.7.

CASING PA

NEL

INNER CASING PA

NEL

SECURING SCREWS (2 OFF)

SECURING SCREWS

Diagram 13.1

13649

IMPORTANT NOTES:

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

2. It is the Law that any servicing is carried out by a

competent person.

3. Before commencing with a service or replacement of parts the boiler should be isolated from the electrical supply and the gas supply should be turned off at the gas isolation valve.

4. When replacing a part on this appliance, use only spare parts that you can be assured conform to the safety and performance speciﬁcation that we require. Do not use reconditioned or copy parts that have not been clearly authorised by Glow-worm.

5. If any electrical connections have been disconnected and after their connection, checks to the earth continuity, polarity, short circuit and resistance to earth must be repeated using a suitable multimeter, as described in section 14.

6. On completion the “Benchmark” Service Record should be completed.

VIEWING WINDOW

13514

Diagram 13.2

13 Servicing

RETAINING STRAP

CONTROL PANEL

13528

Diagram 13.3

ELECTRODE

GASKET

SPARK GAP 4mm

SECURING SCREW (2 OFF)

EARTH LEAD

13273

Diagram 13.5

Diagram 13.6

13518

13.3 Servicing

Note: If the Combustion & Gas rate checks did not

require adjustment then it will not be necessary to service the Combustion Chamber, Heat Exchanger or Burner.

Complete this section, 13.4 and then proceed to 13.9.

All routine servicing requirements can be achieved by the removal of the front and inner panels, see diagram 13.1.

Position the control box into the service position, see diagram

13.4.

Before commencing with a service or replacement of parts. The boiler should be isolated from the electrical and gas supplies. Remove the base cover, diagram 12.4 to gain access to the gas service isolation valve, see diagram 13.3.

13.4 Spark Electrode

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

Inspect the tips for damage.

Clean away any debris and check the spark gap is 3.5 to 4.5 mm.

Check the electrode gasket for signs of damage and replace if necessary.

NOTE: If the burner is not to be serviced, do not perform the following instructions 13.5, 13.6, 13.7 and 13.8 but continue to section 13.9 to complete the servicing.

13.5 Burner

NOTE: If the functional checks did not indicate poor combustion then it is not necessary to service this component.

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

Remove the gas pipe retaining clip, see diagram 12.5.

NOTE: When replacing ensure that the sealing grommet, situated below the gas valve is correctly re-seated.

Disconnect the gas valve electrical plug at the gas valve, see diagram 12.5.

13714

Diagram 13.4

13 Servicing

13527

Disconnect the electrical plug from the fan.

Disconnect the spark electrode plug and earth lead, refer to diagram 13.6.

Remove the ﬁve 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.

NOTE: Removal of the burner is not necessary during a normal service, but if it is removed it will require a new gasket, see diagram 13.8.

13.6. Combustion Chamber and Heat Exchanger

NOTE: If the functional checks did not indicate poor combustion then it is not necessary to service this component.

Remove loose debris from inside the heat exchanger using a soft brush and vacuum cleaner.

Carefully ﬂush 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).

Diagram 13.8

BURNER

FRONT

INSULATION

GASKET

SECURING SCREW (4)

SPARK ELECTRODE

Diagram 13.7

13266

13 Servicing

13.7 Combustion Check

With the appliance operational connect the CO2 combustion analyser to the test point, see diagram 13.9.

IMPORTANT: Remember to replace the cap on completion of the test.

Check the burner %CO2 , at maximum rate(open a hot water tap fully to generate a demand). The values are shown in the “CHECK” column of the table and if the reading falls within the range, disconnect the analyser, ﬁt the test point cap and return to functional checks - gas rate.

If adjustment is required remove the front and inner casing panels, see diagram 13.1. Taking care not to touch any internal components, then proceed as follows:

Adjust the %CO2 to the value shown in the “SETTING” column of the table with the throttle, see diagram 12.5. (Rotate anti-clockwise to increase).

To exit the check sequences press the “mode” and “+” buttons simultaneously, this will reset the boiler to the default display.

Check the burner % CO

at minimum rate is as shown in the

“CHECK” column of the table.

Press the “reset” button on the controls fascia, release and immediately press and hold in the “+” button. After approximately 5 seconds “Hi” will be displayed. Pressing the “+” or “-” buttons will cycle between “Hi” and “Lo”. Pressing the mode button when “Lo” is selected will force the boiler to minimum rate, the display will ﬂash between “Lo” and the “default display” this will indicate the boiler has been forced to minimum.

