Glow-worm Ultrapower sxi Range User Manual

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Ultrapower sxi

Installation and Servicing

100sxi

G.C. No. 41-019-09

13121

170sxi

G.C. No. 41-019-10

High Efﬁciency

System Store

www.glow-worm.co.uk

Guarantee Registration

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

Glow-worm appliances are manufactured to the very highest standard so we are pleased to offer our customers a Comprehensive

Guarantee.

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

shorter, for parts. 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 competent person approved at the time by the Health and Safety Executive,

in accordance with the manufacturer’s recommendations. We strongly recommend regular servicing of your gas appliance, but

where the condition is not met, any chargeable spare parts or components issued within the applicable guarantee period still benet

from a 12 month warranty from the date of issue by the manufacturer.

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

If your guarantee registration card is missing you can obtain a copy or record your registration by telephoning the Glow-worm

Customer Service number 01773 828100.

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 approved at the time by the Health and Safety Executive, to the prevailing standards, installation book and building regulations at the time of installation.

4. The “Benchmark” Installation, Commissioning and Service Record 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 modication 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 828300

Technical Helpline: 01773 828100

General and Sales enquiries:

Tel. 01773 824639 Fax: 01773 820569

To register your Glow-worm appliance

call: 0800 0732142

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

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

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

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

the user on completion of the installation.

CONTENTS DESCRIPTION SECTION PAGE

Warnings 4 Important Information 4 Statutory Requirements 5

INTRODUCTION

Boiler Design 6 Safety Devices 6 Servicing, Maintenance & Spare Parts 6

Boiler Specications 1 7 Boiler Location, Clearances & Ventilation 2 10 Flue Options and Terminal Clearances 3 11 Heating System 4 13 Domestic Hot Water 5 14 Condensate Drain 6 16

INSTALLATION

Installation Preparation 7 18 Gas, Water & Boiler Connection 8 20 Condensate & Safety Discharge Valve Connections 9 22 Flue Preparation and Installation 10 23 Electrical Connection 11 37 Commissioning 12 40

MAINTENANCE

Servicing 13 44 Fault Finding 14 49 Replacement of Parts 15 56 Spare Parts 16 69 Declaration of Conformity 17 71

WARNINGS

Gas Leak or Fault

Turn off the gas emergency control valve immediately. Eliminate all sources of ignition, i.e.smoking,

blowlamps, hot air guns etc.

Do not operate electrical lights or switches either on or off. Open all doors and windows, ventilate the area.

Metal Parts

This boiler contains metal parts (components) and care should be taken when handling and cleaning,

with particular regard to edges.

Sealed Components

Under no circumstances must the User interfere with or adjust sealed parts.

Important Information

Gas Category

This boiler is for use only on G20 natural gas, but may be converted for use on G31 gas (Propane L.P.G.).

Gas Safety (Installation and Use) Regulations

In your own interests and that of safety, it is the Law that ALL gas appliances are installed by competent person approved at the time by the Health and Safety Executive 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 suffer irritation to the eyes or severe irritation to the skin seek medical attention.

Manual Handling

With regards to the “Manual Handling Operations, 1992 Regulations”, it should be noted that each appliance module exceeds the recommended weight for a one person lift.

The handling of the boiler may involve lifting, pushing and pulling, the use of a sack truck may be required.

The following handling techniques and precautions should be considered:

- Grip the boiler at its base

- Be physically capable

- Use safety clothing where appropriate, e.g. gloves, safety footwear.

Ensure safe lifting techniques are used

- Keep back straight.

- Avoid twisting at the waist.

- Avoid upper body/top heavy bending.

- Always grip using the palm of the hand.

- Use designated hand holds.

- Keep load as close to body as possible.

- Always use assistance if required.

Electrical Supply

The electrical installation must be installed by a competent

person approved at the time by the Health and Safety Executive 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 relevant standards.

In GB this is BS 6891.

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

The boiler must be connected to a permanent 230V ac, 50Hz supply.

Connection of the whole electrical system of the boiler, including any heating controls, to the electrical supply must be through one common isolator and must be fused 3 Amp maximum.

Isolation should be by a double pole switched fused spur box, with a minimum gap of 3mm for both poles. The fused spur box should be readily accessible and preferably adjacent to the appliance. It should be identied as to its use.

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

Wiring to the boiler must be PVC 85 less than 0.75mm2 (24/0.20mm).

Immersion Heater - a thermostatically controlled immersion heater with manual reset is tted 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 using 3kW 13amp wiring and in accordance with the relevant standards.

C insulated cable, not

Statutory Requirements

Testing and Certification

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

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

CE Mark

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

Type test for purposes of Regulation 5 certied by: Notied body 0087.

Product/production certied by: Notied body 0086.

The CE mark on this appliance shows compliance with:

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

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

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

IMPORTANT

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

The installation of this boiler must be carried out by a

competent person approved at the time by the Health and Safety Executive 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 notied to the local authority Building Control Department and that the work must be carried out by a competent person approved at the time by

the Health and Safety Executive, as dened 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 approved at the time by the

Health and Safety Executive, as described in the following

regulations:

The manufacturer’s instructions supplied.

The Gas Safety (Installation and Use) Regulations.

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

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

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

The Current I.E.E. Wiring Regulations.

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

In IE, the installation must be carried out by a competent

person approved at the time by the Health and Safety Executive and installed in accordance with the current edition

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

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

1) Central heating system specication (CheSS)

and

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

Gas Supply

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

In GB this is BS6891.

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

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

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

Domestic Hot Water

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

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

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

Heating System

In GB, it is necessary to comply with the Water Supply (Water Fittings) Regulations 1999 (for Scotland, the Water Byelaws 2000, Scotland).

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

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

Boiler Design

This boiler is designed as a high efciency central heating appliance, close coupled to an un-vented cylinder. The pumps, expansion vessels and associated safety devices are all tted 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.

Additionally a thermostatically controlled immersion heater with manual reset is tted to the cylinder as a back up for domestic hot water in the event of the boiler being inoperable. It is intended for use as a back up should the boiler fail, it will not give optimum DHW performance.

Safety Devices

Electrical Supply Failure

The boiler will not work without an electrical supply.

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

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

If the boiler does not resume normal operation press the reset button. If the boiler does not resume normal operation after this, refer to fault nding.

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 tted 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.

Pluming from flue terminal

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

Condensate Drain

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

Condensate should, if possible, be discharged into the internal household draining system. If this is not practical, discharge can be made externally into the household drainage system or a purpose designed soak away, see section 6 for more details.

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.

C or has already reached 35OC.

C after 30 minutes or at any time if the temperature

C for 1 hour every Wednesday at

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 efcient 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 rented property there is a duty of care imposed on the owner of the property by the current issue of the Gas Safety (Installation and Use) Regulations, Section

35. Servicing/maintenance should be carried out by a competent person approved at the time by the Health and Safety Executive in accordance with the rules in force in the countries of destination.

Spare Parts

Remember, when replacing a part on this appliance, use only spare parts that you can be assured conform to the safety and performance specication that we require. Do not use reconditioned or copy parts that have not been clearly authorised by Glow-worm. If a part is required contact Glow-worm’s own service organisation. Please quote the name and model of the boiler. The name badge is on the front of the appliance and the model type is positioned on the top edge of the tank module front panel. If in doubt seek advice from the local gas company or Glowworm’s own service organisation using the telephone number on the inside front cover of this booklet.

1 Boiler Specications

Data

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

See diagram 1.1 and the Boiler Specication Table below.

