Glow-worm Ultrapower 170sxi, Ultrapower 100sxi Installation And Servicing

Page 1
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Installation and Servicing
Ultrapower
100sxi
13121
G.C. No. 41-019-09
170sxi
G.C. No. 41-019-10
High Efficiency
System Store
Glow-worm, Nottingham Road, Belper, Derbyshire. DE56 1JT
www.glow-worm.co.uk
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Guarantee Registration
Thank you for installing a new Glow-worm appliance in your home.
Glow-worm appliances are manufactured to the very highest standard so we are pleased to offer our customers a Comprehensive
Guarantee.
This product is guaranteed for 24 months from the date of installation or 30 months from the date of manufacture, whichever is the
shorter, for parts. 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.
In addition Glow-worm offers a guarantee of 10 years for the stainless steel cylinder against faulty materials or manufacture
provided that:
The following information is important as without it your guarantee may be invalid.
1. The warranty will become invalid if the damage is due to scaling, frost damage, transient voltages, lightning strikes or any act of vandalism or misuse.
2. The proof of purchase must be produced in the event of any warranty claim (bill of sale).
3. The appliance must be installed by a competent person to the prevailing standards, installation book and building regulations at the time of installation.
4. The benchmark log book must be completed on installation and kept up to date.
5. The appliance must be serviced annually.
6. The installation must be in an appropriate location and its use is restricted to potable water (chloride levels less than 200 mg/l).
7. Tampering or modification will invalidate the warranty.
8. The guarantee card must be completed and returned to Glow-worm within 30 days of purchase.
PLEASE NOTE THIS EXTENDED GUARANTEE IS NOT TRANSFERABLE AND RESTS WITH THE ORIGINAL HOUSEHOLDER.
Customer Service:
01773 828100
Technical Helpline:
01773 828300
General and Sales enquiries:
Tel. 01773 824639
Fax: 01773 820569
To register your Glow-worm appliance
call:
0800 0732142
2
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These instructions consist of, Installation, Servicing, Fault Finding, Replacement of Parts
and Spares. The instructions are an integral part of the appliance and must, to comply
with the current issue of the Gas Safety (Installation and Use) Regulations, be handed to
the user on completion of the installation.
CONTENTS DESCRIPTION SECTION PAGE
Warnings 4 Important Information 4 Statutory Requirements 5
INTRODUCTION
Boiler Design 6 Boiler Safety Devices 6 Servicing, Maintenance & Spare Parts 6
Specification Table 1 7 Boiler Dimensions & Hydraulic Schematic 2 8 Boiler Location, Clearances & Ventilation 3 10 Flue Options and Terminal Clearances 4 11 Heating System 5 13 Domestic Hot Water 6 14 Installation Preparation 7 17
INSTALLATION
INSTRUCTIONS
Gas/Water & Appliance Connection 8 19 Electrical Preparation & Cable Routing 9 23 Flue Preparation and Installation 10 24 Electrical Connection 11 38 Commissioning 12 40 Servicing 13 44 Fault Finding 14 49 Replacement of Parts 15 56 Spare Parts 16 69
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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.
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 the above 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 / Ceramic Fibre
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 suf skin seek medical attention.
fer irritation to the eyes or severe irritation to the
Manual Handling
With regards to the “Manual Handling Operations, 1992 Regulations”, it should be noted that each appliance module exceeds the recommended weight for a one man lift.
Electrical Supply
The boiler MUST be earthed.
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 r adjacent to the appliance. It should be identified as to its use.
eadily accessible and preferably
Alternatively connection can be made thr shuttered socket and 3A fused 3-pin plug both to the current issue of BS 1363, pr containing a bath or shower.
Wiring to the boiler must be PVC 85 less than 0.75mm2 (24/0.20mm).
Immersion Heater - An immersion heater is fitted to the cylinder as a back up for domestic hot water in the event of the boiler being inoperable. The immersion heater MUST be wired separately from the rest of the boiler electrical connections using 3kW 13amp wiring and in accordance with the r
elevant standards.
ovided they are not used in a room
ough an unswitched
O
C insulated cable, not
Testing and Certification
This boiler is tested and certificated for safety and performance. It is, therefore, important that no alteration is made to the boiler, without permission, in writing, by Glow­worm.
Any alteration not approved by Glow-worm, could invalidate the certification, boiler warranty and may also infringe the current issue of the statutory requirements.
CE Mark
This boiler meets the requirements of Statutory Instrument, No. 3083 The Boiler (Efficiency) Regulations, and therefore is deemed to meet the requirements of Directive 92/42/EEC on the efficiency requirements for new hot water boilers fired with liquid or gaseous fuels.
Type test for purposes of Regulation 5 certified by: Notified body 0087.
Product/production certified by: Notified body 0086.
The CE mark on this appliance shows compliance with:
Dir
1.
ective 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.
Dir
3.
ective 89/336/EEC on the appr
the Member States relating to electromagnetic compatibility.
oximation of the Laws of
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Statutory Requirements
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 with the rules in force in the countries of destination.
Manufacturer’s instructions must not be taken as overriding statutory requirements.
Statutory Requirements
Installation of this boiler falls within the scope of the Building Regulations 1995 (Part G). This requires that the installation of an unvented system should be notified to the local authority Building Control Department and that the work must be carried out by a competent person as defined in the approved document G3.
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 manufactur
The Gas Safety (Installation and Use) Regulations.
The appr 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 Hazar
dous 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 curr Regulations and reference should be made to the current ETCI rules for Electrical Installation.
In 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.
In IE: I.S.813, BS5546, BS 5449, BS 7074, BS 7593.
NOTE: For further information, see the current issue of the Building Regulations, appr the following curr
1) Central heating system specification (CheSS)
and
2) Contr water. BRECSU.
ols for domestic central heating system and hot
er’s instructions supplied.
opriate Buildings Regulations either The Building
ent Building
oved document L1 ( in the UK) and
ent issues of:
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 gover size to provide a steady inlet working pressure of 20mbar (8in wg) at the boiler.
On completion, test the gas installation for soundness using the pr purge in accordance with the above standard.
e drop method and suitable leak detection fluid,
essur
ned meter must be of adequate
Domestic Hot Water
All domestic hot water circuits, connections, fittings must be in accordance with the relevant standards and water supply regulations.
For GB: Guidance G17 to G24 and recommendation R17 to R24 of the Water Regulations Guide.
For IE: The current edition of I.S.813 “Domestic Gas Installations”.
Heating System
In GB it is necessary to comply with the Water Supply (Water Fittings) Regulations 1999 (for Scotland, the Water Byelaws 2000, Scotland).
To comply with the Water regulations your attention is drawn to: The Water Regulations guide published by the Water Regulations Advisory Service (WRAS) gives full details of the requirements.
In IE the requirements given in the current edition of I.S.813 “Domestic Gas Installations” and the current Building Regulations must be followed.
Electrical Supply
The electrical installation must be installed by a competent
person and in accordance with the relevant standards.
The boiler and immersion heater 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 r
In GB this is BS 7671.
In IE this is the curr Installations”
elevant standards.
ent edition of I.S.813 “Domestic Gas
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Boiler Design
Boiler Design
This boiler is designed as a high efficiency central heating appliance, close coupled to an un-vented cylinder. The pumps, expansion vessels and associated safety devices are all fitted within the appliance, providing a one box solution for properties requiring a high domestic hot water demand. The intelligent control system 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.
Boiler Safety Devices
Electrical Supply Failure
The boiler will not work without an electrical supply.
Normal operation of the boiler should resume when the electrical supply is restored.
Reset any external controls, to resume normal operation of the central heating.
If the boiler does not resume normal operation press the
eset button. If the boiler does not resume normal operation
r after this, call your Installation/Servicing company or Glow-
worm’s own service organisation using the telephone number on the inside front cover of this booklet
Overheating Safety
In the event of the boiler overheating the safety devices will cause a safety shutdown. A “Reset” may be required if a fault code (‘F’ followed by a number) appears on the digital display, refer to ‘F’ codes, section 14 Fault Finding. A manual reset button is also provided on the thermostat in the immersion heater.
Safety Discharge Valves
Three safety discharge valves and discharge pipes are fitted to the boiler, two PRV’s and one pressure/temperature relief
valve. The valves must not be touched.
Should there be any discharge from the pipes, isolate the boiler electrical supply and call your installer or Glow-worm’s own service organisation using the telephone number on the inside front cover of this booklet.
.
Condensate should, if possible, be discharged into the internal household draining system. If this is not practical, discharge can be made externally into the household drainage system or a purpose designed soak away, see section 8 for more details.
Pluming from flue terminal
Like all condensing boilers this appliance will produce a plume of condensation from the flue terminal in cool weather. This is due to the high efficiency and hence low flue gas temperature of the boiler. This is normal and not an indication of a fault.
Frost protection
The appliance has a built in frost protection device that protects the boiler from freezing. With the gas and electric supplies ON and irrespective of any room thermostat setting, the frost protection device will operate the pump when the temperature of the boiler water falls below 8
After 10 minutes the pump will be stopped if the temperature is higher than 10
The burner will activate if the boiler temperature does not reach 10 drops to 5
The burner will switch off when the temperature reaches 35
Frost protection is also built into the cylinder. Should the cylinder temperature fall below 10 re-heated to a temperature of 15
The cylinder has a built in disinfection cycle which raises the water temperature to 70 2:00am.
O
O
C.
O
C or has already reached 35OC.
C after 30 minutes or at any time if the temperature
O
C.
O
C.
O
C for 1 hour every Wednesday at
O
C.
O
C, the tank is
Condensate Drain Blockage
As a safety feature the boiler will stop working if the condensate drain becomes blocked. During freezing conditions this may be due to the forming of ice in the condense drain external to the house. Release an ice blockage by the use of warm cloths on the pipe, the boiler should then restart.
Servicing, Maintenance and Spare Parts
Servicing and Maintenance
To ensure the continued efficient and safe operation of this 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 boiler is installed in a of care imposed on the owner issue of the Gas Safety (Installation and Use) Regulations, Section 35. Servicing/maintenance should be carried out by a competent
person
of destination. To obtain service, please call your own service organisation using the telephone number on the inside front cover of this booklet. Please be advised that the ‘Benchmark’ logbook, located at centre of this booklet, should be completed by the installation engineer on completion of commissioning and servicing.
in accordance with the rules in force in the countries
rented property there is a duty
of the property by the current
installer or Glow-worm’s
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 organisation. Please quote the name and model of the boiler. The name badge is on the fr type is positioned on the top edge of the tank module front panel. If in doubt seek advice from worm’s own service organisation using the telephone number on the inside front cover of this booklet.
6
contact Glow-worm’s own service
ont of the appliance and the model
the local gas company or Glow-
Page 7
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1 Specification Table
BOILER SPECIFICATION 100sxi 170sxi
Lift weight - Tank Module 39kg (86Ib) 48kg (106Ib)
- Boiler Module 50.5kg (111lb) 50.5kg (111lb)
Total weight (installed)
175kg (385Ib) 225kg (495Ib)
Gas connection Ø O.D. 22mm. copper (15mm on jig) 22mm. copper (15mm on jig)
Heating and return connection Ø O.D.
22mm. copper 22mm. copper
Domestic hot water connection Ø O.D.
22mm. copper 22mm. copper
Condensate connection Ø I.D.
