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

Supplied By www.heating spares.co Tel. [phone]

0020023706-02 07.06

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

1

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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. [phone]

Fax: [phone]

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

3

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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

4

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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

5

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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-

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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

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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

Supplied By www.heating spares.co Tel. [phone]

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

Supplied By www.heating spares.co Tel. [phone]

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

Supplied By www.heating spares.co Tel. [phone]

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

Supplied By www.heating spares.co Tel. [phone]

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

Supplied By www.heating spares.co Tel. [phone]

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

Supplied By www.heating spares.co Tel. [phone]

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

Supplied By www.heating spares.co Tel. [phone]

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

Supplied By www.heating spares.co Tel. [phone]

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

Supplied By www.heating spares.co Tel. [phone]

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

Supplied By www.heating spares.co Tel. [phone]

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

Supplied By www.heating spares.co Tel. [phone]

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

Supplied By www.heating spares.co Tel. [phone]

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

Supplied By www.heating spares.co Tel. [phone]

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

Supplied By www.heating spares.co Tel. [phone]

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

Supplied By www.heating spares.co Tel. [phone]

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

Supplied By www.heating spares.co Tel. [phone]

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

Supplied By www.heating spares.co Tel. [phone]

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

Supplied By www.heating spares.co Tel. [phone]

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

Supplied By www.heating spares.co Tel. [phone]

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

Supplied By www.heating spares.co Tel. [phone]

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

Supplied By www.heating spares.co Tel. [phone]

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

Supplied By www.heating spares.co Tel. [phone]

10 Twin Flue - Length, Preparation and Installation

13320

35

Diagram 10.25

Supplied By www.heating spares.co Tel. [phone]

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

Supplied By www.heating spares.co Tel. [phone]

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

Supplied By www.heating spares.co Tel. [phone]

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

Supplied By www.heating spares.co Tel. [phone]

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

Supplied By www.heating spares.co Tel. [phone]

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

Supplied By www.heating spares.co Tel. [phone]

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

Supplied By www.heating spares.co Tel. [phone]

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

Supplied By www.heating spares.co Tel. [phone]

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

Supplied By www.heating spares.co Tel. [phone]

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

Supplied By www.heating spares.co Tel. [phone]

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

Supplied By www.heating spares.co Tel. [phone]

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

Supplied By www.heating spares.co Tel. [phone]

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

Supplied By www.heating spares.co Tel. [phone]

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

Supplied By www.heating spares.co Tel. [phone]

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

Supplied By www.heating spares.co Tel. [phone]

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

Supplied By www.heating spares.co Tel. [phone]

14 Fault Finding

Fault Codes

13412

51

Diagram 14.3

Supplied By www.heating spares.co Tel. [phone]

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

Supplied By www.heating spares.co Tel. [phone]

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

Supplied By www.heating spares.co Tel. [phone]

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

Supplied By www.heating spares.co Tel. [phone]

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

Supplied By www.heating spares.co Tel. [phone]

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

Supplied By www.heating spares.co Tel. [phone]

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

Supplied By www.heating spares.co Tel. [phone]

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

Supplied By www.heating spares.co Tel. [phone]

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

Supplied By www.heating spares.co Tel. [phone]

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

Supplied By www.heating spares.co Tel. [phone]

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

Supplied By www.heating spares.co Tel. [phone]

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

Supplied By www.heating spares.co Tel. [phone]

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

Supplied By www.heating spares.co Tel. [phone]

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

Supplied By www.heating spares.co Tel. [phone]

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

Supplied By www.heating spares.co Tel. [phone]

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

Supplied By www.heating spares.co Tel. [phone]

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

Supplied By www.heating spares.co Tel. [phone]

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

Supplied By www.heating spares.co Tel. [phone]

71

Supplied By www.heating spares.co Tel. [phone]

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

72