The data label is positioned inside the boiler module on the base.

13340

1 Boiler Specications

13247

Diagram 1.1

1 Boiler Specications

13290

Diagram 1.2

2 Boiler Location, Clearances and Ventilation

2.1 Location

This boiler is not suitable for outdoor installation.

This boiler may be installed in any room, although particular attention is drawn to the installation of a boiler in a room containing a bath or shower where reference must be made to the relevant requirements.

This boiler is suitable for installation in bathroom zones 2 and

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

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

2.2 Clearances

The boiler should be positioned so that at least the minimum operational and servicing clearances are provided, see diagram 2.1.

Additional clearances may be benecial around the boiler for installation and servicing.

For ue installations where external access is not practicable, consideration should be given for the space required to insert the ue internally, which may necessitate a clearance larger than those specied in diagram 2.1.

13241

2.3 Timber Frame Buildings

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

2.4 Room Ventilation

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

2.5 Cupboard or Compartment Ventilation

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

Leave existing air vents.

Diagram 2.1

3 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

3.2 Flue Terminal Position

The minimum acceptable siting dimensions for the terminal from obstructions, other terminals and ventilation openings are shown in diagram 4.2. In IE the minimum distances for ue terminal positioning must be those detailed in I.S.813 “Domestic Gas Installations”. The terminal must be exposed to the external air, allowing free passage of air across it at all times. Being a condensing boiler some pluming may occur from the ue outlet. This should be taken into consideration when selecting the position for the terminal. NOTE: If necessary it is permitted to increase the terminal protrusion 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 roof and one wall, require special consideration with respect to any openings, doors, vents or windows under the roof. Care is required to protect the roof if made of plastic sheeting. If the carport comprises of a roof and two or more walls, seek advice from the local gas supply company before installing the boiler. H* and J* See diagram 4.2 . These dimensions comply with the building regulations, but they may need to be increased to avoid wall staining and nuisance from pluming depending on site conditions.

NOTE: If the ue terminal is positioned near a light source insects may enter the ue system. Where safe and practical to do so advise the homeowner to check the ue outlet and clear visible insects from the terminal end.

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

3.3 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 3.2.

A suitable guard is manufactured by: -

Tower Flue Components

Morley Rd.

Tonbridge

Kent TN9 1RA.

Size: 280mm x 165mm. Part No. CGDK3

15583

Diagram 3.1

3.1 Flue Options

There are various ue options to choose from as illustrated in diagram 3.3. The ue lengths and installation of various ue types are described in section 10.

Diagram 3.2

3 Flue Options and Terminal Clearances

Ridge Tile Terminal

Part No. A2043800 Section 10, page 32

14845

Top horizontal telescopic ue Ø60/100

- page 23 Part No. A2043600

Vertical Flue - page 31 Vertical Flue Adapter, concentric ue Ø60/100 Part. No. A2024600

Vertical ue terminal kit, concentric ue Ø60/100 Part. No. 2000460480

Twin Flue - page 34 Twin Flue Adapter, concentric ue Ø80 Part No. A2011000

Top horizontal standard ue Ø60/100

- page 27 Part No. A2043400

Plume Management Kit page 37 Basic set, concentric ue Ø60/100 White - Part No. A2044100 Black - Part No. A2044000 for use with Part No. A2043400 and Part No. A2043600

Diagram 3.3

4 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.

4.1 Safety Valves

The safety valves are factory tted and are an integral part of the boiler and must not be adjusted or used for any other purpose.

NOTE: The pipe from the safety discharge valve must not discharge above an entrance, window or any type of public access area.

4.2 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 current edition of I.S.813 “Domestic Gas Installations”.

4.3 Flow Rate

If it is necessary to alter the ow rate, the system can be tted with a lockable balancing valve in the main ow or return pipes shown as valve “A” in diagram 4.1.

The ow rate through the boiler must not be allowed to fall below that given in section 1 - Specication table.

4.7 ‘Hard’ Water Areas

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

13352

4.4 Bypass

The boiler is tted with an automatic adjustable bypass.

Diagram 4.2 shows the pump head remaining for the heating system depending on the bypass setting and the speed setting of the pump, see section 12 Commissioning.

4.5 Filling the Sealed System

NOTE: The water pressure at the boiler must be at least

0.7bar to enable lling the boiler to a minimum pressure through the integral lling device, see diagrams 4.1 and 12.2.

4.6 Water Treatment

In the case of an existing system, it is ESSENTIAL that prior to installing the new boiler the system is thoroughly ushed. For optimum performance after installation of a new system, the boiler and its associated central heating system should also be ushed. Flushing should be carried out in accordance with BS7593: 2006 using a cleanser such as Sentinel X300 or X400, Fernox Restorer or Salamander corrosion guard cleaner.

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

Diagram 4.1

2O)

(mH

4 Heating System

automatic bypass - closed

automatic bypass - factory setting

automatic bypass - open

14033

Remaining conveyancing capacity

5 Domestic Hot Water

General

All domestic hot water circuits, connections, ttings must be in accordance with the relevant standards and water supply regulations. The boilers are suitable for connection to most types of domestic appliances. When connecting to suitable showers, ensure that: a) The cold water inlet to the boiler is tted with an

approved anti-vacuum or siphon non-return valve.

b) Hot and cold water supplies to the shower are of equal

pressure.

pump speed 1

800 1000 1200 1400 1600 18006004002000

Volumeflow (Litres/hr)

5.4 Safety Valves

The safety valves are factory tted and are an integral part of this boiler and they must not be adjusted or used for any other purpose.

NOTE: The pipe from the safety discharge valve must not

discharge above an entrance, window or any type of public access area.

pump speed 2

Diagram 4.2

5.1 Water Pressure

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 2 bar. NOTE: Higher pressure can be tolerated as the boiler is tted with a pressure reducing valve set at 3.5 bar.

5.2 Expansion Vessel

The boiler has an integral expansion vessel with a capacity of 12 litres (2.6 gallons), with a charge pressure of 3 bar.

5.3 Draining Point

A draining point is provided at the bottom of the hot water storage tank located next to the condensate drain, see diagram 5.1.

CONDENSE TRAP

AND

SIPHONIC DRAIN

DRAIN POINT

13308

SCREW

Diagram 5.1

5 Domestic Hot Water

5.5 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* In 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 species: *Attention is drawn to regulation 18 (supervision of building work 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

certied that the system is capable of performing in a way which satises 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 tted 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 Ofcer.

G3 Requirement

“….there shall be precautions….. to ensure that the hot water discharged from safety devices is safely conveyed to 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 tted as close as possible and within 500mm of the safety device e.g. the temperature relief valve.

NOTE: The tundishes are factory tted during manufacture. 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, preferably be of metal and: 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 ow resistance. An alternative approach for sizing discharger pipes would be to follow BS67100:1987 specication 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 nal point of discharge but where this is not possible or is practically difcult there should be clear visibility at one or other of these locations. Examples of acceptable discharge arrangements are: i) Ideally below a xed 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 ats, 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, inrm or disabled people, consideration should be given to the installation of an electronically operated device to warn when discharge takes place.

5 Domestic Hot Water

NOTE: The discharge will consist of scalding water and

steam. Asphalt, roong felt and non-metallic rain water goods may be damaged by such discharges.

Worked example of discharge pipe sizing

The example given in diagram 5.2 is for a G1/2 temperature relief valve with a discharge pipe (D2) having 4 No. 22mm 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 resistance for 4 No. 22mm elbows at 0.8m 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 from a G1/2 temperature relief valves equates to 18m. Subtract the resistance of 4 No. 28mm elbows at 1.0m each: 4.0m.