21.5mm. plastic 21.5mm. plastic
Safety valve discharge connection Ø O.D. 22mm. copper
22mm. copper
CH safety valve (preset) 3 bar (43/5Ibf/in
2
) 3 bar (43/5Ibf/in2)
Heating system minimum pressure 0.7bar (10.1Ibf/in
2
) 0.7bar (10.1Ibf/in2)
Maximum flow temperature 82°C
82°C
DHW recovery from 15°C to 65°C 10 mins 17 mins
70% draw off 9 mins
12 mins
CH Expansion vessel capacity
10 litres (2.2 gallons) 10 litres (2.2 gallons)
CH Expansion vessel charge pressure 0.75bar (11Ibf/in
2
) 0.75bar (11Ibf/in2)
DHW Expansion vessel capacity 12 litres 12 litres
DHW Expansion vessel capacity pre charge 3 bar (44Ibf/in
2
) 3 bar (44Ibf/in2)
Pressure reducing valve (preset) 3.5 bar (51.5Ibf/in
2
) 3.5 bar (51.5Ibf/in2)
Pressure and temp relief valve 90°C and 7 bar 90
°C and 7 bar
Pressure relief valve on inlet manifold 6 bar (88Ibf/in
2
) 6 bar (88Ibf/in2)
Electrical supply 230V~50Hz 230V~50Hz
Electrical rating
210W fused 3A 210W fused 3A
IP clasification
X4D X4D
Internal fuse rating on main PCB
2A 2A
Gas supply (governed meter only) I
2H
G20 natural gas I2H G20 natural gas
Inlet gas working pressure 20mbar 20mbar
Burner % CO
2
case on (after 5 mins) 9.2 nominal 9.2 nominal
Burner % CO
2
case off (after 5 mins) 9 nominal 9 nominal
3.30 m
3
/hr 3.30 m3/hr
116.5 ft
3
/hr 116.5 ft3/hr
Approximate max. gas rate after 10 mins. from cold
DHW - Heat input NETT Q = kW 31.6 max. 8.9 min. 31.6 max. 8.9 min. DHW - Heat output NETT Q = kW 31.6 max. 8.9 min. 31.6 max. 8.9 min. CH - Heat input
24.5kW
24.5kW
CH - Heat output
24.33kW 24.33kW
Flue type C
13, C33, C53 C13, C33, C53
NOx Class 5 Class 5
Data
All dimensions are given in millimetres (except as noted).
See diagram 2.1 and the Boiler Specification Table below.
The data label is positioned inside the boiler module on the base.
7
13340
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1331
(100sxi)
106.5
600
1260
(100sxi)
L
BOILER
C
575
35
70
80
50
116
70
46
12
PRV DISCHARGE
SIPHON DISCHARGE
DHW DISCHARGE
L
FLUE
C
1591
(170sxi)
1520
(170sxi)
145
2 Boiler Dimensions & Hydraulic Schematic
13247
8
Diagram 2.1
Page 9
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2 Boiler Dimensions & Hydraulic Schematic
PRIMARY CIRCUIT FLOW THERMISTOR
HEATING PUMP
AUTOMATIC
AIR VENT GAS CONTROL V
ALVE
3 WAY V
ALVE
PLATE TO PLATE HEAT
EXCHANGER
AUTOMATIC ADJUSTABLE BYPASS
HEATING
W
ATER EXPANSION VESSEL
PRESSURE SENSOR
CONNECTOR
CONNECTOR
BYPASS FILTER
DHW THERMISTOR
DOMESTIC PUMP
PRIMARY CIRCUIT RETURN THERMISTOR
PRV
M
DOMESTIC WATER
EXPANSION VESSEL
PRIMARY HEAT EXCHANGER
TPRV
TUNDISH 'A'
TUNDISH 'B'
PRESSURE REDUCING V
ALVE
PRV
TUNDISH 'A'
SHIFT LOAD TANK
IMMERSION HEA
TER
TANK THERMISTOR
DT
FILLING LOOP
CH FLOW
DHW
GAS
CH RETURN
DCW
BOILER MODULE
TANK MODULE
JIG
13290
9
Diagram 2.2
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3 Boiler Location, Clearances and Ventilation
3.1 Location
This boiler is not suitable for outdoor installation.
This boiler may be installed in any room, although particular attention is drawn to the installation of a boiler in a room containing a bath or shower where reference must be made to the relevant requirements.
This boiler is suitable for installation in bathroom zones 2 and
3.
In GB this is the curr BUILDING REGULATIONS.
In IE reference should be made to the current edition of I.S.813 “Domestic Gas Installations” and the curr rules.
ent I.E.E. WIRING REGULATIONS and
ent ETCI
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 a clearance lar than those specified in diagram 3.1.
ger
13241
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 Room Ventilation
The boiler is room sealed so a permanent air vent is not required.
3.5 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
10
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4 Flue Options and Terminal Clearances
Flue Options
Top horizontal telescopic flue Ø60/100 Part No. A2043600
13245
Plume Management Kit Basic set, concentric flue Ø60/100 White - Part No. A2044100 Black - Part No. A2044000 for use with Part No. A2043400 and Part No. A2043600
Top horizontal standard flue Ø60/100 Part No. A2043400
Vertical Flue Vertical Flue Adapter, concentric flue Ø60/100 Part. No. A2024600
V
ertical flue terminal kit, concentric flue Ø60/100 Part. No. 2000460480
11
Twin Flue Twin Flue Adapter, concentric flue Ø80 Part No. A2011000
Diagram 4.1
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4 Flue Options and Terminal Clearances
HORIZONTAL FLUES
A DIRECTLY BELOW AN OPENING, AIR BRICK, OPENING WINDOWS 300 B ABOVE AN OPENING, AIR BRICK, OPENING WINDOWS 300 C HORIZONTALLY TO AN OPENING, AIR BRICK, OPENING WINDOWS 300 D BELOW GUTTER, DRAIN/SOIL PIPE 25 E BELOW EAVES 25 F BELOW A BALCONY OR CAR PORT 25 G FROM VERTICAL DRAIN PIPES AND SOIL PIPES 25 H FROM INTERNAL/EXTERNAL CORNERS 25
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
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
The minimum acceptable siting dimensions for the terminal from obstructions, other terminals and ventilation openings are shown in diagram 4.2. For Ireland 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.
NOTE: If necessary it is permitted to increase the terminal pr
otrusion through the outside wall to greater than the
minimum dimension of 87mm but no more than 600mm.
Carports or similar extensions of a roof only, or a r 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 r to avoid wall staining and nuisance from pluming depending on site conditions.
Plume Management Kit: Part No.A2044100 (white) or A2044000 (black) can be used to overcome many site issues.
egulations, but they may need to be increased
oof and
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 guar
Tower Flue Components
Morley Rd.
T
onbridge
Kent TN9 1RA.
Size: 280mm x 280mm x 270mm.
d is manufactured by: -
12325
Diagram 4.2
12
Diagram 4.3
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5 Heating System
General
The boiler is for use only with sealed central heating systems.
The digital readout on the controls fascia indicates the system pressure when there is no demand.
The circulation pump is integral with the boiler.
5.1 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.
5.2 Expansion Vessel
The boiler has an integral expansion vessel with a capacity of 10 litres (2.2 gallons), with a charge pressure of 0.75bar.
NOTE: The expansion vessel volume depends on the total water system volume and the initial system design pressure. Guidance on vessel sizing is also given in the current issue of BS5449 and BS7074 Part 1, for IE refer to the curr of I.S.813 “Domestic Gas Installations”.
ent edition
5.3 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.
13352
5.4 Bypass
The boiler is fitted with an automatic adjustable bypass.
Diagram 5.2 shows the pump head remaining for the heating system depending on the bypass setting and the speed setting of the pump, see section 11 Commisioning.
5.5 Filling the Sealed System
NOTE: The water pressure at the boiler must be at least
0.7bar to enable filling the boiler to a minimum pressure. The boiler is supplied with a filling device, see diagram 5.1.
5.6 Water Treatment
In the case of an existing system, it is ESSENTIAL that prior to installing the new boiler the system is thoroughly flushed. For optimum performance after installation of a new system, 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.
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.
13
Diagram 5.1
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5 Heating System
DRAIN POINT
CONDENSE TRAP
AND
SIPHONIC DRAIN
SCREW
0
1
2
3
4
pump speed 1
pump speed 2
Remaining conveyancing capacity
(mH
2O)
800 1000 1200 1400 1600 18006004002000
Volumeflow (Litres/hr)
automatic bypass - open
automatic bypass - factory setting
automatic bypass - closed
13375
6 Domestic Hot Water
General
All domestic hot water circuits, connections, fittings must be in accordance with the relevant standards and water supply regulations. The boilers are suitable for connection to most types of washing machine and dishwasher appliances. When connecting to suitable showers, ensure that: a) The cold water inlet to the boiler is fitted with an
approved anti-vacuum or siphon non-return valve.
b) Hot and cold water supplies to the shower are of equal
pressure.
6.1 Water Pressure Flow Rate
This boiler will operate satisfactorily at low water inlet pressure. However for optimum performance it is recommended that 22mm feed pipe is used with an inlet pressure, at the appliance, of 2bar. NOTE: Higher pressure can be tolerated as the boiler is fitted with a pressure reducing valve set a 3.5 bar.
Diagram 5.2
Guidance on vessel sizing is also given in the current issue of BS5449 and BS7074 Part 1, for IE refer to the current edition of I.S.813 “Domestic Gas Installations”.
6.4 Draining Point
A draining point is provided at the bottom of the hot water storage tank located next to the condensate drain, see diagram 6.1.
6.5 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.
13308
6.2 ‘Hard’ Water Areas
The temperatures within the heat exchanger are limited by the boiler control system to minimise scale formation within the hot water pipework. However, in areas where the water is ‘hard’ (i.e. more than 200mg/litre), it is recommended that the hot water setting is reduced and that a scale reducer is fitted, refer to the manufacturer’s instructions or consult the local water company for additional advice.
6.3 Expansion Vessel
The boiler has an integral expansion vessel with a capacity of 12 litres (2.6 gallons), with a charge pressure of 3bar.
NOTE: The expansion vessel volume depends on the total water system volume and the initial system design pressure.
14
Diagram 6.1
Page 15
Supplied By www.heating spares.co Tel. 0161 620 6677
6 Domestic Hot Water
SYSTEM REQUIREMENTS – Domestic Hot Water
Domestic Hot Water Requirements
NOTE: Attention is drawn to the following extracts from the Building Regulations 1991. Regulation 11(1) (Giving of a building notice or deposit of plans) “Subject to the following provisions of this regulation, a person who intends to carry out building work or to make a material change of use shall: a) Give to the local authority* a building notice in
accordance with 12; or
b) Deposit full plans with the local authority* I accordance
with regulation 13”.
Regulation 12(4) (Particulars and plans where a building notice is given)
“………a building notice shall be accompanied by a statement which specifies: *Attention is drawn to regulation 18 (supervision of building ork otherwise than by local authorities). a) The name, make, model and type of hot water storage
system to be installed;
b) The name of the body, if any, which has approved or
certified that the system is capable of performing in a way which satisfies the requirements of paragraph G3 of Schedule 1;
c) The name of the body, if any, which has issued any
current registered operative identity card to the installer or proposed installer of system.”
Regulation 13(3) (Full plans)
“Full plans shall consist of: a) Description of the proposed building work or material
change of use, and the plans, particulars and statements required by paragraphs (1) to (4) of regulation 12: and …….*
NOTE:
Bye-laws of the appropriate Water Undertake also apply.
Discharge Pipework
It is a requirement of Building Regulation G3 that any discharge from an unvented system is conveyed to where it is visible but will not cause danger to persons in or about the building. The tundish and discharge pipes should be fitted in accordance with requirements and guidance notes of Building Regulation G3. The G3 Requirements and Guidance section 3.9 are reproduced in the following sections. Information Sheet No. 33 available from the British Board of agreement gives further advice on discharge pipe installation. For discharge pipe arrangements not covered by G3 Guidance or BBA info sheet no. 33 advice should be sought from your local Building Control Officer.
G3 Requirement
“….there shall be precautions….. to ensure that the hot water discharged from safety devices is safekly conveyed t where it is visible but will not cause danger to persons in or about the building”.
G3 Guidance SECTION 3.9
The discharge pipe (D1)from the vessel up to and including the tundish is generally supplied by the manufacturer of the hot water storage system. Where otherwise, the installation should include the discharge pipe(s) (D1) from the safety device(s). In either case the tundish should be vertical, located in the same space as the unvented hot water storage system and be fitted as close as possible and within 500mm of the safety device e.g. the temperature relief valve.