Adjustment of the %CO2 at minimum rate is very coarse so carefully adjust the %CO2 to the value shown in the “SETTING” column of the table with the offset adjustment, see diagram 12.5 and %CO2 Table (Rotate clockwise to increase).

To exit the function press the “mode” and “+” buttons simultaneously, this will reset the boiler to the default display.

13.8 Gas Rate Adjustment

This appliance incorporates a pre-mix burner and cannot be adjusted, however, it is acceptible to set the combustion rate with a gas analyser as described in section 13.7.

13.9 Inner Casing Panel Seal check

Check the condition of the seal, if worn or damaged remove the seal and thoroughly clean the casing surface before ﬁtting the new seal, see diagram 13.10.

Reﬁt the inner casing panel.

NOTE: Ensure the seal is ﬁtted correctly giving an airtight joint.

13.10 Service Completion

On completion of the service the “Benchmark” Service Record should be completed.

FLUE ELBOW

COMBUSTION ANALYSER SAMPLE

POINT

VERTICAL FLUE ADAPTOR

Diagram 13.9

13566

10063

INNER CASING PA

NEL

FRONT CASING PA

NEL

SEAL

Diagram 13.10

13872

MODEL

18sxi

30sxi

G31 BURNER % CO2

CHECK

(case on)

SETTING

(case off)

9.2 to 10.2

10.0 to 11.0

10.1

10.5

+ 0.0

- 1.0

+ 0.3

- 0.8

MODEL

18sxi

30sxi

G20 BURNER % CO2

CHECK

(case on)

SETTING

(case off)

8.5 to 9.6

9.1

+ 0.2

- 0.5

+ 0.2

- 0.5

14 Fault Finding

14.1 Preliminary fault finding

The following checks should be performed before proceeding onto speciﬁc diagnostics:

• Check the external electrical supply to the boiler is on and a supply of 230V is present at the ‘L’ and ‘N’ terminals on the installer interface, refer to section 11.5 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 13.1 and the control panel securing screw 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 12.6.

• Check that the heating system pressure indicates at least 1mb, if not, ﬁll and vent the system as described in section

12.3.

• Check that all external controls are on.

• Check the functional ﬂow diagram, 14.5

14.2 Fault Codes

Fault codes take priority over all other display functions in the event of a fault occuring, refer to diagram 14.4.

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 ﬂashing ‘0’ press ‘MODE’ button.

c) Press a ‘+’ button to scroll back through the fault memory (Position 1 is most recent), see fault memory display.

To exit this menu, press the ‘MODE’ button.

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.

RETAINING SLOTS

SECURING SCREW

REAR PANEL

CONTROL PANEL

RETAINING CLIPS

Diagram 14.1

13535

13452

Indicates fault memory position

Fault code

Fault memory display

Diagram 14.3

Diagram 14.2

13845

MAIN PCB BOARD

230Vac 50Hz LIVE (PIN 3) AND NEUTRAL (PIN 1) TEST POINT AT MAIN PCB BOARD POSITION X17

230V

X 1 7

X17

X1 9

14 Fault Finding

13167

Diagram 14.4

g/y

GAS CONTROL VALV

HEATING FLOW THERMISTOR

HEATING RETURN THERMISTOR

PUMP

CHASSIS EARTH

IGNITION ELECTRODE

TER

PRESSURE

SENSOR

IGNITER UNIT

MAIN CONTROL BOARD

APPLIANCE INTERF

ACE

BOARD

g/y

br BROWN b BLUE g/y GREEN/YELLOW gy GREY bk BLACK y YELLOW

p PURPLE

or ORANGE

w WHITE

r RED

KEY

14 Fault Finding

13012

Diagram 14.5

CENTRAL HEATING

14 Fault Finding

13860

Diagram 14.6

If -9OC is displayed, check that the thermistor wires are unconnected, faulty or trapped.

Fault Codes

14 Fault Finding

13447

Diagram 14.6

Fault Codes (continued)

14 Fault Finding

Diagnostic Menu

The Diagnostic Menu provides the ability to view and change certain parameters. See Diagram 14.5 for available parameters.

To enter the diagnostic menu:

a) Press and hold the ‘MODE’ button for 5 seconds. The display will change to ﬂashing ‘

0’.

b) Use the ‘+’ or ‘-’ buttons to scroll to

96 (This is

the installer level access password).

c) Press ‘MODE’ to conﬁrm, see diagnostic display 1.