Therefore the maximum permitted length equates to: 14m. As the actual length is 7m a 28mm min (D2) copper pipe will be satisfactory.

TABLE 1

Valve outlet size

Discharge pipe D1

Discharge pipe D2 from tundish

Maximum resistance allowed, expressed as a length of straight pipe (i.e. no elbow or bends)

Resistance created by each elbow or bend

13449

G 1/2

15mm

22mm

up to 9m

0.8m

12529

WARNING:

• Under no circumstances should the factory tted

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 tted and MUST NOT be

removed.

6 Condensate Drain

6.1 Condensate Drain

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

Diagram 5.2

6.2 Condensate Connection

A exible condensate connection pipe is supplied and should be used to connect to a drain outlet pipe 22mm to 25mm OD. non corrosive plastic . The drain outlet pipe should have a fall of at least 2.50 away from the boiler.

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 incorrectly.

6 Condensate Drain

INTERNAL SOIL AND VENT STACK

Internal Soil and Vent Pipe

EXTERNAL LENGTH OF PIPE 3M MAX.

BOILER

DIA. 22mm MIN. NO RESTRICTION ON LENGTH

BOILER

EXTERNAL SOIL AND VENT STACK

EXTERNAL MAX. 3M

DIA. 22mm MIN. NO RESTRICTION ON LENGTH

BOILER

External Soil and Vent Pipe or Rainwater Pipe

SINK (CONSTITUTES AIR BREAK)

BOILER

13443

DIA. 22mm MIN.

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

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

External Termination to a Gulley or Hopper

DIA. 22mm MIN. NO RESTRICTION ON LENGTH

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

BOILER

SINK

Internal Termination Downstream of Sink Waste

DIA. 22mm MIN. NO RESTRICTION ON LENGTH

Internal Termination into Combined Sink Waste

EXTERNAL LENGTH OF PIPE 3M MAX.

DIA. 22mm MIN. TERMINATION FROM APPLIANCE.

GROUND

500mm MIN.

25mm MIN. DIA. 100mm PLASTIC TUBE

BOTTOM OF TUBE SEALED

LIMESTONE CHIPPINGS

HOLE DEPTH 400mm MIN.

SEAL

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

(either/or)

300mm MIN.

External Termination into Soakaway

NOTE: PIPEWORK SHOULD ALWAYS FALL AWAY FROM BOILER BY AT LEAST 2.5 44mm FOR EVERY 1M.

Diagram 6.1

PLUMBING JIG

7 Installation Preparation

TANK / BOILER MODULE

CONNECTION WASHERS

13405

13248

Retaining screws

stored in cartridge

CONNECTION WASHERS

LOOSE ITEMS PACK

A Installation booklet (not illustrated) 1 OFF B User Instructions (not illustrated) 1 OFF C Condensate Connection Pipe 1 OFF D 22mm Copper Tails 4 OFF E 15mm Copper Tail 1 OFF F 3/4" Sealing Washer (white plastic) 4 OFF G 1/2" Sealing Washer 2 OFF H 3/4" Sealing Washer (beige) 5 OFF J Pump Washer 1 OFF K Floor Template 1 OFF L Electrical Cartridge 1 OFF M Cartridge Screws (stored in cartridge) 2 OFF N 3/4" Sealing Washer (blue) 4 OFF

TANK / JIG

Diagram 7.1

7 Installation Preparation

7.1 Loose Items Pack

Please check the contents of loose items pack as shown in diagram 7.1.

The plumbing jig is located within the tank module polystyrene top pack.

7.2 Site Requirements

The appliance should be sited on a level oor, however slight adjustment can be made using the adjustable feet at the base of the tank module.

The oor strength should be suitable for the combined weight of appliance and water:

100sxi 175kg

170sxi 225kg

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

7.3 Floor Template

Take the oor template from the loose items pack and place

in the desired position on the oor, giving due consideration to the required boiler clearances, see diagram 2.1, and the ue you are tting.

Mark the position of the ue centre, if tting a side ue, extend the ue centerline into the corner then along the adjacent wall, see diagram 7.2.

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

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

7.4 Flue Hole Cutting

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

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

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

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

(44mm/metre) FALL TOWARDS THE BOILER IS

REQUIRED WHEN FLUE EXTENSIONS ARE USED

1331 (100sxi)

1591 (170sxi)

TEMPLATE

Diagram 7.2

13376

13418

7.5 Plumbing Jig

Align the template with the ue hole then mark the position of the xing holes for the jig, see diagram 7.3.

Align the location notches on the jig and secure to the oor using suitable screws.

Diagram 7.3

8 Gas, Water & Boiler Connection

8.1 Systems Connection

The water and gas isolation valve connections are on the jig.

The condense drain and safety discharges connections are not on the jig but their pipe runs are shown on the template.

Assemble the copper tails and washers to the jig, secure, then plumb the system as shown in diagram 8.1. taking into account the need to plumb the condense and safety valves also.

NOTE: Do not subject isolation valves to heat.

Slacken the test point screw, see diagram 8.1, connect a manometer.

The whole of the gas installation, including the meter, should be inspected, tested for tightness and purged in accordance with the current issue of BS6891 and in IE the current edition of I.S.813 “Domestic Gas Installations”.

Remove the manometer and secure the test point screw.

On completion of system connections and as an aid to installation, slacken the jig securing screws, this will allow a greater tolerance of site conditions when connecting the isolation valves to the boiler.

PIPE WORK

68/78

ROUTING (IF REQUIRED)

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.

8.2 Tank Module Connection

IMPORTANT:

immersion heater need to be routed before the installation of the tank module.

Remove the tank module top polystyrene packing, then the carton sleeve.

Pull the tank module front panel forward off the retaining clips.

Slide the tank module into position over the jig and align with the isolation valves.

The electrical cables to the boiler and the

NOTE: If there is restricted clearance where the boiler is

to be located, the tank and boiler modules can be assembled before sliding into position over the jig.

Position the plastic sealing washers as shown in diagram 8.3 and connect the isolation valves. The pipe retaining bracket can be slackened to ease connection.

13402

VIEW SHOWING SIDE OUTLET PIPE WORK ROUTING AT BACK OF BOILER (IF REQUIRED)

CONDENSATE

DRAIN

CENTRAL

HEATING

FLOW

ADJUSTABLE FEET

DHW

OUTLET

GAS ISOLATION VALVE

CH SAFETY RELIEF VALVE DISCHARGE

GAS

GAS INLET PRESSURE TEST POINT

VALVES SHOWN CLOSED

15mm COPPER TAIL

SEALING WASHER

INLET

DHW

22mm COPPER TAIL

SEALING WASHER

ISOLATION VALVE (typical)

DHW SAFETY RELIEF VALVE DISCHARGE

CENTRAL

HEATING

RETURN

Diagram 8.1

FEET

BOILER MODULE

8 Gas, Water & Boiler Connection

13416

TANK THERMISTOR CABLE

FLEXIBLE CONDENSATE HOSE CONNECTION

FRONT PANEL

SECURING SCREW (2 OFF)

Diagram 8.2

8.3 Boiler Module Connection

Unpack the boiler module from its carton.

Position the boiler on top of the tank ensuring the correct engagement of the locating pins, see diagram 8.3.

Remove the front panel securing screws and lift the panel off at the top locating bracket, see diagram 8.2.