NOTE: The tundish is factory fitted during manufacture of the istor. The discharge pipe (D2) from the tundish should terminate in a safe place where there is no risk to persons in the vicinity of the discharge, pr a) Be at least one pipe size larger than the nominal outlet size of the safety device unless its total equivalent hydraulic resistance exceeds that of straight pipe 9m long i.e. discharge pipes between 9m and 18m equivalent resistance length should be at least two sizes larger than the nominal outlet size of the safety device, between 18 and 27m at least 3 sizes larger and so on. Bends must be taken into account in calculating the flow resistance. An alternative approach for sizing discharger pipes would be to follow BS67100:1987 specification for design installation, testing and maintenance of services supplying water for domestic use within buildings and their curtilages. Appendix E section E2 and table 21. b) Have a vertical section of at least 300mm long, below the tundish before any elbows or bends in the pipework. c) Be installed with a continuous fall. d) Have discharges visible at both the tundish and the final point of discharge but where this is not possible or is practically difficult there should be clear visibility at one or other of these locations. Examples of acceptable discharge arrangements are: i) Ideally below a fixed grating and above the water seal in a trapped gully. ii) Downward discharges at low level; i.e. up to 100mm above external surfaces such as car parks, hard standings, grassed areas etc. are acceptable providing that where children may play or otherwise come into contact with discharges a wire cage or similar guard is positioned to prevent contact whilst maintaining visibility. iiI) Discharges at high level; e.g. into a metal hopper and metal down pipe with the end of the discharge pipe clearly visible (tundish visible or not) or onto a roof capable of withstanding high temperature discharges of water and 3m from any plastic guttering system that would collect such discharges (tundish visible). iv) Where a single pipe serves a number of discharges, such as in blocks of flats, the number served should be limited to not more than 6 systems so that any installation discharging can be traced reasonably easily. The single common discharge pipe should be at least one pipe size larger than the largest individual discharge pipe (D2) to be connected. If unvented hot water storage systems are installed where discharges from safety devices may not be apparent i.e. in dwellings occupied by blind, infirm or disabled people, consideration should be given to the installation of an electronically operated device to warn when discharge takes place.
eferably be of metal and:
15
Page 16
Supplied By www.heating spares.co Tel. 0161 620 6677
6 Domestic Hot Water
D1
D2
Discharge pipe D2 from tundish
Resistance created by each elbow or bend
Maximum resistance allowed, expressed as a length of straight pipe (i.e. no elbow or bends)
Discharge pipe D1
Valve outlet size
15mm
22mm
0.8m
up to 9m
G 1/2
TABLE 1
NOTE: The discharge will consist of scalding water and steam. Asphalt, roofing felt and non-metallic rain water goods may be damaged by such discharges.
Worked example of discharge pipe sizing
The example given in diagram 6.2 is for a G1/2 temperature relief valve with a discharge pipe (D2) having 4 No. elbows and length of 7m from the tundish to the point of discharge.
From Table 1:
Maximum resistance allowed for a straight length of 22mm copper discharge pipe (D2) from a G1/2 temperature relief valve is 9.0m.
Subtract the r each = 3.2m.
Therefore the permitted length equates to 5.8m.
5.8m is less than the actual length of 7m therefore calculate the next largest size. Maximum resistance allowed for a straight length of 28mm pipe (D2 fr relief valves equates to 18m. Subtract the resistance of 4 No. 28mm elbows at 1.0m each: 4.0m.
Ther
efore the maximum permitted length equates to: 14m. As the actual length is 7m a 28mm min (D2) copper pipe will be satisfactory.
esistance for 4 No. 22mm elbows at 0.8m
om a G1/2 temperature
13449
WARNING:
Under no circumstances should the factory fitted
temperature/pressure relief valve be removed other than by authorised personnel. To do so will invalidate any warranty claim.
Table 1. Sizing of copper discharge pipe (D2).
Control and safety valves MUST NOT be tampered with.
The discharge pipe MUST NOT be blocked or used for
any other purpose.
The tundish is factory fitted and MUST NOT be
removed.
13308
Diagram 6.2
16
Page 17
Supplied By www.heating spares.co Tel. 0161 620 6677
C
D
D
E
F
F
F
F
G
G
D
N
N
N
N
H
H
H
H
H
J
L
M
Stored in cartridge
TANK / BOILER MODULE
CONNECTION WASHERS
N 3/4" Sealing Washer (blue) 4 OFF
M Cartridge Screws (stored in cartridge) 2 OFF
L Electrical Cartridge 1 OFF
K Floor Template 1 OFF
J Pump Washer 1 OFF
H 3/4" Sealing Washer (beige) 5 OFF
G 1/2" Sealing Washer (blue) 2 OFF
F 3/4" Sealing Washer (white plastic) 4 OFF
E 15mm Copper Tail
1 OFF
D 22mm Copper Tails 4 OFF
C Condensate Connection Pipe
1 OFF
B User Instructions (not illustrated) 1 OFF
A Installation booklet (not illustrated)
1 OFF
LOOSE ITEMS PACK
D
FIXING JIG
7 Installation Preparation
13405
13248
17
Diagram 7.1
Page 18
Supplied By www.heating spares.co Tel. 0161 620 6677
7 Installation Preparation
TEMPLATE
TEMPLATE
2
1
/
2
o
(44mm /metre) FALL TOWARDS THE BOILER IS
REQUIRED WHEN FLUE EXTENSIONS ARE USED
1331 (100)
1591 (170)
IMPORTANT
With regards to the Health and Safety Manual Handling requirements, two persons shall be required to lift the appliance. It should be noted that the appliance is made up of two modules each module requiring two persons to lift.
Please check the contents of packs as shown in diagram 7.1.
NOTE: The packs are located in the top polystyrene packing of the tank module.
The floor fixing jig is located with the tank module.
The electrical cartridge is located in the fittings kit.
IMPOR
the installation of the cartridge and wiring of the appliance and also the separate wiring required for the immersion
.
heater
7.1 Site Requirements
NOTE: Due to the varied site conditions we do not supply
fixings and advise that the installer should supply those which are suitable.
Where possible the appliance should be sited on a level floor, however slight adjustment can be made using the adjustable feet at the base of the tank module.
Refer to section 11 - Electrical Connection, for
TANT:
13418
7.2 Fixing Template
Take the fixing template from the loose items pack which is situated in the tank module pack and place in the desired
position on the floor, giving due consideration to the required boiler clearances, see section 3, and the flue you are fitting.
Mark the position of the flue center, if fitting a side flue, extend the flue centerline into the corner then along the adjacent wall, see diagram 7.2.
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 fr side wall, a horizontal line should be marked. The vertical centre line of the flue should then be marked on the back wall.
o allow for the flue passing through the wall at this angle
T a 125mm hole should be drilled irrespective of internal or external installation.
om the boiler. Where this line reaches the
7.3 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/ metr
e (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 r slope at 44mm/metre (2.5°) towards the boiler.
equired. This will allow the extension pieces to
Diagram 7.2
13374
7.4 Fixing Jig
The floor fixing jig is located with the tank module.
Place the fixing template on the floor and mark the position of the fixing holes for the jig, see diagram 7.3.
Drill fixing holes and secure the jig to the floor using suitable securing screws.
18
Diagram 7.3
Page 19
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8 Gas / Water & Appliance Connection
CENTRAL
HEATING
RETURN
CENTRAL
HEATING
FLOW
VALVES SHOWN CLOSED
DHW
OUTLET
GAS
DHW
INLET
CONDENSATE
DRAIN
PIPE WORK ROUTING (IF REQUIRED)
ADJUSTABLE FEET
31
68/78
VIEW SHOWING SIDE OUTLET PIPE WORK ROUTING AT BACK OF BOILER (IF REQUIRED)
CH SAFETY RELIEF VALVE DISCHARGE
DHW SAFETY RELIEF VALVE DISCHARGE
15mm COPPER TAIL
22mm COPPER TAIL
SEALING WASHER
ISOLATION VALVE (typical)
GAS ISOLATION VALVE
SEALING WASHER
8.1 Systems Connection
All water and gas connections are on the fixing jig with the exception of the condense drain and safety discharge, the positions of these are shown on the floor template.
Assemble the pipes to the jig as shown in diagram 8.1.
Plumb the system pipe work to the copper tails.
NOTE: Do not subject isolation valves to heat.
IMPOR
Prior to filling the water system, see section 12 Commissioning, ensure that the isolation valves are secur
Flush out the domestic hot water and the heating systems.
The whole of the gas installation, including the meter should be inspected, tested for soundness and purged in accordance with the current issue of BS6891 and in IE the current edition of I.S.813 “Domestic Gas Installations”.
TANT: Tighten the copper tails to the valves.
,
ed.
8.2 Appliance Connection
NOTE: The appliance and may contain a small amount
of water, place a water container beneath the boiler connections.
8.3 Safety Discharge Valve
The pipe must be extended, using not less than 22mm 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 22mm compr
ession elbow type fitting to extend the safety discharge
valve tubes.
13402
19
Diagram 8.1
Page 20
Supplied By www.heating spares.co Tel. 0161 620 6677
8 Gas / Water & Appliance Connection
BOILER MODULE FRONT PANEL
SECURING SCREW (2 OFF)
BOILER MODULE
TANK MODULE
LOCATING PIN (4 OFF)
ADJUSTABLE FEET
FLOOR FIXING JIG
PLASTIC WASHERS
PIPE RETAINING BRACKET
PUMP WASHER
SEALING WASHER (beige) (5 OFF)
SEALING WASHER (white plastic) (4 OFF)
SEALING WASHER (blue)
13416
Diagram 8.2
Unpack the boiler module and remove the front panel, see diagram 8.2. Place to one side to avoid damage.
The tank module front panel will need to be removed to gain access to pipe connections.
If there is restricted clearance where the boiler is to be positioned, connect the boiler module onto the tank module using the locating pins before positioning over the jig, see diagram 8.3.
Slide the assembled appliance over the jig and align with the isolation valves.
If necessary, level the boiler using the adjustable feet.
Make sur
Position the plastic sealing washers supplied in the loose Items pack, these ar
Engage the fixing jig and make good the final connections.
e the isolation valves are closed.
e as shown in diagram 7.1.
13415
20
Diagram 8.3
Page 21
Supplied By www.heating spares.co Tel. 0161 620 6677
8 Gas / Water & Appliance Connection
CONDENSE TRAP
& SIPHONIC DRAIN
FLEXIBLE
CONDENSATE
HOSE
FLEXIBLE CONDENSATE CONNECTION
PIPE
HEAT EXCHANGER CONDENSATE CONNECTION (push-fit)
FLEXIBLE CONDENSATE HOSE
FLEXIBLE CONDENSATE HOSE CONNECTION TO BOILER MODULE
8.4 Condensate Drain Connection
A flexible condensate hose runs from a push-fit connection at the bottom of the heat exchanger to a drain connection on the boiler module base plate, see diagrams 8.4 and 8.5. From this connection the hose runs to the condensate trap & siphonic drain on the left hand side of the boiler, see diagram
8.6.
A flexible condensate connection pipe is supplied in the fittings kit and should be fitted between the condense trap & siphonic drain and the condensate drain pipe, see diagram
8.1, to discharge condensate to a drain. The drain pipe 22mm to 25mm OD. non corrosive plastic pipe should have a fall of at least 2.5
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 8.7.
0
away from the boiler.
13444
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 trap inside the boiler. Fitting an extra trap may cause the boiler siphon to work incorr
ectly.
13312
13458
Diagram 8.4
Diagram 8.5
21
Diagram 8.6
Page 22
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8 Gas / Water & Appliance Connection
INTERNAL SOIL AND VENT STACK
Ø22mm MIN. NO RESTRICTION ON LENGTH
EXTERNAL SOIL AND VENT STACK
Ø22mm MIN. NO RESTRICTION ON LENGTH
Ø22mm MIN.
EXTERNAL LENGTH OF PIPE 3M MAX.
OPEN END OF PIPE DIRECT INTO GULLEY BELOW GROUND BUT ABOVE WATER LEVEL
Ø22mm MIN. NO RESTRICTION ON LENGTH
SINK (CONSTITUTES AIR BREAK)
Ø22mm MIN. NO RESTRICTION ON LENGTH
SINK
OPEN END OF PIPE DIRECT INTO GULLEY BELOW GROUND LEVEL BUT ABOVE WATER LEVEL.
Ø22mm MIN. TERMINATION FROM APPLIANCE.