Use the ‘+’ or ‘-’ buttons to view the appropriate diagnostic number, see diagram 14.5.

If necessary the values can be changed by:

a) Pressing the ‘MODE’ button.

b) The diagnostic value ﬂashes, see diagnostic display 2.

13450

13451

c) Use the ‘+’ and ‘-’ buttons to cycle through available values.

d) The change is saved by pressing ‘MODE’ once more.

(NOTE: Only certain parameters can be adjusted)

To exit the diagnostic menu press and hold the ‘MODE’ button for 5 seconds.

Diagnostic value

Diagnostic number

Diagnostic display 1

Diagnostic display 2

14 Fault Finding

Diagram 14.7

13454

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

Diagnostic Menu - Level 1 Installer Access

Minutes

> 80 No flame < 40 Good flame

d.99 State List (see table opposite)

d.24 System water pressure in bar.

d.28 Option Relay 2 Reserved for future use

d.9 Flow target temp. from external intelligent control

d.27 Option Relay 1 Reserved for future use

d.91 Internal Programmer type 0:24 hour 1:7 day (default) d.92 Enable/Disable Internal Programmer 0: CH Off, DHW Off (Default)

1: CH Off, DHW On 2: CH On, DHW Off 3: CH On, DHW On

Tank temperature

Flow temperature setpoint

Description Range

- 99 will be displayed. Reserved for future use.

ption)

External intelligent control connect

Central heating mode (Priority 3) Possible Causes

S.00 no heating required S.01 fan pre-run S.02 pump pre-run S.03 ignition S.04 burner on S.05 pump / fan overrun S.06 fan overrun S.07 pump overrun S.08 Anti cycling period

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

Domestic hot water mode (Priority 2)

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

Cycling / preheat mode (Priority 1)

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

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 8O C - check thermistor

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

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

Diagram 14.8

13011

STATE LISTS

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

14 Fault Finding

IGNITION LEAD

ELECTRICAL CONNECTIONS PLUG

IGNITER UNIT

SPADE CONNECTOR

IGNITER SECURING SCREWS (2)

BRACKET

IGNITER BRACKET SECURING SCREW

15 Replacement of Parts

15.1 General

IMPORTANT: The replacement 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 the burner door seal and self locking nuts.

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

Replacement of parts must be carried out by a competent person.

Before replacing any parts of the boiler it should be isolated from the mains electric supply and the gas should be turned off at the gas service isolation valve on the boiler, see diagram 13.3.

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

After replacing any parts always test for gas tightness and if necessary carry out functional test of the controls.

Boiler Access

For replacement of parts the front casing and the inner casing panel of the boiler will need to be removed. To remove undo the two screws on the underside of the front casing and lift off. Undo the two screws on the front of the inner front panel and lift off.

The side panels can be hinged sideways and removed to aid replacement of parts.

To hinge a side panel undo and remove the three screws securing each side panel to the boiler, two at the front and one at the top.

Draining of Boiler Heating Circuit

Drain down the Heating Circuit of the boiler only, by closing the heating ﬂow and return isolating valves, see diagram

12.2.

Attach a length of hose to the drain point and open the drain valve, see diagram 12.1.

After servicing or replacing parts, close the drain valve and remove the hose. Open the heating ﬂow and return isolating valves and reﬁll, vent and pressurise the heating circuit. See section 12.1.

Check for leaks.

15.2 Spark Electrode

For access, refer to section 15.1.

Refer to section 13.4 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 13.6. and the spade connector connected to the igniter unit, see diagram 15.1.

Diagram 15.1

13274

VENTURI PLATE

SECURING SCREW (3)

15 Replacement of Parts

15.5 Gas Valve

For access, refer to section 15.1.

Refer to section 13.5 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 13.8.

15.6 Fan

For access, refer to section 15.1.

Refer to section 13.5 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”.

15.7 Burner

For access, refer to section 15.1.

Refer to section 13.5 for removal of the fan, gas valve and burner assembly.

Remove the four screws that secure the burner, see diagram

13.8.

NOTE: The burner will require a new gasket.

15.8 Front Insulation

For access, refer to section 15.1.

Refer to section 13.5 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 reﬁtted.

15.9 Rear Insulation

For access, refer to section 15.1.

Refer to section 13.5 for removal of the burner module.

Remove securing screw and washer in the centre of the insulation and withdraw insulation, see diagram 15.4.