Position the plastic sealing washers as shown in diagram 8.3 and secure to the pipes to the connectors beneath the boiler as shown in diagram 8.2.

On completion secure the pipe retaining bracket if previously slackened and level the boiler using the adjustable feet.

13415

SEALING WASHER (beige) (5 OFF)

PUMP WASHER

BOILER MODULE

LOCATING PIN (4 OFF)

TANK MODULE

SEALING WASHER 1/2"

SEALING WASHER (white plastic) (4 OFF)

PIPE RETAINING BRACKET

PLASTIC WASHERS

FLOOR FIXING JIG

ADJUSTABLE

Diagram 8.3

9 Condensate & Safety Discharge Valve Connections

CH SAFETY RELIEF VALVE DISCHARGE CONNECTION

DHW SAFETY RELIEF VALVE DISCHARGE CONNECTION

22mm compression (not supplied) is the preferred method of connection for servicing.

9.1 Safety Discharge Valve

The pipes 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.

It is advisable to use a 22mm compression elbow to aid in future servicing, see diagram 9.1.

13463

9.2 Condensate Drain Connection

A exible condensate hose runs from a push-t connection at the bottom of the heat exchanger and terminates on the boiler module base plate, see diagram 8.2.

Connect the exible condensate hose to the boiler module, see diagram 9.2.

A exible condensate connection pipe is supplied in the loose items pack and should be tted between the condense trap and siphonic drain to the condensate drain pipe, see diagram

9.3, and refer to section 6 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

away from the boiler.

Diagram 9.1

FLEXIBLE CONDENSATE HOSE CONNECTION TO BOILER MODULE

13312

FLEXIBLE

CONDENSATE

HOSE

13458

CONDENSE TRAP

& SIPHONIC DRAIN

FLEXIBLE

CONDENSATE

CONNECTION

PIPE

FLEXIBLE CONDENSATE HOSE

Diagram 9.2

Diagram 9.3

10 Telescopic Flue - Length, Preparation and Installation

320 min. to 523 max.

10.1 Flue Length

The maximum achievable rear and side ue length for a telescopic ue, diagram 10.2, is as shown in diagram 10.1.

The maximum permissible horizontal ue length is 8 metres plus the ue terminal assembly, this can be achieved by use of the accessories, see diagram 10.3, however should additional 87.5 MUST be reduced by 1metre.

or 2 x 45o elbows be used then the length

Horizontal Telescopic Flue

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

87min

When extension pipes are used the ue system must be designed to have a continuous fall to the boiler of at least 2.5o 44mm/metre to allow condensate to run back into the boiler and out via the condense trap & siphonic drain.

The ue 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.

WALL THICKNESS

FLUE

13337

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

Max. distance from outside

wall face to min clearance.

LH - 269mm

RH - 482mm

87min

OUTSIDE WALL FACE

INSIDE WALL

Max flue length 668mm

5mm min. clearance

455145

FLUE

13339

181394

Min. distance from outside

wall face to min clearance.

LH - 75mm

RH - 75mm

INTERNAL SURFACE

OUTSIDE WALL FACE

Diagram 10.1

10 Telescopic Flue - Length, Preparation and Installation

A2043600 Top Outlet Horizontal telescopic flue pack

SECURING COLLAR

FLUE ELBOW

SCREW x 4

13221

SEALING TAPE (telescopic only)

TELESCOPIC TERMINAL ASSEMBLY

SEALING COLLAR

SCREW x 2

SCREW x 1

TRIM RING

SCREW x 2

GASKET (fitted)

Diagram 10.2

15418

Diagram 10.3

10 Telescopic Flue - Length, Preparation and Installation

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 ue can be used without extensions.

With the ue elbow temporarily tted, measure the distance from the outside wall to the butt joint, see diagram 10.4. If the measurement ‘Y’ exceeds 522mm, then the appropriate length of extension pipe is required.

If the dimension is less than 320mm DO NOT cut the ue, it can project to a maximum of 600mm, if this is not desirable then a Standard ue MUST be used and cut to length.

10.4 SIDE Flue

With the ue elbow temporarily tted, 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 ue, it can project to a maximum of 600mm, if this is not desirable then a Standard ue MUST be used and cut to length.

Diagram 10.4

1322413295

Diagram 10.5

Diagram 10.6

12979

10 Telescopic Flue - Length, Preparation and Installation

Diagram 10.7

Diagram 10.8

12929

12977

13296

10.5 Flue Fitting

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

During the installation of the ue system, ensure that debris such as mortar, lings or swarf are cleared from the ue system before completion. Inspect the ue pipes before tting and do not install damaged or dented ue components. When assembling the ue system, ensure that the inner seals are not damaged, do not install a ue component with a damaged seal. When tting ue elbows ensure that they are tted at the correct angle to avoid strain, this will ensure that the seal ts correctly preventing leakage.

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

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

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

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

Draw the ue assembly from wall and engage the ue duct into the elbow and butt t between the air duct and ue elbow. Fit the securing collar into position. Ensuring correct alignment of the ue, mark through two of the pre drilled holes in the securing collar. Remove securing collar and drill two 3mm diameter holes one in the elbow and one in the air duct, take care not to pierce the inner ue duct. Fit the securing collar and secure with screws provided, see diagram 10.9.

Slide the internal trim ring back against the wall, securing in place with a small amount of sealant if required.

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

Check that the outer rubber sealing collar makes an effective seal against the wall face.

Diagram 10.9

10 Standard Flue - Length, Preparation and Installation

75 min. to 586 max.

10.6 Flue Length

The maximum achievable rear and side ue length for a standard ue, diagram 10.12, is as shown in diagram 10.11.

The maximum permissible horizontal ue length is 8 metres plus the ue terminal assembly, this can be achieved by use of the accessories, see diagram 10.13, however should additional 87.5o or 2 x 45o elbows be used then the length MUST be reduced by 1metre.

Standard Horizontal Flue

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

87min

The ue 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.

WALL THICKNESS

FLUE

13401

Max. distance from outside

wall face to min clearance.

LH - 334mm

RH - 547mm

OUTSIDE WALL FACE

INSIDE WALL

455145

13338

Min. distance from outside

wall face to min clearance.

LH - 75mm

RH - 75mm

Diagram 10.11

10 Standard Flue - Length, Preparation and Installation

12841

Diagram 10.12

15418

Diagram 10.13

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 ue elbow temporarily tted, 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 ue can project to a maximum of 600mm, if this is desirable, refer to diagram 10.16.

10.9 SIDE Flue

With the ue elbow temporarily tted, measure the distance from the outside wall to the butt joint, see diagram 10.15. If the measurement ‘Y’ exceeds 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 ue can project to a maximum of 600mm, if this is desirable, refer to diagram 10.16.

10.10 Flue Fitting

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

During the installation of the ue system, ensure that debris such as mortar, lings or swarf are cleared from the ue system before completion. Long lengths of ues must be secured to the walls or ceilings they run against. Use at least one xing bracket for every ue extension that is used. After cutting inner ue tubes ensure that you de-burr and chamfer the male tube end to prevent damage. Inspect the ue pipes before tting and do not install damaged or dented ue components. When assembling the ue system, ensure that the inner seals are not damaged, do not install a ue component with a damaged seal. When tting ue elbows ensure that they are tted at the correct angle to avoid strain, this will ensure that the seal ts correctly preventing leakage.

Remove the ue elbow.

Separate the ue duct from the terminal by twisting to release the terminal catch, then pull out of the retaining seal, refer to diagram 10.17.