EXTERNAL LENGTH OF PIPE 3M MAX.
25mm MIN.
SEAL
BOTTOM OF TUBE SEALED
Ø100mm PLASTIC TUBE
300mm MIN.
GROUND (either/or)
500mm MIN.
HOLE DEPTH 400mm MIN.
LIMESTONE CHIPPINGS
2 ROWS OF 3 x 12mm HOLES AT 25mm CENTRES 50mm FROM BOTTOM OF TUBE. HOLES TO FACE AWAY FROM HOUSE.
External Soil and Vent Pipe or Rainwater Pipe
Internal Soil and Vent Pipe
External Termination into Soakaway
Internal Termination Downstream of Sink Waste
Internal Termination into Combined Sink Waste
External Termination to a Gulley or Hopper
*
NOTE: PIPEWORK SHOULD ALWAYS FALL AWAY FROM BOILER BY AT LEAST 2.5 44mm FOR EVERY 1M.
o
EXTERNAL MAX. 3M
*NOTE: FOR EXTENDED PIPE RUNS 32mm DIA. PIPE SHOULD BE USED.
BOILER
BOILER
BOILER
BOILER
BOILER
13443
Diagram 8.7
22
Page 23
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9 Electrical Preparation & Cable Routing
CABLE STRAIN RELIEF
SECURING SCREW
ELECTRICAL CARTRIDGE
CABLE TIES
GROMMETS
CABLE TIES
CABLE TIES
ELECTRICAL CABLES
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 r
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 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:
a) They ar shower.
b) Both the plug and socket comply with the current issue of BS1363.
Immersion Heater - An immersion heater is fitted to the cylinder and can be used in the event of boiler failur it MUST be wired separately from the rest of the boiler electrical connections.
The heater should be wired through a double-pole switch or contr on each pole. Use a cable size of at least 1.5sq. mm flexible cable, 85 deg.C rubber insulated HOFR sheathed to comply with BS6141 Table 8 and must be fully earthed.
For internal access to the appliance the tank module front panel will need to be removed.
9.1 Electrical Preparation
Remove the electrical cartridge, from the fittings kit.
Remove the electrical cartridge securing screw and hinge back the cover, see diagram 9.1.
Remove the two loose cartridge retaining screws from inside the electrical cartridge body. These shall be required for securing into the interface housing upon completion of the cartridge wiring, r
Diagram 9.2 shows the cable routing along the left hand side of the tank module through the two grommets and the cable ties to the electrical cartridge.
IMPORTANT
immersion heater need to be routed before the installation of the boiler
equirements of the BEAB.
.
. It should be
e not used in a room containing a fixed bath or
oller having a minimum contact separation of 3mm
efer to section 11.
: The electrical cables to the boiler and the
.
13291
e,
Diagram 9.1
13455
23
Diagram 9.2
Page 24
Supplied By www.heating spares.co Tel. 0161 620 6677
10 Telescopic Flue - Length, Preparation and Installation
Y
INNER PLASTIC COLLAR
L
FLUE
OUTSIDE W
ALL FACE
C
OUTER RUBBER COLLAR
AIR DUCT
FLUE DUCT
COLLAR
DRILL AND SCREW
L
FLUE
C
Max flue length 668mm
181394
5mm min. clearance
A
OUTSIDE WALL FACE
87min
NOTE. If necessary, it is permitted to increase this dimension to 600mm max.
INTERNAL SURFACE
10.1 Flue Length
The maximum permissable horizontal flue length is 8 metres plus the flue terminal assembly, this can be achieved by use of the accessories, see diagram 10.3, however should additional 90o or 2 x 45o elbows be used then the length MUST be reduced by 1metre.
When extension pipes are used the flue system must be designed to have a continuous fall to the boiler of at least
2.5o 44mm/metre to allow condensate to run back into the boiler and out via the condensate drain.
Horizontal Telescopic Flue
The flue can be installed from inside the building, when access to the outside wall face is not practicable.
The diagrams below describe the lengths achievable without the use of extensions or elbows.
13337
Max. distance from outside
wall face to min clearance.
LH - 269mm
RH - 482mm
Min. distance fr
wall face to min clearance.
LH - 75mm
RH - 75mm
A
om outside
24
13339
Diagram 10.1
Page 25
Supplied By www.heating spares.co Tel. 0161 620 6677
TELESCOPIC TERMINAL ASSEMBLY
SEALING COLLAR
SEALING COLLAR
SECURING COLLAR
FLUE ELBOW
GASKET (fitted)
SEALING T
APE (telescopic only)
Top Outlet Horizontal Concentric Flue Packs: A2043600 Horizontal telescopic flue pack.
SCREW x 1
SCREW x 2
SCREW x 2
SCREW x 4
10 Telescopic Flue - Length, Preparation and Installation
45o Bend
2000460485
(2off)
90
o
Bend
2000460484
0.5m
EXTENSION
2000460481
1m
EXTENSION
2000460482
2m
EXTENSION
2000460483
VERTICAL
FLUE
ADAPTOR
A2024600
12841
25
Diagram 10.2
12842
Diagram 10.3
Page 26
Supplied By www.heating spares.co Tel. 0161 620 6677
BUTT JOINT
10 Telescopic Flue - Length, Preparation and Installation
BUTT JOINT
10.2 Horizontal Telescopic Flue
Refer to diagram 10.2 for kit contents.
10.3 REAR Flue
If a wall thickness is between 233mm min. to 522mm 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 522mm, then the appropriate length of extension pipe is requir
If the dimension is less than 320mm DO NOT cut the flue, it can project to a maximum of 600mm, if this is not desirable then a Standard flue MUST be used and cut to length.
ed.
10.4 SIDE Flue
With the flue elbow temporarily fitted, measure the distance from the outside wall to the butt joint, see diagram 9.6. If the measurement ‘Y’ exceeds LH 204mm, RH 417mm, then the appropriate length of extension pipe is required.
If the dimension is less than 320mm DO NOT cut the flue, it can project to a maximum of 600mm, if this is not desirable then a Standard flue MUST be used and cut to length.
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 inter 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 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.
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 r
The cut ducts must be de-burred and all filings and debris removed.
Insert the flue duct into the air duct terminal assembly, r
emembering 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 r
ecommended.
nal trim ring (if required) to be positioned
equired.
13295
Diagram 10.4
13224
Diagram 10.5
12979
Diagram 10.6
26
Page 27
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10 Telescopic Flue - Length, Preparation and Installation
AIR DUCT
FLUE DUCT
13mm
L
L + 11mm
L
TERMINAL CATCH
12929
Diagram 10.7
12847
12977
Diagram 10.10
Diagram 10.8
13296
Diagram 10.9
27
Page 28
Supplied By www.heating spares.co Tel. 0161 620 6677
L
FLUE
C
Max flue length 733mm
181394
5mm min. clearance
A
OUTSIDE WALL FACE
87min
NOTE. If necessary, it is permitted to increase this dimension to 600mm max.
INTERNAL SURFACE
10 Standard Flue - Length, Preparation and Installation
75 min. to 586 max.
WALL THICKNESS
87min
NOTE. If necessary, it is permitted to increase this dimension to 600mm max.
455145
OUTSIDE WALL FACE
INSIDE WALL
L
FLUE
C
81
10.6 Flue Length
The maximum permissable horizontal flue length is 8 metres plus the flue terminal assembly, this can be achieved by use of the accessories, see diagram 10.13, however should additional 90o or 2 x 45o elbows be used then the length MUST be reduced by 1metre.
When extension pipes are used the flue system must be designed to have a continuous fall to the boiler of at least
2.5o 44mm/metre to allow condensate to run back into the boiler and out via the condensate drain.
Standard Horizontal Flue
The flue can be installed from inside the building, when access to the outside wall face is not practicable.
The diagrams below describe the lengths achievable without the use of extensions or elbows.
13401
Max. distance from outside
wall face to min clearance.
Min. distance fr
wall face to min clearance.
A
LH - 334mm
RH - 547mm
om outside
LH - 75mm
RH - 75mm
28
13338
Diagram 10.11
Page 29
Supplied By www.heating spares.co Tel. 0161 620 6677
SEALING COLLAR
SECURING COLLAR
FLUE ELBOW
GASKET (fitted)
Top Outlet Horizontal Concentric Flue Packs: A2043400 Standard horizontal flue pack.
STANDARD TERMINAL ASSEMBLY
SCREW x 2
SCREW x 2
SCREW x 4
SEALING COLLAR
45o Bend
2000460485
(2off)
90
o
Bend
2000460484
0.5m
EXTENSION
2000460481
1m
EXTENSION
2000460482
2m
EXTENSION
2000460483
VERTICAL
FLUE
ADAPTOR
A2024600
10 Standard Flue - Length, Preparation and Installation
12841
Diagram 10.12
12842
29
Diagram 10.13
Page 30
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BUTT JOINT
BUTT JOINT
10 Standard Flue - Length, Preparation and Installation
10.7 Standard Horizontal Flue
Refer to diagram 10.12 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 10.14. If the measurement ‘Y’ exceeds 667mm, then the appropriate length of extension pipe is required. The minimum dimension is 156mm to suit a 75mm min wall thickness. The flue can project to a maximum of 600mm, if this is desirable, refer to diagram 10.16.
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 667mm, then the appropriate length of extension pipe is required. The minimum dimension for LH is 408mm and RH 195mm to suit a minimum wall thickness of 75mm. The flue can project to a maximum of 600mm, if this is desirable, refer to diagram 10.16.
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 10.17.
The flue duct cutting length (L + 11mm.) is shown in diagram
10.17.
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-burr removed.
Insert the flue duct into the air duct terminal assembly, remembering to engage the catch within the terminal.
NOTE: If the seals requir not use mineral oils or gr recommended.
Fit the sealing collar onto the locating ring on the flue terminal, see diagram 10.8.
Push the flue assembly into the wall, externally or internally, initially until the end of the assembly pr from the inside face of the wall. This will enable the internal trim ring (if r 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.
equired) to be positioned and allow the flue
ed and all filings and debris
e lubricant to ease installation, do ease, only silicon grease or water is
otrudes a short way
Left Hand illustrated
13223
Diagram 10.14
13224
Diagram 10.15
12979
Diagram 10.16
30
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AIR DUCT
FLUE DUCT
13mm
L
L + 11mm
L
TERMINAL CATCH
10 Standard Flue - Length, Preparation and Installation
Draw the flue assembly from wall and engage the flue duct into the elbow and butt fit between the air duct and flue elbow.
Ensure 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 car Fit the securing collar and secure with screws provided, see diagram 10.18.
Slide the internal trim ring back against the wall, securing in place with a small amount of sealant if r
NOTE: If the air and flue ducts have been correctly cut to the instructions the sealing collar should fit fl wall.
e not to pierce the inner flue duct.
equired.
ush with the outside
12847
Diagram 10.17
13297
Diagram 10.18
31
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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 or rear flue system.
The system is made up of accessories. The accessories include terminal assembly, bends 45º and 90º, flue extensions, fixing bracket and appropriate weather collar, see diagram 10.20.
The maximum permitted straight flue length is 12 metres plus the terminal. for each 90 length must be reduced by 1 metre, see diagram 10.19.
o
or 2x45o bends fitted, the maximum
13319
32
Diagram 10.19
Page 33
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10 Vertical - Flue Length, Preparation and Installation
12969
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
10.19.
Alternatively use 45º bends to avoid horizontal runs, see (b) in diagram 10.19.
The terminal should be positioned at least 600mm from any opening into the building, refer to diagram 3.2.
Measur installation.
The flue must be designed with a continuous fall towar boiler.
e the distance of flue length required for the
ds the
Flue Terminal Installation
Refer to diagram 10.21. Secure the flue adapter in position on top of the boiler with four torx headed screws supplied, making sure the nib fits into the locating slot in the boiler casing to ensure correct orientation.
The rubber ‘O’ rings of each section should be lubricated prior to assembly.
NOTE: Do not use mineral oils or grease, silicon grease or water is recommended.
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 scr collar, see diagram 10.22.
Fit mor
e extension pipes as required using the collar and screws supplied with each extension pipe. T 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 10.23.