13276

13238

SECURING SCREW (2)

GAS MANIFOLD

SECURING SCREW

HEAT EXCHANGER

WASHER

REAR INSULATION

Diagram 15.4

13277

Diagram 15.3

Diagram 15.2

CONDENSE HOSE SECURING CLIP

HEAT EXCHANGER

15 Replacement of Parts

15.10 Viewing Window

For access, refer to section 15.1.

Refer to diagram 15.5.

Remove circlip.

Remove steel washer.

Remove glass.

Remove ﬁbre washer.

Replace in reverse order.

15.11 Expansion Vessel

For access, refer to section 15.1.

Refer to section 15.1 and drain the boiler heating circuit.

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.

Reﬁll, vent and pressurise the boiler.

Check for leaks.

15.12 Heat Exchanger

Refer to Manual Handling section.

For access, refer to section 15.1.

Refer to section 13.5 for removal of the fan, gas valve and burner assembly.

Refer to section 15.1 and drain the boiler heating circuit.

Remove the securing clip from the heat exchanger adapter then disconnect the adapter and ﬂexible hose, see diagram

15.7.

Undo the two nuts of the ﬂow 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.

Remove condense pipe connector from bottom of heat exchanger.

Carefully ease heat exchanger out.

13279

13278

FIBRE WASHER

GLASS

STEEL WASHER

CIRCLIP

Diagram 15.7

13570

Diagram 15.6

15.13 Flue Hood

For access, refer to section 15.1.

Remove heat exchanger as per section 15.12.

Remove the two securing screws and pull the ﬂue hood down and away from the ﬂue hood bracket and ﬂue elbow, see diagram 15.9.

Diagram 15.5

13522

SECURING SCREWS AND CLAMPS

Diagram 15.8

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 ﬂow 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 5.3 to improve accessibility.

SECURING SCREWS

FLUE HOOD

FLUE HOOD BRACKET

Diagram 15.9

11602

15 Replacement of Parts

HEATING

RETURN

THERMISTOR

HEATING

FLOW

THERMISTOR

HEAT

EXCHANGER

13316

Remove the securing clip from the heat exchanger adapter, then disconnect the adapter and ﬂexible hose.

Lift the siphon adapter and hose out of the condensate trap and siphonic drain, do not disconnect the hose.

Disconnect the the drain connection.

Slacken to disengage but do not remove the the two securing screws.

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

After replacement and before ﬁtting the adapter ﬁll the trap with water.

Cleaning

Remove the condense trap as previously described.

Remove the ﬂoat to clean it.

Remove any solids found.

Flush water through the trap to remove any remaining solids.

Check for any debris in the outlet hose of the condensate drain and clean as necessary.

13544

CONDENSATE TRAP AND SIPHONIC DRAIN

SCREW

FLOAT

ADAPTER

Diagram 15.11

Diagram 15.10

15.17 Pump (head only)

For access, refer to section 15.1.

Drain the boiler heating circuit as described in the appropriate paragraph 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 ﬁt 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 retaining clip, see diagram 15.12.

Disconnect the central heating ﬂow 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.

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.

Reﬁll, vent and pressurise the boiler.

15.19 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 15.14 and gain access through the plastic maintenance cover.

Remove the retaining clip.

Remove the automatic air vent.

Fit the new automatic air vent and ‘O’ ring ensuring the vent cap is left loose.

Reﬁll, vent and pressurise the boiler.

15 Replacement of Parts

SAFETY DISCHARGE VALVE

SECURING CLIP

13256

Diagram 15.13

PUMP HEAD

CAP HEAD SCREW (4)

CABLE COVER

13530

Diagram 15.12

13589

PUMP SECURING CLIP

EXPANSION VESSEL PIPE SECURING CLIP

UNION CONNECTION

15 Replacement of Parts

15.20 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 15.15.

Disconnect the electrical leads.

Remove the retaining clip, remove the low water pressure sensor.

Fit new ‘O’ ring.

Fit the new low water pressure sensor.

Reﬁll vent and pressurise the boiler.

15.21 Automatic Bypass and Housing

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.

Remove the retaining clip to remove the automatic bypass.

Remove the retaining clips and three securing screws to remove the automatic bypass housing. Fit new ‘O’ rings before replacing the assembly.

Reﬁll, vent and pressurise the boiler.