The ue 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 ue duct MUST be cut at the opposite end to the terminal catch.

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

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

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

Left Hand illustrated

13223

Diagram 10.14

13224

Diagram 10.15

12979

Diagram 10.16

10 Standard Flue - Length, Preparation and Installation

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

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

Slide the internal trim ring back against the wall, securing in place with a small amount of sealant if required.

NOTE: If the air and ue ducts have been correctly cut to the instructions the sealing collar should t ush with the outside wall.

12847

Diagram 10.17

Diagram 10.18

13297

10 Vertical Flue - Length, Preparation and Installation

10.11 Vertical flue

The vertical ue system is available as an option where the boiler position does not permit the use of the top outlet horizontal concentric ue pack.

The system is made up of accessories. The accessories include terminal assembly, bends 45º and 87.5º, ue extensions, xing bracket and appropriate weather collar, see diagram 10.20.

The maximum permitted straight ue length is 12 metres plus the terminal. for each 87.5 maximum length must be reduced by 1 metre, see diagram

10.19.

or 2x45o bends tted, the

NOTE: 2x45º bends can replace 1x87.5º bend if necessary. When using 87.5º bends any horizontal extension pipe should be inclined by a minimum of 44mm/metre (2.5°) towards the boiler to facilitate condense removal, see (a) in diagram 10.19.

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.

Measure the distance of ue length required for the installation.

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

14862

Diagram 10.19

10 Vertical - Flue Length, Preparation and Installation

14849

Long lengths of ues must be secured to the walls or ceilings they run against. Use at least one xing bracket for every ue extension that is used. After cutting inner ue tubes ensure that you de-burr and chamfer the male tube end to prevent damage. Inspect the ue pipes before tting and do not install damaged or dented ue components. When assembling the ue system, ensure that the inner seals are not damaged, do not install a ue component with a damaged seal.

When tting ue elbows ensure that they are tted at the correct angle to avoid strain, this will ensure that the seal ts correctly preventing leakage.

Refer to diagram 10.22. Secure the ue adapter in position on top of the boiler with four torx headed screws supplied, making sure the nib ts 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.

Secure the rst extension pipe to the ue adapter with the securing collar supplied by positioning the collar centrally over the joint, then tighten the two screws on the securing collar, see diagram 10.23.

Fit more extension pipes as required using the collar and screws supplied with each extension pipe. To t position the collar centrally over the joint, tighten the two screws on the securing collar. Using the holes provided in the securing collar, drill and insert the two self tapping screws supplied, see diagram 10.24.

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

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

Diagram 10.20

Flue Installation

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

During the installation of the ue system, ensure that debris such as mortar, lings or swarf are cleared from the ue system before completion.

Flue Terminal Installation

(a) Pitched Roof

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

(b) Flat Roof

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

From above carefully place the ue terminal through the weather collar.

Ridge Tile Terminal

A ridge tile terminal is available - part no. A2043800, see diagram 10.21.

The installation of a ridge tile will be required.

A suitable ridge tile is manufactured by: -

Aspect East Anglia Limited The Old Mill East Harling NORWICH NR16 2QW Website: www.aspectroong.co.uk Contact: Chris Haythorpe General Manager - Tile Division Tel: 01953 717777 Fax: 01953 717164

10 Vertical Flue - Length, Preparation and Installation

Completion of Installation

With the ue terminal positioned in the roof the length of the nal pipe can be determined. If a telescopic length cannot be used, then a standard ue length can be cut to make the correct length. Cut the ue to the desired length measuring from the ‘O’ ring end and discard the plain end of the tube. The cuts must be square and made free of burrs to allow correct assembly.

NOTE: The ue pipe is 10mm longer than the air pipe, see diagram 10.25.

Carefully push the terminal assembly upwards to allow room for tting the nal ue piece. Fit a xing bracket to the terminal assembly. Pull the terminal assembly down and join to the ue system. Ensure that the terminal is making a weather tight seal on the weather collar. Secure the xing bracket tted to the terminal to the roong struts or a purpose made batton.

13317

14853

130

103

133

min. 25

130

103

max. 125°

Diagram 10.21

min. 20

Diagram 10.23

12982

13243

Diagram 10.24

12983

Diagram 10.22

Diagram 10.25

10 Twin Flue - Length, Preparation and Installation

Secure long flue lengths to walls or ceiling at every joint or on straight flue runs at every joint and every metre flue run

WALL SEAL

15407

WALL SEAL

Diagram 10.26

10 Twin Flue - Length, Preparation and Installation

14869

10.12 Twin flue

The twin ue system is available as an option when the top outlet horizontal concentric rear or vertical ue system is not appropriate, see diagram 10.26.

The system is made up of accessories. The accessories include terminal assembly, bends 45º and 90º, ue extensions, xing bracket and appropriate weather collar, see diagram

10.27.

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

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

The maximum permitted combined straight pipe length is 40 metres plus terminal assemblies, for each 90° tted, 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 ue pipe.

or 45° x 2 bends

Terminal Position

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

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

Installation Details

The parts available for a twin ue system installation are shown in diagram 10.27.

Diagram 10.27

Boiler Connection

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

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

Push the twin ue 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.

Air and Flue Pipe Installation

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

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

9.25.

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

To avoid rain ingress to the air Inlet terminal, it is good practice to aim the inlet downwards by approx 2° as rain can damage the boiler. The Flue outlet pipe must always run at 44mm/ metre (2.5°) back to the boiler.

IMPORTANT:

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

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

Do not use the ue pipe to attach other pipes or equipment. If visible, advise the householder not to hang or clip items to ue pipes.

minimum, see diagram

10 Twin Flue - Length, Preparation and Installation

Do not stress the ue connections during the installation this can damage the ue seals.

Horizontal Terminal Installation

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

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

10.26).

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 10.26.

13318

Diagram 10.28

Vertical Terminal Installation

With due consideration to terminal clearances mentioned in Section 3.2, project the rise of the ue pipe to roof level and cut 150mm hole in the roof.

(a) Pitched Roof

(b) Flat Roof

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

Horizontal Pipes-Completion of Installation

Having built the pipe(s) from the boiler to the terminal(s), the length of the nal pipe piece can be determined. Cut pipes at the opposite end to the ‘O’ ring seal making square and free from burrs.

10 Deector Flue Terminal Kit

Push the horizontal terminal through the wall to engage the nal pipe piece and pull back ensuring the grey wall seals are fully pulled up to the outside and inside wall faces.

Vertical Pipes-Completion of Installation

Refer to diagram 10.26.

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

With the vertical terminal assembly positioned in the roof, the length of the nal pipe can be determined. Cut the ue to the desired length measuring from the ‘O’ ring seal end and discard the plain end of the tube. The cut end should be square and free from burrs. Carefully push the terminal assembly upwards to allow room for tting the nal ue piece(s). Fit a 100mm xing bracket to the terminal assembly Part No2000460486. Pull the terminal assembly down and join to the ue system. Ensure that the terminal is making a weather tight seal on the weather collar. Secure the xing bracket tted to the terminal to the roong struts or a purpose made batton.

14465

45°

Diagram 10.29

10.13 Deector Flue Terminal Kit

The terminal kit ts onto the telescopic and standard horizontal ue, see diagram 4.1 for kit contents.

The kit is also supplied with installation instructions.

NOTE: The deector ue terminal kit can be tted after the boiler and ue have been installed.