The rubber ‘O’ rings of each section should be lubricated prior to assembly
NOTE: Do not use mineral oils or grease, silicon grease or water is recommended.
When building the flue up it is recommended that it is supported every 2 metr bracket.
Project the rise of the flue pipe to roof level and cut a 150mm hole in the roof.
.
es and at every bend by a fixing
ews on the securing
o fit position
Diagram 10.20
33
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10 Vertical Flue - Length, Preparation and Installation
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 r
oof ensuring a weather tight seal.
From above carefully place the flue terminal through the weather collar.
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 10.24. 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.
13317
Diagram 10.22
13243
12982
Diagram 10.23
12983
Diagram 10.21
34
Diagram 10.24
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10 Twin Flue - Length, Preparation and Installation
13320
35
Diagram 10.25
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10 Twin Flue - Length, Preparation and Installation
12970
10.12 Twin flue
The twin flue system is available as an option when the top horizontal, rear 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.
NOTE: The air and flue outlets do not have to be equal lengths. 2x45° bends can r
The maximum permitted combined straight pipe length is 40 metres plus terminal assemblies, for each 90° 2 bends fitted, the maximum length must be reduced by 1 metre.
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.
eplace 1x90° bend if necessary.
or 45° x
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 10.26
36
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10 Twin Flue - Length, Preparation and Installation
Installation Details
The parts available for a twin flue system installation are shown in diagram 10.26.
Boiler Connection
Push the twin flue adaptor onto the outlet of the boiler with the air inlet to the left hand side. Secure the adaptor to the top panel with the screws provided. Care should be taken when inserting the screw through the hole in adaptor top.
To facilitate engagement, it is recommended that the rubber ‘O’ rings are lubricated with silicone grease or water prior to assembly.
See diagram 9.24 new adaptor in position.
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°)
9.25.
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 gr
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 3.2 drill the one or two holes as required with a 90mm core drill.
Push the horizontal terminal through the wall allowing approx. 100mm to protrude outside.
Push a grey rubber wall seal onto either side of the wall ensuring that both wall seals are pushed up to the wall surface, see examples (b) and (c) diagram 9.25.
Vertical Terminal Installation
With due consideration to terminal clearances mentioned in Section 3.2, project the rise of the flue pipe to roof level and cut 150mm hole in the roof.
(a) Pitched Roof
Fit the required pitched roof weather collar over the 150mm hole in the roof. Make good the tiling or slating around the collar incorporating the flashing of the weather collar. Position the angle cap over the weather collar in the corr orientation to attain the correct angle for your roof. One way round gives a pitch of 25°-38° and the other gives 37°- 50°.
(b) Flat Roof
Fit the aluminium weather collar over the 150mm hole in the r
oof ensuring a weather tight seal.
minimum, see diagram
ease.
ect
Diagram 10.27
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 10.25.
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 fr and discard the plain end of the tube. The cut end should be square and free from burrs. Carefully push the terminal assembly upwards to allow room for fitting the final flue piece(s). Fit a 100mm fixing bracket to the terminal assembly Part No2000460486. Pull the terminal assembly down and join to the flue system. Ensure that the terminal is making a weather tight seal on the weather collar. Secure the fixing bracket fitted to the made batton.
terminal to the roofing struts or a purpose
om the ‘O’ ring seal end
13318
37
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10 Plume Management Kit
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.
10.13 Plume Management Kit
12997
The Plume Management Kit: Part No. A2044100 (white) or A2044000 (black) can be used to overcome many site issues.
The Plume Management Kit will 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. The flue air inlet can be sited closer to doors, opening windows and air bricks, see diagram 10.28.
The maximum length of the Plume Management Kit must NOT exceed 6m with a horizontal concentric max.
For each 90 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.
o
bend or 2 x 45o bends the maximum length of
flue length of 2m
Diagram 10.28
11 Electrical Connection
11.1 Electrical Connection
Loosen the two screws of the cable strain relief in the electrical cartridge, see diagram 9.1.
Route the mains supply and systems cables through the strain relief and connect to the relevant plug dependant upon your choice of system controls, see diagrams 11.1 and 11.2.
Initially if system controls are not fitted then fit the wire link in place between “L” and “R”, this will allow the boiler to run continuously on heating.
Fit electrical cartridge into the interface housing on completion of the wiring, see diagram 11.3.
Secur
e with the two cartridge retaining screws that were
provided in the cartridge body.
11.2 Tank Thermistor
The tank thermistor should be connected between the boiler and tank modules.
When connecting, ensure that the cable and connection plug from the control box passes through its grommet on the base of the boiler module to the connection on the LH side of the tank module, this is situated above the condensate trap and siphonic drain.
11.3 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 11.1. External controls should be fitted in accordance with the rules in force.
If fitting a pr controls the internal central heating programmer will need to be disabled as described in section 11.5.
11.4 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 11.2.
External controls should be fitted in accordance with the rules in force.
If fitting a proprietary programmer as part of the system controls the internal central heating programmer will need to be disabled as described in section 11.5.
38
oprietary programmer as part of the system
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11 Electrical Connection
24V SYSTEM CONTROLS
RETAINING SCREW
(2 OFF) ELECTRICAL CARTRIDGE
Diagram 11.1
13368
13369
11.5 Disabling the internal CH Programmer
If fitting an external proprietary CH Programmer, it is necessary to disable the Internal Programmer.
a) Press and hold the ‘mode’ button for 5 seconds.
The display will change to flashing ‘0’. b) Use the ‘+’ or ‘-’ button to scroll to 96. c) Press ‘MODE’ to confirm. d) The display now shows a flashing ‘d. 0’ Use the
‘+’ or ‘-’ key to scroll to ‘d.92’. e) Press ‘MODE’ to confirm. f) The display now shows a flashing ‘3’ above the
‘d.92’. g) Use the ‘+’ or ‘-’ button to change this value to
1’. h) Press ‘MODE’ to confirm, ‘1’ stops flashing and is
saved. i) Press and hold ‘MODE’ to exit.
The CH Programmer has now been disabled. The DHW Programmer is still active. See the diagnostic menu instructions in the Fault Finding section for further details.
11.6 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.
13306
Diagram 11.2
39
Diagram 11.3
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12 Commissioning
FILLING LOOP VALVE
FILLING LOOP FLEXIBLE HOSE
DOUBLE CHECK INLET VALVE
QUICK RELEASE NUT
QUICK RELEASE NUT
FILLING TAP "B"
FILLING TAP "A"
CLOSED
GAS SERVICE COCK
13445
12.1 Filling Domestic Water Circuit
Make sure that the isolation valves are securely tightened.
Open all domestic hot water taps.
Fully open the DHW outlet and DCW inlet valves, see diagram 12.1. Water will now flow through the boiler to the domestic water tank and to the hot water taps.
Starting at the lowest tap, turn the hot taps off one at a time until the hot water pipework is purged of air. It may also be necessary to use the air vent scr see diagram 12.4.
Check for water soundness of the complete domestic water system.
ew on the domestic pump,
12.2 Filling the Heating System
Refer to diagrams 12.1, 12.2 and 12.3.
With the boiler in place:
1. Ensure that the filling loop flexible hose is securely connected to the double check inlet valve.
2. Ensure that the gas service cock is closed.
3. Switch on the power supply to the appliance.
The boiler should be in OFF mode. This is indicated
by the ‘OFF’ symbol on the user interface display. If not, press the ‘mode’ button repeatedly until the ‘OFF’ symbol
is displayed.
The display will now show a flashing system pressure.
4. Fully open the taps on the filling loop to fill the heating system to a pr taps. If the domestic cold water is below 10 frost protection may operate and a F1 will be displayed, clear by pressing “Reset”, you may have to repeat this process until the pressure is 1 bar.
essure of 1.0bar. Close the filling
O
C the tank
Diagram 12.1
13371
Diagram 12.2
40
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DOMESTIC PUMP
AIR VENT SCREW
12 Commissioning
AUTOMATIC
AIR VENT
CAP
13438
Diagram 12.3
5. Vent all air from the system - repeat step 4 as neccessary until the system is full and all the air has been removed.
6. Make sure that the automatic air vent works correctly and that the black cap is loosely fitted to allow air to escape.
7. To comply with the water regulations the flexible hose must be disconnected from the double check inlet valve
- undo the nut and pull the flexible hose from the valve.
12.3 Initial Lighting
The lighting procedure of the boiler is fully automated.
Check that all external controls are calling for heat.
Repeatedly press the “MODE” button until the
symbols are displayed.
The hot water tank has priority over central heating.
The appliance will enter a self-checking routine then the ignition sequence will commence.
The digital display will show the tank temperature setting in hot water mode.
If the bur due to air in the gas supply line. The boiler will automatically have five attempts at ignition.
If the bur
Depress the “reset” button on the fascia to clear the display and repeat the ignition sequence.
When the tank is full (and after a short pump overrun period) a central heating demand will be initiated.
Once the system has been pur the desired temperature by using the hot water “+” and “-” buttons.
Open a hot water tap, check that hot water is available and then close the hot water tap.
Set the central heating water temperatur temperature by using the central heating “+” and “-” buttons.
ner fails to light the fan will stop. Initially this may be
ner fails to ignite the display will show F1.
ged of air set the hot water to
e to the desir
and
ed
Diagram 12.4
The appliance will then continue to fire in central heating mode until the user contr demand made for hot water
NOTE: After ignition in central heating demand the boiler will remain at minimum power for one minute befor rate.
ols are satisfied or there is another
.
12.4 Re-pressurising System (if required)
1. Ensure that the filling loop flexible hose is securely connected to the double check inlet valve, see diagram
12.2.
2. Fully open tap”A”, then gradually open tap “B” to fill the heating system to a pressure of 1.0bar. When completed close the filling taps.
3. Vent all air from the system - repeat step 2 as neccessary until the system is full and all the air has been removed.
4. IMPORTANT: To comply with the water regulations the flexible hose must be disconnected fr inlet valve - undo the nut and pull the flexible hose from the valve.
om the double check
13406
e going to full
41
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AUTOMATIC BYPASS VALVE
BYPASS SCREW
12 Commissioning
12.5 Gas Rate
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, making sure that all other gas burning appliances and pilot lights are off.
The boilers are fully modulating for central heating, and it is therefore not necessary to range rate the boiler.
For approximate gas rates, refer to section 1 Specification Table.
The gas valve is factory set for natural gas (G20) and should need no adjustment. It should be checked that the supply pr
essure is 20mbar when the boiler is firing at full rate. This can be achieved by turning on several hot water taps and checking the inlet pressure at the pressur cock, see diagram 12.1. Turn taps off and disconnect pressure gauge.
In the unlikely event that the gas valve needs adjusting, refer to section 13 Servicing - Combustion Check. Re-setting of the gas valve requires a combustion analyser and any adjustment should only be carried out by a competent person.
NOTE: The burner pr as it is altered by the suction of the fan and modulated according to demand.
Testing Flue Gases: If any doubt exists that the flue products are not exhausting corr analyser.
essure cannot be measured at the gas valve
ectly, investigate by use of a flue gas
e test point on the gas service
12.6 Range Rating
The boilers are fully modulating for central heating, and it is therefore not necessary to range rate the boiler. However, if desired, it is possible to range rate the boiler between 9 and 24kW as follows:
a) Press and hold the ‘MODE’ button for 5 seconds.
The display will change to flashing ‘0’. b) Use the ‘+’ or ‘-’ button to scroll to 96. c) Press ‘MODE’ to confirm. d) The display now shows a flashing ‘d. 0’. The part
load setting is displayed above in kW e) Press ‘MODE’ to change, use the ‘+’ or ‘-’
button to change this value to the desired setting. h) Press ‘MODE’ to confirm, the new setting has been
saved. i) Press and hold ‘MODE’ to exit.
13234
12.7 Water Systems
Check that all external controls are calling for heat, the boiler will fire automatically. Fully open all radiator valves and the flow control valve, if fitted, see diagram 5.1.
Balance the radiators as required and if fitted adjust the 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 across flow and return.
The pump has two speeds and can be adjusted depending on the requirements of the central heating system, see diagram 5.2.