RETAINING

CLIP

LOW WATER

PRESSURE

SENSOR

ELECTRICAL

LEADS

HYDROBLOCK

Diagram 15.15

13532

13854

RETAINING CLIP

SECURING SCREW (3)

RETAINING CLIP

AUTOMATIC BYPASS HOUSING

Diagram 15.16

13526

PUMP HEAD

CABLE COVER

AUTOMATIC AIR VENT

RETAINING CLIP

MAINTENANCE COVER

Diagram 15.14

15 Replacement of Parts

BYPASS TUBE

RH HYDROBLOCK

LH HYDROBLOCK

CH OUTLET PIPE

SECURING SCREW

PRIMARY FLOW PIPE

SPIGOT (4 OFF)

MOUNTING BRACKET

BLANKING PLATE RUBBER SEAL (4 OFF)

BLANKING PLATE

AUTOMATIC BYPASS HOUSING SEALS

CH FILTER

(in Hydroblock)

RETAINING CLIP

Diagram 15.17

13531

15.22 Hydroblock and Bypass Tube

For access, refer to section 15.1.

IMPORTANT: To replace the bypass tube 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.

Drain the boiler heating circuit as described in the appropriate section of 15.1.

Isolate the gas supply at the gas service isolation valve, see diagram 13.3.

Remove the low water pressure sensor from the LH hydroblock, refer to section 15.20.

Remove the blanking plate, see diagram 15.17.

Remove clips from the plastic LH hydroblock retaining the primary ﬂow pipes and CH outlet pipe, see diagram 15.17.

Remove the primary ﬂow pipe from the LH hydroblock.

Remove the CH ﬁlter from the primary ﬂow pipe port in the LH hydroblock. The ﬁlter is a push-ﬁt in the hydroblock port.

Undo the union nuts on the CH outlet pipe and gas pipe at the connections between the top and bottom modules.

Undo the locknuts retaining the CH outlet pipe and the gas pipe to the boiler chassis.

Rotate the gas pipe upwards and clear of the chassis panel.

Remove the 3 screws which retain the automatic bypass housing, refer to section 15.21.

Grip the LH and RH hydroblocks simultaneously and lift clear of the spigots on the mounting bracket. The RH hydroblock should be drawn upwards past the plastic three way valve body.

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.

NOTE: Before lowering the assembly onto the bracket spigots, ensure that the two port axis in each hydroblock run parallel to each other and also that the bottom faces of the hydroblocks are level and aligned.

Lower the assembly onto the bracket ensuring that the brass washers on the DHW and DCW pipes are not displaced. Check also that the seals on the front of the RH hydroblock remain in place as it slides past the automatic bypass housing. Before reﬁtting 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.

Reﬁll system, vent and pressurise the boiler.

15.23 Access User Interface and Main PCB

For access, refer to section 15.1.

Remove control box retaining screw, see diagram 15.18.

Hinge down the control box.

Release the control box cover by carefully pressing the four retaining clips, see diagram 15.18.

15.24 Main PCB

IMPORTANT: When replacing the board refer to instructions

supplied with the replacement.

For access, refer to section 15.23.

Remove the electrical connections to the PCB.

Ease back the four PCB retaining clips and withdraw the PCB from the retaining lugs, see diagram 15.19.

When reﬁtting the rear panel ensure the leads are not trapped.

15.25 User Interface

IMPORTANT: When replacing the board refer to instructions

supplied with the replacement.

Refer to section 15.23 for access.

Remove main PCB, refer to section 15.24.

Remove electrical connection.

Gently ease back the retaining clips, see diagram 15.20.

Withdraw the board.

15.26 Fuse, Main PCB - Control Box

For access, refer to section 15.23.

The fuse is located at top left hand side of the PCB, see diagram 15.19.

15.27 Control Box

For access, refer to section 15.23.

Remove relevant plugs and connectors, refer to wiring diagram 14.2.

Withdraw grommets and leads so they are hanging loose.

Unthread the retaining cord and remove the control box. by drawing it outwards away from its retaining slots, see diagram 15.18.

15.28 Inner Casing Panel Seal

For access, refer to section 15.1.

Refer to diagram 13.10.

Remove the inner casing panel.

To replace remove the old seal, thoroughly clean the casing surfaces. Fit the new seal, it is supplied to the correct length.

Reﬁt the inner casing panel.

NOTE: Ensure the seal is ﬁtted correctly giving an airtight joint.

USER INTERFACE BOARD

RETAINING CLIPS

ELECTRICAL CONNECTION

13355

Diagram 15.18

13535

15 Replacement of Parts

RETAINING

CLIPS (4 OFF)

MAIN PCB

RETAINING

LUGS

FUSE

Diagram 15.19

Diagram 15.20

RETAINING SLOTS

SECURING SCREW

REAR

CONTROL PANEL

RETAINING CLIPS

13536

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.