The deector part of the deector ue terminal can be rotated 45º to allow pluming away from openings, people, cars, windows etc., see diagram 10.29. Should the deector terminal be positioned under a soft or horizontal surface, it is allowed to project the ue 600mm from the wall, to allow the discharge of ue gases produced into free air.

IMPORTANT: Do not t the deector ue terminal with the deector positioned downwards.

10 Plume Management Kit

10.13 Plume Management Kit

12997

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

The Plume Management Kit will t to the Top Horizontal Telescopic, Rear Horizontal Telescopic and Standard Horizontal Flue. This enables the ue products to exhaust further away from the boiler, thereby reducing the impact of pluming. The ue air inlet can be sited closer to doors, opening windows and air bricks, see diagram 10.30.

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

For each 90 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.

bend or 2 x 45o bends the maximum length of the

Diagram 10.30

11 Electrical Connection

WARNING: This appliance must be earthed.

● This appliance must be wired in accordance with these instructions. Any fault arising from incorrect wiring cannot be put right under the terms of the Glow-worm guarantee.

● All system components must be of an approved type.

Electrical components have been tested to meet the equivalent requirements of the BEAB.

● Do not interrupt the mains supply with a time switch or programmer.

● Connection of the whole electrical system and any heating system controls to the electrical supply must be through a common isolator.

● Isolation should preferably be by a double pole switched fused spur box having a minimum contact separation of 3mm on each pole. The fused spur box should be readily accessible and preferably adjacent to the boiler. It should be identied as to its use.

● A fused three pin plug and shuttered socket outlet may be used instead of a fused spur box provided that:

a) They are not used in a room containing a xed bath or shower.

b) Both the plug and socket comply with the current issue of BS1363.

Immersion Heater - the thermostatically controlled

immersion heater with manual reset is tted to the cylinder as a back up for domestic hot water in the event of the boiler being inoperable, it MUST be wired separately from the boiler electrical connections.

The heater should be wired through a double-pole switch or controller having a minimum contact separation of 3mm on each pole. Use a cable size of at least 1.5sq. mm exible cable, 85 deg.C rubber insulated HOFR sheathed to comply with BS6141 Table 8 and must be fully earthed.

ELECTRICAL

11 Electrical Connection

11.1 Electrical Connection

Take the previously laid electrical cable and route along the left hand side of the tank module through the two grommets and the cable ties and across to the installers interface as shown in diagram 11.1.

Take the electrical cartridge from the loose items pack.

Remove the securing screw to open the cartridge.

NOTE: There are two screws supplied loose in the electrical cartridge, these will be required to secure the cartridge into the electrical interface housing.

Slacken the two screws of the cable strain relief in the electrical cartridge, see diagram 11.2.

Route the mains supply and systems cables through the strain relief and connect to the relevant plug dependant upon your choice of system controls, refer to relevant sections 11.2 and 11.3.

Initially, if system controls are not available then t a wire link 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.

Secure with the two cartridge retaining screws provided in the cartridge body.

SECURING SCREW

13291

CARTRIDGE

CABLE STRAIN RELIEF

CABLE TIES

GROMMETS

ELECTRICAL CABLES

Diagram 11.2

13306

13455

RETAINING SCREW

(2 OFF) ELECTRICAL CARTRIDGE

CABLE TIES

Diagram 11.1

Diagram 11.3

11 Electrical Connection

To Control Box

Diagram 11.4

13368

13369

11.2 System Controls 24V

WARNING: UNDER NO CIRCUMSTANCES MUST

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

Connect the mains supply and system heating controls e.g. room thermostat as diagram 11.4. External controls should be tted in accordance with the rules in force.

If tting a proprietary programmer as part of the system controls the internal central heating programmer will need to be disabled as described in section 11.4. If tting the Glowworm Climapro programmer the internal programmer will automatically be disabled.

11.3 Mains Voltage System Controls

WARNING: UNDER NO CIRCUMSTANCES MUST

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

Connect mains supply and system controls as diagram 11.5.

External controls should be tted in accordance with the rules in force.

GROMMET

Diagram 11.5

BOILER MODULE

TANK MODULE

11.4 Disabling the internal CH Programmer

If tting 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 ashing ‘0’. b) Use the ‘+’ or ‘-’ button to scroll to 96. c) Press ‘MODE’ to conrm. d) The display now shows a ashing ‘d. 0’ Use the ‘+’

or ‘-’ key to scroll to ‘d.92’. e) Press ‘MODE’ to conrm. f) The display now shows a ashing ‘3’ above the

‘d.92’. g) Use the ‘+’ or ‘-’ button to change this value to ‘1’. h) Press ‘MODE’ to conrm, ‘1’ stops ashing and is

saved. i) Press and hold ‘MODE’ to exit.

13460

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.

11.5 Tank Thermistor

The tank thermistor should be connected between the boiler and tank modules. The cable and connection plug from the control box passes through a grommet on the base of the boiler module to the connection on the LH side of the tank module, see diagram 11.6.

TANK THERMISTOR CONNECTION

Diagram 11.6

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.

12 Commissioning

13445

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

12.1 Preliminaries - All Systems

Do Not operate the boiler without water.

The commissioning should be carried out by a competent person approved at the time by the Health and Safety

Executive in accordance with the current issue of BS6798.

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

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

12.2 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 ow 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.

Carefully slacken, but DO NOT remove the air vent screw on the domestic pump to release any trapped air within the boiler, see diagram 12.2, secure when procedure completed.

NOTE: The water pressure at the vent point is that of the

incoming water main (max 3.5bar due to pressure reducing valve).

Check for water soundness of the complete domestic water system.

Diagram 12.1

DOMESTIC PUMP VENT

DOMESTIC PUMP

Diagram 12.2

12.3 Filling the Heating System

Refer to diagrams 12.1, 12.2 and 12.3.

With the boiler in place:

1. Ensure that the lling loop exible hose is securely connected to the double check inlet valve.

2. Ensure that the gas service isolation valve 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 ashing system pressure.

13406

12 Commissioning

QUICK

FILLING

4. Fully open the taps on the lling loop to ll the heating system to a pressure of 1.0bar. Close the lling taps. If the domestic cold water is below 10

C the tank 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.

5. Vent all air from the system and vent the CH pump via the front screw - repeat step 4 as necessary 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 tted to allow air to escape.

7. To comply with the water regulations the exible hose must be disconnected from the double check inlet valve

- undo the nut and pull the exible hose from the valve.

12.4 Initial Lighting

NOTE: The combustion for this appliance has been checked,

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

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

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

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

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

● the gas service isolation valve, diagram 12.1, is open.

LPG Conversion: See section 12.11.

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

Light the appliance by following the procedure below:

Refer to diagram 12.4 and repeatedly press the “MODE” button

until the

and

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 burner fails to light the fan will stop. Initially this may be due to air in the gas supply line. The boiler will automatically have ve attempts at ignition.

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

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 purged of air set the hot water to 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 temperature to the desired temperature by using the central heating “+” and “-” buttons.

symbols are displayed.

The appliance will then continue to re in central heating mode until the user controls are satised or there is another demand made for hot water.