The boiler has an inbuilt automatic adjustable bypass valve. The pressure can be adjusted between appr
2O but is factory pre-set to approx 2.5mH2O. The
3.5mH pressure changes by approx 0.1mH 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.
Lock or remove the handle from the control valve, if fitted.
Adjust the boiler temperature controls and any system contr
ols to their required settings.
We recommend that the domestic hot water should be run for a short period until clear.
o
C can be achieved
ox 1.5 and
2O for each full turn
Diagram 12.4
42
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12 Commissioning
12.8 Benchmark
It is necessary to complete the “Benchmark” logbook.
For 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 curr Gas Safety (Installation and Use) Regulations, Section 35, which imposes a duty of care on all persons who let out any pr
operty 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 pr
oduce 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 pr damage to the system, boiler and the building, in the event of the heating system being out of use during fr 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 of 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, r competent person.
Leave these instructions and the ‘Benchmark’ logbook with the user.
.
f for any long periods during severe weather, it is
efilling and pressurising MUST be carried out by a
ent issue of the
event
ost or freezing
43
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BOILER MODULE FRONT PANEL
SECURING SCREW (2 OFF)
13 Servicing
VIEWING WINDOW
IMPORTANT NOTES
1. To ensure the continued efficient and safe operation of the boiler it is recommended that it is checked and serviced at
regular intervals. The frequency of servicing will depend upon the particular installation and usage, but in general once a year should be enough.
2. It is the Law that any servicing is carried out by a competent person.
3. Before commencing with a service or replacement of parts the boiler should be isolated from the electrical supply and the
gas supply should be tur
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 r Glow-worm.
5. On completion of servicing the “Benchmark” log book should be completed.
ned off at the gas service cock, see diagram 12.1.
equire. Do not use reconditioned or copy parts that have not been clearly authorised by
13.1 General Inspection
Prior to servicing carry out an initial inspection of the following:
1. Condition of case and flue.
2. Flue terminal for obstructions.
3. Electrical supply connection
4. Water connections.
5. Gas connection.
6. System pressure.
13.2 Functional Checks
With the appliance operational carry out the following functional checks:
1. COMBUSTION - preferably with a flue gas analyser as section 12.5. If no flue gas analyser is available remove the tank module front panel to gain access to the boiler module front panel securing screws, see diagram 13.1, and taking care not to touch any components, check the flame picture
ough the viewing window, see diagram 13.2.
thr
Should the flame show signs of lift, sooting or appear yellow then it will be necessary to service the burner, if the servicing does not correct the condition, then proceed to the combustion test described in section 13.8.
13440
Diagram 13.1
13441
2. GAS RATE - If the gas rate is lower than the minimum gas rate the burner will require servicing. However should the combustion measurement or flame and gas rate be correct, then it is not necessary to remove the bur service.
3. CHW FLOW RATE - agrees with the technical specification, if it does not, clean the filter and if necessary check the gas rate as described in commissioning.
ner assembly for a
13.3 Servicing
For ease of servicing, the control box and domestic expansion vessel can be moved into their service positions, this will improve access to components, see diagrams 13.3 to 13.6.
44
Diagram 13.2
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13 Servicing
CONTROL BOX MOUNTING BRACKETS
CONTROL BOX SERVICE BRACKET
*
CONTROL BOX
CONTROL BOX SERVICE BRACKET
* To move the control box into its service position
carefully pull the control box forwards and upwards to release from its mounting brackets.
BOILER MODULE
CONTROL BOX IN SERVICE POSITION
DOMESTIC EXPANSION V
ESSEL
SERVICE SUPPORT BRACKET
SERVICE POSITION
FILLING LOOP
DOMESTIC EXPANSION VESSEL
FLEXIBLE HOSE
BRACKET
UNION NUT (Do not loosen)
LOCK NUT
13417
13330
Diagram 13.5
13329
Diagram 13.3
Diagram 13.4
13344
Diagram 13.6
13.4 Silencer
For access to the heat exchanger the silencer will need to be removed, see diagram 13.7.
Remove the securing screw and pull the silencer from the fan,
this is a push fit.
13.5 Spark Electrode
Disconnect the ignition lead and two securing screws. Withdraw the spark electrode carefully from the combustion chamber, see diagram 13.8 and 13.9.
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
.
45
Page 46
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SECURING SCREW
HEAT EXCHANGER
SILENCER
13 Servicing
ELECTRODE
GASKET
SPARK GAP 4mm
SECURING SCREW (2 OFF)
EARTH LEAD
SILENCER BRACKET
EARTH LEAD
IGNITION LEAD
HEAT EXCHANGER
13343
Diagram 13.7
13346
Diagram 13.9
13.6 Burner
Diagram 13.8
13273
NOTE: If the functional checks did not indicate poor
combustion then it is not necessary to service the burner.
The following procedure will require that you replace the
burner door seal and nyloc nuts.
After turning off the gas supply at the gas service cock, see diagram 12.1, loosen the gas connection at the union nut between the boiler module and tank module.
Remove the gas supply pipe securing clip and withdraw the gas pipe from gas valve, see diagram 13.10.
Disconnect the electrical connection at the gas valve and disconnect the electrical connection from the fan.
Disconnect the ignition lead and earth lead from the burner door, see diagram 13.9.
Disconnect the flue overheat thermostat, see diagram 13.11.
Remove the four burner door nyloc nuts, one of these also holds the silencer bracket, see diagram 13.11.
Gently remove the fan, gas valve and bur the combustion chamber.
ner assembly from
Clean the burner with a soft brush taking great car 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.
Removal of the burner is not necessary during a normal service.
NOTE: If the burner has to be removed it will require a new gasket when refitted, see diagram 13.12.
46
e not to
Page 47
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13 Servicing
ELECTRICAL CONNECTION
GAS VALVE
FAN
ELECTRICAL CONNECTION
GAS SUPPLY PIPE SECURING CLIP
BURNER
FRONT INSULATION
GASKET
SECURING SCREW (4)
SPARK ELECTRODE
GAS VALVE AND FAN
BURNER DOOR
NYLOC NUT (4 OFF)
GAS VALVE
FAN
BURNER DOOR
SILENCER BRACKET
SEAL
HEAT EXCHANGER
FLUE OVERHEAT THERMOSTAT
Diagram 13.10
Diagram 13.11
13350 13356
13373
13.7 Heat Exchanger
Refer to diagram 13.11.
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).
13.8 Combustion Setting
A combustion check should not be necessary unless a gas carrying component has been replaced or the combustion setting is suspect.
Connect a flue gas analyser to the test point, see diagram
13.13.
IMPORTANT: Products of combustion will be discharged when the cap is removed. It is important to replace the cap immediately. If no flue gas analyser is available and with the boiler module front panel removed, check the flame picture thr viewing window
Turn on the gas service cock, see diagram 12.1.
Turn on the electrical supply, the appliance will begin the ignition sequence.
A competent person only should carry out any adjustment to the gas valve, r
Monitor the combustion reading and at max rate the r should be 9.2% ± 0.5.
If adjustment proves necessary then proceed as follows:
Pr
ess the “reset” button on the contr and immediately press and hold in the “+” button. After approximately 5 seconds “Hi” will be displayed.
essing the mode button when “Hi” is selected will force the
Pr boiler to maximum rate, the display will flash between “Hi” and the “default display” this will indicate the boiler has been for
ced to maximum.
Adjust the maximum rate CO (Rotate anti-clockwise to increase).
To exit the check sequences press the “+” buttons, this will reset the boiler to the default display.
efer to diagram 13.14.
ols fascia, release
with the throttle to 9.3%.
2
ough the
eading
Diagram 13.12
47
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13 Servicing
FLEXIBLE
CONDENSATE
HOSE
CONDENSE TRAP
& SIPHONIC DRAIN
Turn anti-clockwise to remove
SERVICE
FILL LEVEL
GAS CONTROL VALVE
THROTTLE A
DJUSTER
FLUE ELBOW
FLUE GAS ANALYSER TEST POINT
FLUE DUCT EXTENSION
Diagram 13.13
13347
13326
13.9 Condense Trap & Siphonic Drain
The condense trap and siphonic drain does not normally need removing during servicing unless the service fill level is at full, see diagram 13.15.
To flush the condense trap and siphonic drain carefully pour water into the heat exchanger and check that water flows freely to drain.
13439
Diagram 13.14
48
Diagram 13.15
Page 49
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14 Fault Finding
WARNING
Always isolate the boiler from the electrical supply before carrying out any electrical replacement work.
Always check for gas soundness after any service work.
NOTE:
Before trying to operate the boiler make sure that :
• All gas supply valves are open and that the gas supply has been purged of air.
• There is a permanent mains supply to the boiler.
• There is a heating demand from the external controls.
Electrical Testing
Should there be any doubt about the voltage supply to any of the components, it is possible to carry out a simple electrical test.
IMPORTANT: On completion of the Service/Fault Finding tasks which have required the breaking and remaking of the electrical connections the earth continuity, polarity, short cir
cuit and resistance to earth checks must be repeated using a suitable multimeter.
To carry out the electrical test, gain access, as follows:
Hinge down the control box and unclip the cover to gain access. Refer to the wiring diagram 14.1 and fault finding charts, diagrams 14.2 to 14.5.
13119
49
Diagram 14.1
Page 50
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14 Fault Finding
Is the power switched on?
Switch the power on
Successful ignition
Check wires between
main PCB and display
PCB
Does the display flash 'F'
during or after a CH
demand?
Consult the Fault Table
Is there anything displayed
on the LCD?
Is the display flashing 'F'?
Initiate a CH demand.
Does the boiler light?
Adjust CH setpoint to 820C
and make sure external
control is calling for a
demand. Does the boiler
light?
No No
Yes
Yes
Yes
Yes
Yes
No
No
No
Yes
START
Yes
No
No
No
Consult the State List
Is the power switched on?
Switch the power on
Successful ignition
Check wires between
main PCB and display
PCB
Does the display flash 'F'
during or after a DHW
demand?
Consult the Fault Table
Is there anything displayed
on the LCD?
Is the display flashing 'F'?
Initiate a DHW demand.
Does the boiler light?
Adjust DHW setpoint to 62
0
C and turn on a hot
water tap.
Does the boiler light?
No No
Yes
Yes
Yes
Yes
Yes
No
No
No
Yes
START
Yes
No
No
No
Consult the State List
CENTRAL HEATING
13012
DHW
13411
50
Diagram 14.2
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14 Fault Finding
Fault Codes
13412
51
Diagram 14.3
Page 52
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14 Fault Finding
Indicates fault memory position
Fault code
Fault memory display
Fault Codes (continued)
13447
Fault Memory
The Fault memory stores details of the ten most recent faults.
To access this menu:
a) Press and hold ‘MODE’ for 5 seconds.
b) When the display shows a flashing ‘0’ press ‘MODE’ button.
c) Pr
ess a ‘+’ button to scroll back through the fault memory
(Position 1 is most recent), see fault memory display.
T
o exit this menu, press the ‘MODE’ button.
13452
Diagram 14.3a
52
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14 Fault Finding
Diagnostic value
Diagnostic number
Diagnostic display 1
Diagnostic display 2
Diagnostic Menu
The Diagnostic Menu provides the ability to view and change certain parameters. See Diagram 14.4 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.
13450
Use the ‘+’ or ‘-’ buttons to view the appropriate diagnostic number
If necessary the values can be changed by:
a) Pr
essing the ‘MODE’ button.
b) The diagnostic value flashes, see diagnostic display 2.
c) Use the ‘+’ and ‘-’ buttons to cycle through available values.
d) The change is saved by pressing ‘MODE’ once more.
(NOTE: Only certain parameters can be adjusted)
To exit the diagnostic menu press and hold the ‘MODE’ button for 5 seconds.
, see diagram 14.4.
13451
53
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14 Fault Finding
Outside temperature
Domestic hot water demand
d.99 State List (see table opposite)
d.24 System water pressure in bar.
d.28 Option Relay 2 Reserved for future use
d.27 Option Relay 1 Reserved for future use
d.91 Internal Programmer t
ype 0:24 hour 1:7 day (default)
d.92 Enable/Disable Internal Programmer 0: CH Off, DHW Off 1: CH Off, DHW On 2: CH On, DHW Off 3: CH On, DHW On (Default)
Domestic hot water flow temperature reading
Tank setpoint
Tank temperature
Domesti
c hot water setpoint
Flow temperature
setpoint
Description Range
Diagnostic Menu - Level 1 Installer Access
13454
Indicates read and write function - all other diagnostics are read only
54
Diagram 14.4
Page 55
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14 Fault Finding
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.