16 Spare Parts

Key No. Part No. Description GC Part No.

1 2000802463 Burner - 18sxi ********* 1 2000802662 Burner - 30sxi ********* 2 0020014173 Pressure Relief Valve ********* 3 0020014161 Automatic Air Vent ********* 4 0020014171 Pump ********* 5 801655 Igniter ********* 6 0020038061 User Interface ********* 7 0020023825 Main PCB ********* 8 0020037309 Fan ********* 9 2000802664 Gas Valve ********* 10 0020014169 Bypass ********* 11 0020020781 NTC ********* 12 2000802462 Electrode ********* 13 801635 Burner Door Seal Kit *********

16 Spare Parts

Diagram 15.21

13861

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-ordi

nated movements during lift. Avoid upper body/top heavy bending

- do not lean forward/sideways. Recommend wear suitable cut resist

ant gloves with good grip to protect against sharp edges and ensure good grip. Always use assistance if required.

Removal of carton from delivery van

Recommend 2 person lift or 1 person with use of sack truck. If 1 person is performing lift, straddle the load, tilt and place carton into position on truck. Recommend secure appliance onto truck with suitable straps. Ensure safe lifting techniques are used – keep back straight – bend using legs. Keep load as close to body as possible. If 2 persons performing lift, ensure co-ordinated movements during lift. Always use assistance if required.

Carriage of carton from point of delivery to point of installation – ground ﬂoor.

movements during lift. Clear the route before attempting the lift. If removing boiler from truck straddle the load and tilt forwards to facilitate secure grip. Ensure safe lifting techniques are used – keep back straight – bend using legs. Do not twist – reposition feet instead. Take care to

avoid trip hazards, slippery or wet surfaces and when climbing steps and stairs. Always use assistance if required.

Carriage of carton from point of delivery to point of installation – ﬁrst or higher ﬂoor, cellar.

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

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

Recommend 2-person lift. Ensure co-ordinated movements during lift. Avoid upper body/top heavy bending - do not lean forward/side

ways. Clear the route before attempting the lift. Take care to avoid trip hazards, slippery or wet surfaces and when climbing steps and stairs. When transferring appliance into roofspace, recommend 1 person to be in roofspace to receive the appliance and other person to be below to pass up and support appliance. Ensure safe lifting techniques are used – keep back straight – bend using legs. Keep load as close to body as possible. Always use assistance if required. It is assumed safe access, ﬂooring and adequate lighting are 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 ﬂooring, lighting and other factors, and appropriate measures taken.

Unpacking of appliance from carton.

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

Positioning of Appliance for Final Installation – no obstructions.

Recommend 2 persons lift appliance to position into place. Fit bracket securely onto wall before lifting appliance into position. Obtain ﬁrm grip on front and sides of appliance, lift upwards, ensure stable balance achieved and lift upwards to position in place on bracket. Ensure safe lifting techniques are used – keep back straight – bend using legs - when lifting load from ﬂoor level. Do not twist – reposition feet instead. Keep boiler as close as possible to body through

out lift to minimise strain on back. Ensure co-ordinated movements to ensure equal spread of weight of load. Always use assistance if required. Recommend wear suitable cut resistant gloves with good grip to protect against sharp edges and ensure good grip when handling appliance.

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

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

Positioning of Appliance for Final Installation – within compart

ment etc. restricting installation.

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

Positioning of Appliance for Final Installation – in roof space re

stricting installation.

ing 2 person lifts to ensure equal spread of weight of load. If 1 person positioning onto bracket recommend obtain ﬁrm grip supporting base of boiler. Ensure safe lifting techniques are used - keep back straight – bend using legs - when lifting load from ﬂoor level. Do not twist – reposition feet instead. Keep boiler as close as possible to body throughout lift to minimise strain on back. Always use assistance if re

quired. Recommend wear suitable cut resistant gloves with good grip to protect against sharp edges and ensure good grip when handling appliance. It is recommended a risk assessment of the roof space area be carried out before moving the appliance into the area to take into account access, stability of ﬂooring, lighting and other factors, and appropriate measures taken.

17 Manual Handling

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

Because of our constant endeavour for improvement, details

may vary slightly from those shown in these instructions.

0020020821-02 02.07

Glow-worm ULTRACON 18SXI, ULTRACON 30SXI Installation And Servicing Manual

Specifications and Main Features

Frequently Asked Questions

User Manual