NOTE: After ignition in central heating demand the boiler will remain at minimum power for one minute before going to full rate

TAP "B"

RELEASE NUT

FILLING LOOP VALVE

FILLING LOOP FLEXIBLE HOSE

DOUBLE CHECK INLET

QUICK RELEASE NUT

VALVE

FILLING TAP "A"

MODE

PROG

TOGGLE BUTTON

MODE and PROG

SYMBOLS DISPLAYED ON THE LCD AND DESCRIPTIONS

Central Heating Function

Domestic Hot Water Function

Central Heating Timed Mode

Appliance OFF

Temperature

System Pressure

Programmer Adjustment Mode

LCD

DISPLAY

Ext

RESET

BUTTON

Will be displayed when domestic hot

Eco

water temperature is less than 50

Glow-worm control (Optional)

Ext

Min burner display

Max burner display

Outdoor sensor (if fitted)

Diagram 12.3

DHW CH

TEMPERATURE

ADJUSTMENT

Diagram 12.4

13371

13176

12 Commissioning

12.5 Re-pressurising System (if required)

1. Ensure that the lling loop exible hose is securely connected to the double check inlet valve, see diagram

12.3.

2. Fully open tap”A”, then gradually open tap “B” to ll the heating system to a pressure of 1.0bar. When completed close the lling taps.

3. Vent all air from the system - repeat step 2 as necessary until the system is full and all the air has been removed.

4. IMPORTANT: To comply with the water regulations the exible hose must be disconnected from the double check inlet valve - undo the nut and pull the exible hose from the valve.

12.6 Gas Inlet Pressure and Gas Rate

The supply from the governed meter must be of adequate size to provide a steady inlet working pressure of 20mbar (8in wg) at the boiler. On completion, test the gas installation for tightness using the pressure drop method and suitable leak detection uid, purge as necessary.

NOTE: Due to the modulating operation of the boiler and the need to check the gas inlet pressure and measure the gas rate at maximum rate, it will be necessary to force it to maximum.

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

Operational Gas Inlet Pressure

With ALL other gas appliances operating, check the operational supply pressure at the gas service isolation valve test point, see diagram 12.1. The nominal supply pressure for Natural Gas (G20) is 20mbar. The nominal supply pressure for LPG (G31) is 37mbar. Turn the taps and appliances off, then disconnect the pressure gauge.

If you require to measure the gas inlet pressure at the

NOTE:

gas valve there will be a pressure drop over the gas service isolation valve, this is normal and the inlet pressure can be up to 2mbar less. Additionally the safe nominal maximum heat input of the appliance can be achieved at an inlet pressure down to 15mbar.

The BURNER PRESSURE cannot be measured.

NOTE:

Gas Rate

Make sure that ALL other gas burning appliances and pilot lights are off. Check the gas rate using the gas meter test dial and stop watch, at least 10 minutes after the burner has lit, see table opposite for approximate rates. In communal or LPG installations where the gas rate cannot be measured it is acceptable to measure the combustion rate as described in the servicing section. On completion, press the “mode” and “+” buttons simultaneously, this will reset the boiler.

12.7 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 in 1kW increments, refer to diagram 12.4, then:

a) Press and hold the ‘MODE’ button for 5 seconds.

The display will change to ashing ‘0’. b) Use the ‘+’ or ‘-’ button to scroll to 96. c) Press ‘MODE’ to conrm. d) The display now shows a ashing ‘d. 0’. 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 conrm, the new setting has been

saved. i) Press and hold ‘MODE’ to exit.

NOTE: For approximate gas rates at part load, refer to table opposite.

12.8 Water Systems

Check that all external controls are calling for heat, the boiler will re automatically. Fully open all radiator valves and the ow control valve, if tted, see diagram 4.1.

Balance the radiators as required and if tted 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 ow and return.

The pump has two speeds and can be adjusted depending on the requirements of the central heating system, see diagram

4.2.

The boiler has an inbuilt automatic adjustable bypass valve. The pressure can be adjusted between approx 1.5 and

3.5mH

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

pressure changes by approx 0.1mH2O for each full turn of the bypass screw, see diagram 12.5. 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 tted.

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

We recommend that the domestic hot water should be run for a short period until clear.

C can be achieved

kW m3/hr ft3/hr kW m3/hr ft3/hr

24 2.5 88.6 16 1.7 58.9

23 2.4 84.7 15 1.6 55.4

22 2.3 81.2 14 1.5 51.5

21 2.2 77.3 13 1.4 48.0

20 2.1 73.8 12 1.3 44.1

19 1.1 69.9 11 1.2 40.6

18 1.9 66.4 10 1.0 36.7

17 1.8 62.9 9 0.9 33.2

12 Commissioning

15346

AUTOMATIC

BYPASS

AUTOMATIC

AIR VENT

CAP

RETAINING

CLIP

BYPASS

SCREW

Diagram 12.5

12.9 Completion

Fit the boiler module front panel, see diagram 8.2.

Fit the tank module front panel, this is a push-t.

Ensure that the magnetic lighting instruction label is placed on the surface of the boiler casing

GB: It is a requirement that the “Benchmark” Installation, Commissioning and Service Record is completed and left with the user.

IE: it is necessary to complete a “Declaration of Conformity” to indicate compliance to I.S.813. An example of this is given in the current edition of I.S.813.

12.10 Instruct the User

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

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

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

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

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

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

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

● Advise the user that the permanent mains electrical supply SHOULD NOT be switched off, as the built in frost protection and pump saver program will not operate.

● Advise the User if the mains electricity and gas are to be turned off for any long periods during severe weather, it is recommended that the whole system, including the boiler, should be drained to avoid the risk of freezing.

Note: Sealed System: Contact your installation/servicing company as draining, relling and pressurising MUST be carried out by a competent person approved at the time by the Health and Safety Executive.

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

12.11 LPG CONVERSION

Do Not operate the boiler without water.

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

Ensure that the appliance supply pressure = 37mbar.

(1) To access the gas valve you will need to remove the silencer tube, see diagram 13.7 and section 13.4.

(2) Refer to diagram 13.13 and turn the gas valve throttle fully clockwise using a small at blade screwdriver.

(3) Turn the throttle back anti-clockwise by 2

(4) Ensure that the gas analyser is set to the correct fuel setting - Propane.

(5) Attach combustion analyser to the combustion test point. See diagram 13.1.

NOTE: Before measuring combustion the silencer must be replaced.

(6) Turn on the gas service isolation valve, see diagram

12.1.

Turn on the electrical supply, the appliance will begin the ignition sequence.

Monitor the combustion reading and after 5 mins at max rate, the reading should be:-

G31 - 10.2% ± 0.5 case on, 10.0% ± 0.5 case off after 5 minutes.

To achieve maximum rate (input) press the “reset” button on the controls fascia, release and immediately press and hold in the “+” button. After approximately 5 seconds “Hi” will be displayed.

Pressing the mode button when “Hi” is selected will force the boiler to maximum rate, the display will ash between “Hi” and the “default display” this will indicate the boiler has been forced to maximum.

If adjustment proves necessary then proceed as follows:

Adjust the maximum rate CO anti-clockwise to increase, clockwise to decrease, see diagram 13.13.

NOTE: Adjust only in very small increments (approx.

turn) and wait approx. 1 minute after each adjustment

until the value stabilises.

To exit the check sequences press the “+” button, this will reset the boiler to the default display.

(7) Remove analyser probe from the test point and replace the cap.

(8) IMPORTANT: Fit the LPG conversion label supplied

in the documentation pack to the base panel alongside the data label. Ensure the silencer is tted and front panel replaced.

by turning the throttle

/4 turns.

13 Servicing

IMPORTANT NOTES:

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

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

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

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

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

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

General Inspection

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

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

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

● Electrical, gas and water connections.

● System pressure.

● the combustion performance, refer to the following procedure.

● The operational gas inlet pressure and gas rates, refer to the commissioning section paragraph 12.7. Correct any fault before continuing.