Check flow & return thermistor connections to pipes. Check harness connection to thermistor. Check harness wires are not trapped between any internal components.
Check flow & return thermistor connections to pipes. Check harness connection to thermistor. Check harness wires are not trapped between any internal components.
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 8
O
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 tim
e: no water in system, temperature
(gradient error) rise flow / return sensor too high
S.76 W
aiting 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
State list - Accessed through Diagnostic Codes - Level 1, Installer Access d.99
STATE LISTS
13011
55
Diagram 14.5
Page 56
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15 Replacement of Parts
IGNITER
UNIT
BRACKET
SECURING
SCREW
(2 OFF)
IGNITION LEAD
ELECTRICAL CONNECTION
DOMESTIC EXPANSION VESSEL
FLEXIBLE HOSE
BRACKET
UNION NUT
LOCK NUT
15.1 General
Replacement of parts must be carried out by a competent person.
Before replacing any parts the boiler and immersion heater should be isolated from the mains electric supply and the gas should be turned off at the service cock on the boiler, see diagram 12.1.
Unless stated otherwise parts ar order to removal.
After replacing any parts always test for gas soundness and if necessary carry out functional test of the contr
For replacement of parts the front casing panels will need to be removed.
The tank module front panel will need to be removed first to gain access to the boiler module front panel securing screws.
Remove the two screws on the underside of the panel and lift off, see diagram 13.1.
For ease of servicing, the control box and domestic expansion vessel can be moved into their service positions, this will impr diagrams 13.3 to 13.6.
ove access to hydraulic components, see
e replaced in the reverse
Draining of Boiler Primary Circuit
To drain the boiler primary circuit, isolate the flow and return valves, see diagram 12.1.
Open the top tap on the filling loop to drain the boiler out through the filling loop hose.
After servicing or replacing parts open the heating flow and return isolating valves and refill, vent and pressurise the heating circuit, refer to section 12.2.
Close the drain valve and disconnect the hose.
Check for leaks.
Draining of Boiler Hot Water Circuit
Drain the Domestic Hot Water circuit by closing the cold­water isolation valve, see diagram 12.1.
Open one or more hot water taps to drain the hot water circuit.
After servicing or replacing parts open the cold-water isolation valve and slowly open a hot water tap to remove air. Close the hot water tap and check for any leaks.
15.2 Domestic Expansion Vessel
For access, refer to section 15.1.
Isolate the DHW inlet valve, see diagram 12.1 and drain through a domestic tap.
Loosen the locknut at the top of the vessel, see diagram
15.1.
To r
emove the expansion vessel slide forward out of its
hanging bracket.
Remove the flexible hose from the expansion vessel by undoing the union nut and lock nut, see diagram 15.1.
Fit the replacement unit.
Refill, vent and pr
Check for leaks.
essurise the boiler.
ols.
15.3 Silencer assembly
For access, refer to section 15.1.
To aid access to the silencer and securing screw, loosen the locknut at the top of the domestic expansion vessel, see diagram 15.1 and slide the vessel forward out of its bracket and put in its service position, see diagram 13.6.
To remove, undo the securing screw and pull the silencer from the fan, this is a push fit so no tools or fixings are required for its removal or fitting, see diagram 13.7.
13330
Diagram 15.1
13341
Diagram 15.2
56
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ELECTRODE
GASKET
SPARK GAP 4mm
SECURING SCREW (2 OFF)
EARTH LEAD
15 Replacement of Parts
GAS CONTROL VALVE
GASKET
SECURING SCREWS
FAN
15.4 Ignition Lead
For access, refer to section 15.1.
Refer to diagram 13.9. Pull the spark plug style connector off the spark electrode and the ignition lead connected to the igniter unit, see diagram 15.2.
15.5 Igniter Unit
For access, refer to section 15.1.
To aid access to the igniter unit, loosen the locknut at the top of the domestic expansion vessel and slide forward out of its bracket and put into its service position, see diagrams 13.5 and 13.6.
Remove ignition lead and electrical connections then remove igniter unit by removing two securing screws, see diagram
15.2.
15.6 Spark Electrode
For access, refer to section 15.1.
Remove the spark plug ignition lead, earth lead and two securing screws. Withdraw the spark electrode carefully from the combustion chamber, see diagram 15.3.
15.7 Gas Valve
For access, refer to section 15.1.
Remove the electrical plug from the gas valve, see diagram
13.10.
Refer to section 13.6 for removal of the fan, gas valve and burner assembly.
Before removing the gas valve from the fan note its position and mark its orientation on the fan and gas valve bodies, this will help when r
Remove the two scr see diagram 15.4.
Remove the gas valve.
Fit new gasket when r
After re-fitting check the combustion CO necessary, see section 13 Servicing.
After assembly test for gas soundness and purge in accordance with the current issue of BS6891or in IE, the current edition of I.S.813 “Domestic Gas Installations”.
e-assembling.
ews that secure the gas valve to the fan,
eplacing.
and adjust if
2
13273
Diagram 15.3
13273
15.8 Fan
For access, refer to section 15.1.
Refer to section 13.6 for removal of the fan, gas valve and burner assembly.
Remove the two screws securing the fan to the gas valve.
Remove the fan.
Fit new gasket when r
eplacing.
57
Diagram 15.4
Page 58
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15 Replacement of Parts
FIBRE WASHER
GLASS
STEEL WASHER
CIRCLIP
HEAT EXCHANGER
REAR INSULATION
WASHER
SECURING SCREW
15.9 Burner
For access, refer to section 15.1.
Refer to section 13.6 for removal of the fan, gas valve and burner assembly.
Remove the four screws that secure the burner, see diagram
13.12.
NOTE: THE BURNER WILL REQUIRE A NEW GASKET WHEN REFITTED.
15.10 Front Insulation
For access, refer to section 15.1.
Refer to section 13.6 for removal of the fan, gas valve and burner assembly.
Remove spark electrode, see section 15.6.
Remove burner as per section 15.9 and withdraw the insulation, see diagram 13.12.
NOTE: THE BURNER WILL REQUIRE A NEW GASKET WHEN REFITTED.
15.11 Rear Insulation
For access, refer to section 15.1.
Refer to section 13.6 for removal of the fan, gas valve and burner assembly.
Remove securing screw and washer in the centre of the insulation and withdraw insulation, see diagram 15.5.
13278
Diagram 15.5
13278
15.12 Viewing Window
For access, refer to section 15.1.
Refer to diagram 15.6.
Remove circlip.
Remove steel washer.
Remove glass.
Remove fibr
e washer.
Diagram 15.6
58
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RETAINING BRACKET
PRIMARY EXPANSION VESSEL
FLEXIBLE CONNECTIONS
SECURING SCREW (2 OFF)
E.V. CLAMP
RETAINING CLIP
Top view of CH pump
CH PUMP
15 Replacement of Parts
15.13 Primary Expansion Vessel
For access, refer to section 15.1.
Drain the boiler primary circuit, refer to section 15.1.
Remove the retaining clip from the flexible hose at the central heating pump, see diagram 15.7.
Remove the flexible hose fr on the connection is seated correctly before re-fitting.
Remove the expansion vessel clamp, see diagram 15.7.
Slide the expansion vessel forwar bracket.
Remove the flexible hose union nut from the expansion vessel. When re-fitting ensure that a new sealing washer is fitted and that the elbow of the flexible connection faces
ds the front of the appliance.
towar
om the pump, ensure the ‘O’ ring
d and out from the r
etaining
13354
Diagram 15.7
59
Page 60
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RETAINING BRACKET
INSIDE VIEW OF CONTROL BOX
ELECTRICAL CONNECTION
RETAINING CLIP
UNION NUT
PUMP RETAINING SCREW
TOP VIEW OF CENTRAL HEATING PUMP
UNION NUT
RETURN PIPE
15 Replacement of Parts
CONNECTION
CLIPS
HEATING
RETURN
HEATING
FLOW
HEAT EXCHANGER
SILENCER BRACKET
EARTH LEAD
IGNITION LEAD
HEAT EXCHANGER
SECURING NUT (4 OFF)
SECURING SCREW (2 OFF)
CLAMP
SECURING SCREW (2 OFF)
CLAMP
IGNITER UNIT
15.14 Heat Exchanger
Refer to Manual Handling Operations, 1992.
For access, refer to section 15.1.
Drain the boiler primary circuit, see section 15.1.
Drain the boiler hot water circuit, see section 15.1.
Disconnect the flue connection, see diagram 10.12.
Remove the silencer, refer to section 13.4.
Remove the igniter unit electrical connections, refer to diagram 15.2.
Refer to section 13.6 for r burner assembly.
emoval of the fan, gas valve and
13351
Remove the two connection clips securing the flow and return pipes to the heat exchanger, see diagram 15.9.
Move the pipes away from the heat exchanger.
Remove the four heat exchanger securing screws and clamps, see diagram 15.8.
CAUTION: There will be water in the heat exchanger.
Remove the push fit condense pipe fr heat exchanger, see diagram 8.4.
Carefully remove the heat exchanger and disconnect the flue overheat thermostat, see diagram 13.11.
om the bottom of the
13342
Diagram 15.8
13327
Diagram 15.9
60
Diagram 15.10
Page 61
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15 Replacement of Parts
3 WAY VALVE
RETAINING CLIP
ELECTRICAL PLUG
SECURING SCREW (3 OFF)
CH PUMP
CH INLET CONNECTION
DOMESTIC PUMP
SECURING CLIP
BOTTOM PUMP CONNECTOR
UNION NUT
ELECTRICAL
CONNECTION
UNION NUT
UNION NUT
T
OP PUMP CONNECTOR
15.15 Central Heating Pump
For access, refer to section 15.1.
Drain the boiler primary circuit, see section 15.1.
Unscrew the union nut of the return pipe to the pump connection, see diagram 15.10.
Unscr
ew the union nut from the safety discharge valve.
Remove the flexible connection from the CH pump, see diagram 15.7.
Disconnect the electrical connections inside the contr to the main PCB, see diagram 15.10.
Remove the securing screw from the pump r and ease off the bracket from the spigot on the rear of the pump.
Remove the pump r
The pump can now be pulled sidewards away from its three way valve connection.
When r
e-fitting, ensure that all seals are in place.
etaining clip.
etaining bracket
ol box
15.16 Three Way Valve
For access, refer to section 15.1.
Remove the CH pump, refer to section 15.15.
Refer to diagram 15.11.
Remove the electrical plug.
Undo the CH inlet connection at the union nut between the boiler module and the tank module.
Remove the r
Remove the three securing screws.
Carefully remove the three way valve assembly
etaining clip.
.
15.17 Domestic Pump
For access, refer to section 15.1.
Drain the boiler hot water circuit, see section 15.1.
Remove the domestic expansion vessel and place in its service position, see diagram 13.6.
Disconnect the electrical connection fr diagram 15.12.
Unscrew the union nut at the pump top connector to the DHW pipe.
Unscrew the pipe union nut fr connection, see diagram 15.12.
Remove pump securing clip at the bottom pump connection. The pump can now be lifted up and clear of the boiler
Remove the pump top and bottom connectors making note of the orientation of the top connection.
When re-fitting the top and bottom connectors ensure that the rubber seals are in place and that the top connector is orientated correctly, with the DHW pipe connection at 90 the pump axis.
When re-fitting any part, ensure that all seals and clips are in place.
After replacing parts open the cold-water isolation valve and slowly open a hot water tap to remove air. Close the hot water tap and check for any leaks.
om the bottom pump
om the main PCB, see
.
O
to
13336
13410
Diagram 15.11
61
Diagram 15.12
Page 62
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PRIMARY
FLOW
THERMISTOR
HEAT EXCHANGER
15 Replacement of Parts
SAFETY
DISCHARGE
VALVE
SECURING
CLIP
UNION
NUT
DOMESTIC
HOT WATER
THERMISTOR
LOW WATER
PRESSURE
SENSOR
15.18 Safety Discharge Valve
For access, refer to section 15.1.
Refer to section 15.1 and drain the boiler primary circuit.
The safety discharge valve is situated towards the RH side of the boiler module, refer to diagram 15.13.
Unscrew the pipework union nut from the safety discharge valve.
Remove the securing clip and withdraw the safety dischar valve.
Fit new ‘O’ ring.
ge
15.19 Domestic Hot Water Thermistor
For access, refer to section 15.1.
The domestic hot water thermistor is situated centrally in the boiler module on the DHW inlet pipe, refer to diagram 15.14.
Disconnect the domestic hot water thermistor electrical connections
Remove hot water thermistor.
NOTE:
When reconnecting electrical connections, polarity is
not important.
Carry out a functional test of the contr
ols.
13307
Diagram 15.14
13328
15.20 Primary Flow Thermistor
For access, refer to section 15.1.
The primary flow thermistor is situated underneath the heat exchanger, refer to diagram 15.15.
Remove the electrical connections from the thermistor.
Remove the thermistor noting its position on the flow pipe.
NOTE: When reconnecting, the polarity of the wiring to thermistors is not important.
13252
Diagram 15.15
Diagram 15.13
62
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15 Replacement of Parts
AUTOMATIC
AIR VENT
RETAINING
CLIP
RETAINING
CLIP
LOW WATER
PRESSURE
SENSOR
ELECTRICAL
LEADS
LH
HYDROBLOCK
PRIMARY
RETURN
THERMISTOR
FAN
Diagram 15.16
15.21 Primary Return Thermistor
For access, refer to section 15.1.
Refer to diagram 15.16.
Remove the electrical connections from the thermistor.
Remove the thermistor and noting its position on the return pipe.
NOTE: When reconnecting, the polarity of the wiring to thermistors is not important.
13310
13304
Diagram 15.17
13315
15.22 Automatic Air Vent
For access, refer to section 15.1.
Refer to section 15.1 and drain the boiler primary circuit.
Refer to diagram 15.17.
Remove the r
Fit the new automatic air vent and ‘O’ ring ensuring the vent cap is left loose.
15.23 Water Pressure Sensor
For access, refer to section 15.1.
Refer to section 15.1 and drain the boiler primary circuit.
Refer to diagram 15.18.
Disconnect the electrical lead and withdraw the lead plug.
Remove the r sensor.
Fit new ‘O’ ring.
etaining clip to release the automatic air vent.
etaining clip to remove the low water pressure
Diagram 15.18
63
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15 Replacement of Parts
PLATE TO PLATE HEAT EXCHANGER
SECURING SCREWS (4)
15.24 Plate-to-Plate Heat Exchanger
For access, refer to section 15.1.
Refer to section 15.1 to drain the boiler primary circuit.
Refer to section 15.1 and drain the boiler hot water circuit.
Refer to diagram 15.19.
Remove the four scr exchanger to the hydroblock.
There will still be water present so carefully pull the plate-to­plate heat exchanger upwards to r
When replacing the plate-to-plate heat exchanger ensure that the four rubber seals are fitted into the hydroblock.
NOTE: The plate-to-plate heat exchanger only fits one way.
Open the cold-water isolation valve and slowly open a hot water tap to r
Close the hot water tap and check for any leaks.
Open the heating circuit isolation valves, re-pr
system as necessary.
ews securing the plate-to-plate heat
emove.
emove air.
essurise the
13348
Diagram 15.19
64
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15 Replacement of Parts
BYPASS TUBE
RH HYDROBLOCK
LH HYDROBLOCK
DHW PIPE
DCW PIPE
CH OUTLET PIPE
PRIMARY FLOW PIPE
SPIGOT (4 OFF)
MOUNTING BRACKET
PLATE TO PLATE RUBBER SEAL (4 OFF)
3 WAY VALVE SEALS
CH FILTER
(in Hydroblock)
RETAINING CLIP
15.25 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.
Refer to section 15.1 and drain the boiler primary circuit and the boiler hot water circuit.
Isolate the gas supply at the gas service cock, see diagram
12.1.
Remove the silencer
Remove the plate to plate heat exchanger, refer to section
15.24.
Remove the low water pr hydr
oblock, refer to section 15.23.
Remove clips from the plastic LH and RH hydr retaining the DHW, DCW and primary flow pipes, see diagram
15.20.
Remove the primary flow pipe fr
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 r pipe to the boiler chassis.
Rotate the gas pipe upwards and clear of the chassis panel.
Remove the 3 scr to section 15.16.
, refer to section 15.3.
essure sensor from the LH
oblocks
om the LH hydroblock.
etaining the CH outlet pipe and the gas
ews which r
etain the three way valve, refer
Grip the LH and RH hydr of the spigots on the mounting bracket. The RH hydroblock should be drawn upwar body.
NOTE: Befor 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, ensur parallel to each other and also that the bottom faces of the hydr
oblocks 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 hydr remain in place as it slides past the three way valve body. Befor
e 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.
e removing the bypass tube from the
e that the two port axis in each hydroblock run
oblocks simultaneously and lift clear
ds past the plastic three way valve
oblock
65
13409
Diagram 15.20
Page 66
Supplied By www.heating spares.co Tel. 0161 620 6677
AUTOMATIC BYPASS VALVE
BYPASS SCREW
RETAINING CLIP
15 Replacement of Parts
TEMPERATURE AND PRESSURE RELIEF VALVE
UNION NUT
CYLINDER TANK
BOILER / TANK MODULE CONNECTIONS
GRUB SCREW
6 bar SAFETY RELIEF VALVE
3.5 bar PRESSURE REDUCING VALVE
UNION NUTS
SAFETY RELIEF VALVE PIPE
15.26 Filling Loop
For access, refer to section 15.1.
Refer to section 15.1 and drain the boiler hot water circuit.
Refer to diagram 12.2.
Undo the union nuts on the filling loop valve and the double check inlet valve to r
Fit new ‘O’ rings.
After r
eplacing the filling loop open the cold-water isolation valve and slowly open a hot water tap to remove air. Close the hot water tap and check for any leaks.
IMPORTANT:
flexible hose must be disconnected from the double check inlet valve - undo the nut and pull the flexible hose from the valve.
emove the filling loop.
To comply with the water regulations the
15.27 Automatic Bypass Valve
For access, refer to section 15.1.
Refer to section 15.1 and drain the boiler primary circuit.
Refer to diagram 15.21.
Remove the r
Fit new ‘O’ rings.
Replace the bypass valve, r boiler.
Adjust the bypass as described in commissioning, see section 12.7.
etaining clip to remove the bypass valve.
efill, vent and pressurise the
13234
Diagram 15.21
13345
15.28 Pressure Reducing Valve
For access, refer to section 15.1.
Refer to diagram 15.22.
Slacken the three screws securing the pipe retaining bracket, see diagram 8.3.
Undo the union connection at the isolation valve and then the union nuts to r
Fit new ‘O’ rings.
emove the reduced pressure zone valve.
15.29 Safety Relief Valve
For access, refer to section 15.1.
Refer to diagram 15.22.
Undo the two nuts securing the safety relief valve pipe and remove.
Loosen the grub screw to remove the safety relief valve.
15.30 Temperature and Pressure Relief Valve
For access, refer to section 15.1.
Refer to section 15.1 and drain the boiler hot water circuit.
Refer to diagram 15.23.
Undo the union nut on the right hand side of the valve and disconnect pipe, unscr
Apply the sealant supplied before replacing the relief valve.
ew the valve body to remove.
Diagram 15.22
13334
66
Diagram 15.23
Page 67
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15 Replacement of Parts
IMMERSION HEATER
SECURING SCREW
CONDENSE TRAP & SIPHONIC DRAIN
FLOAT
15.31 Immersion Heater
For access, refer to section 15.1.
Refer to section 6.3 and drain the hot water storage tank.
Remove the flexible condensate hose from the condensate trap and siphonic drain, see diagram 13.15.
The trap may also be removed if r
15.32.
Isolate any electrical connections to the immersion heater.
Unscrew the lar place on the hot water tank, see diagram 15.24.
Remove immersion heater and gasket.
When r
eplacing the immersion heater a new gasket is also
supplied.
15.32 Condense Trap & Siphonic Drain
For access, refer to section 15.1.
Remove the flexible condensate hose by pulling out of condense trap and siphonic drain, see diagram 13.15.
Refer to diagram 15.25.
Remove the securing scr
Remove the float to clean it. When replacing, ensure that the float is inserted correctly as shown in diagram 15.25.
Flush water through the trap/drain to remove any r solids.
Check for any debris in the outlet pipe of the condense trap and siphonic drain and clean as necessary
Reassemble and refit.
ge locknut holding the immersion heater in
ew holding the trap/drain.
equired, refer to section
.
emaining
13333
Diagram 15.24
13332
67
Diagram 15.25
Page 68
Supplied By www.heating spares.co Tel. 0161 620 6677
RETAINING
CLIPS
CONTROL
BOX
15 Replacement of Parts
MAIN PCB
RETAINING CLIP (4 OFF)
ELECTRICAL CONNECTION
RETAINING LUG (2 OFF)
FUSE
USER INTERFACE BOARD
RETAINING CLIPS
ELECTRICAL CONNECTION
15.33 Access to Switches and User Interface
For access, refer to section 15.1.
Release the front of the control box by carefully pushing on the retaining clips to release, see diagram 15.26. Carefully rotate the control box front forward on its hinges to gain access to electrical connections, main PCB and user interface.
Do not allow the fr be loosely held by its electrical connections.
ont of the control box to swing down and
15.34 Main PCB
For access, refer to section 15.33.
Remove the electrical connections to the PCB.
Ease back the four PCB retaining clips and withdraw the PCB from the retaining lugs, see diagram 15.27.
When refitting the control box cover ensure the leads do not become trapped.
15.35 Fuse, Main PCB - Control Box
For access, refer to section 15.33.
The fuse is located at top left hand side of the main PCB, see diagram 15.27.
13446
Diagram 15.26
13372
15.36 User Interface
Refer to section 15.33 for access.
Remove the main PCB, refer to section 15.34.
Remove the electrical connection.
Gently ease back the retaining clips, see diagram 15.28.
Withdraw the board.
When replacing the board refer to instructions supplied with replacement PCB.
Diagram 15.27
13355
68
Diagram 15.28
Page 69
Supplied By www.heating spares.co Tel. 0161 620 6677
16 Spare Parts
16.1 Spare Parts
When ordering spare parts, contact Glow-worm’s own service organisation using the telephone number on the inside front cover of this booklet. Please quote the name of the appliance and serial number, to be found on the data label. If ordering from British Gas also quote the G.C. number of the part.
Key No. Part No. Description GC Part No.
1 103565 Plate to Plate Heat Exchanger ********
2 2000460124 Igniter Unit ********
3 256700 DHW Thermistor ********
4 048940 Burner ********
5 507010 Flow/Return Thermistor ********
6 980632 Burner Door Seal ********
7 0020022579 Domestic Pump ********
8 043123 Electrode ********
9 0020005804 Central Heating Pump ********
10 103516 Safety Discharge valve ********
11 0020012959 Appliance Interface ********
12 053349 Gas Valve ********
13 0020016405 Fan ********
14 0020026285 Main PCB ********
15 ********** Fuse ********
16 101050 Primary Expansion Vessel ********
17 0020022569 Domestic Expansion Vessel ********
18 0020023005 Temperature & Pressure Relief Valve ********
19 ********** 6 bar Safety Relief Valve ********
20 0020022759 Immersion Heater ********
21 253550 NTC ********
22 253586 Water Pressure Switch ********
69
Page 70
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16 Spare Parts
14
1
2
3
4
5
6
7
9
10
8
11
12
13
18
19
17
16
22
15
20
21
13325
70
Diagram 16.1
Page 71
Supplied By www.heating spares.co Tel. 0161 620 6677
71
Page 72
Supplied By www.heating spares.co Tel. 0161 620 6677
Because of our constant endeavour for improvement, details may vary slightly from those shown in these instructions.
72
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