COMPETENCY TO CARRY OUT THE CHECK OF COMBUSTION PERFORMANCE

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

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

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

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

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

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

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

COMBUSTION CHECK AND SETTING THE AIR/ GAS RATIO VALVE

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

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

”, constant central heating with DHW

13347

FLUE ELBOW

FLUE GAS ANALYSER TEST POINT

FLUE DUCT EXTENSION

Diagram 13.1

GAS RATES (G20) (approx)

after 10 mins from cold

Model

100sxi 170sxi

MIN

/h ft3/h

0.48 3.30 0.004

16.8

0.48 16.8

GAS RATES (G31)

after 10 mins from cold

Model

100sxi

170sxi

MIN

kg/hr

0.7

MAX

/h ft3/h

116.5

3.30 116.5

(approx)

MAX kg/hr

2.4 10.2 ± 0.5 10.0 ± 0.5

2.4

BURNER % CO2

(nominal)

(Case Off)(Case On)

9.2 ± 0.5 9.0

BURNER % CO2

(nominal)

(Case Off)(Case On)

10.2 ± 0.5 10.0 ± 0.5

CO/CO2

RATIO

0.004

CO/CO2

RATIO

0.004

1. Maximum Rate Check and Adjustment

NOTE: To verify the maximum gas rate CO2 setting the appliance must be checked at the maximum rate rst. Press the “reset” button on the controls fascia, release and immediately press and hold in the “+” button. After approximately 5 seconds “Hi” will be displayed. Pressing the mode button when “Hi” is selected will force the boiler to maximum rate, the display will ash between “Hi” and the “default display” this will indicate the boiler has been forced to maximum. Wait until the CO2 value is stable and check that the value is within the range specied in table in the “check” column.

13760 14052

13 Servicing

If the combustion reading is not within the acceptable values AND the integrity of the complete ue system and combustion circuit seals have been veried and the inlet gas pressure (and gas rate) have been veried, then, it will necessary to adjust the combustion rate of the appliance. NOTE: Adjustment is made by turning the gas valve throttle an ⅛ of a turn, waiting 1 minute to allow the appliance to stabilise before checking or making further adjustments.

● Remove the sticker covering the “throttle” adjustment screw, if tted.

● Rotate the “throttle” (anti-clockwise to increase), to the required CO2, refer to diagram 13.13 and the “SETTING” column in the table.

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

GAS RATE CHECK

Check the gas rates as described in the commissioning section.

COMPLETION

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

13440

SECURING SCREW (2 OFF)

13417

*CONTROL BOX

BOILER MODULE FRONT PANEL

Diagram 13.2

CONTROL BOX SERVICE BRACKET

13.1 Servicing

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

checks did not require adjustment then it will not be necessary to complete a full service.

All routine servicing requirements can be achieved by the removal of the front panels, see diagram 13.2.

Position the control box and domestic expansion vessel into their service positions, see diagrams 13.3 to 13.6. Before commencing with a service or replacement of parts. The boiler should be isolated from the electrical and gas supplies see diagram 12.1 for the position of the gas service isolation valve.

CONTROL BOX SERVICE BRACKET

BOILER MODULE

CONTROL BOX MOUNTING BRACKETS

* To move the control box into its service position

carefully pull the control box forwards and upwards to release from its mounting brackets.

Diagram 13.3

13 Servicing

SERVICE SUPPORT

FLEXIBLE

BRACKET

SPARK GAP

13.2 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 gas valve, this is a push t.

CONTROL BOX IN SERVICE POSITION

UNION NUT (Do not loosen)

LOCK NUT

DOMESTIC EXPANSION VESSEL

Diagram 13.4

HOSE

Diagram 13.5

13344

13330

13343

SILENCER

SECURING SCREW

HEAT EXCHANGER

Diagram 13.7

13.3 Spark Electrode

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

component.

Disconnect the spark electrode plug and earth lead. Remove the two securing screws and withdraw the spark electrode carefully from the combustion chamber, see diagrams 13.8 and 13.9.

Inspect the tips for damage.

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

4.5mm.

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

NOTE: If the burner is not to be serviced, do not perform the following instructions 13.6, 13.7, 13.8 and 13.9 but continue to section 13.10 to complete the servicing.

13273

DOMESTIC EXPANSION VESSEL

BRACKET

SERVICE POSITION

Diagram 13.6

FILLING LOOP

13329

4mm

GASKET

ELECTRODE

SECURING SCREW (2 OFF)

EARTH LEAD

Diagram 13.8

13 Servicing

SILENCER

ELECTRICAL CONNECTION

GAS VALVE

FAN

ELECTRICAL CONNECTION

GAS SUPPLY PIPE SECURING CLIP

FLUE

13.4 Burner

NOTE:

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

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

● When replacing ensure that the sealing grommet, situated

below the gas valve is correctly re-seated.

Slacken 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, see diagram

13.10.

Disconnect the ignition lead and earth lead from the burner door, see diagram 13.9.

Disconnect the ue 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 burner assembly from the combustion chamber, taking care not to trap the primary return thermistor electrical cables.

BRACKET

IGNITION LEAD

HEAT EXCHANGER

EARTH LEAD

13346

Diagram 13.9

13350

Clean the burner with a soft brush taking great care not to damage the front insulation. DO NOT use wire or sharp instruments to clean the holes of the burner. Inspect the burner for any signs of damage.

Remove and discard the burner door seal and replace with new.

13.5 Heat Exchanger

Refer to diagram 13.11.

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

Carefully ush by spraying water into the heat exchanger, any remaining debris should pass through the condensate trap (Ensure the water is kept away from electrical components).

Diagram 13.10

13373

OVERHEAT THERMOSTAT

HEAT EXCHANGER

NYLOC NUT (4 OFF)

SILENCER BRACKET

SEAL

BURNER DOOR

GAS VALVE

FAN

Diagram 13.11

13 Servicing

BURNER

GAS CONTROL VALVE

OFFSET ADJUSTMENT

THROTTLE ADJUSTER

FRONT INSULATION

BURNER DOOR

GASKET

SPARK ELECTRODE

SECURING SCREW (4)

GAS VALVE AND FAN

Diagram 13.12

13.6 Condense Trap and Siphonic Drain

The condensate trap & siphonic drain does not normally need servicing unless material deposits exceed beyond the service ll level, see diagram 13.14. To clean the condense trap remove the sump and rinse with water.

15452

13356

13326

FLEXIBLE

CONDENSATE

HOSE

Turn anti-clockwise to remove

SERVICE

FILL LEVEL

CONDENSE TRAP

& SIPHONIC DRAIN

Diagram 13.14

13.7 Boiler Module Front Casing Panel Seal Check

Check the condition of the seal, if worn or damaged remove the seal and thoroughly clean the casing surface before tting the new seal, see diagram 13.15.

Ret the casing panel.

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

13762

SEAL (4 pieces)

Diagram 13.13

BOILER MODULE FRONT CASING PANEL

Diagram 13.15

14 Fault Finding

Indicates

Diagnostic

Diagnostic display 1

Diagnostic display 2

14.1 Preliminary fault nding

The following checks should be performed before proceeding onto specic diagnostics:

• Check the external electrical supply to the boiler is on and a supply of 230V is present at the ‘L’ and ‘N’ terminals at the installer interface. For access remove and open the electrical cartridge, see diagrams 11.3. and 11.2. Test at the ‘L’ and ‘N’ terminals on the installer interface, refer to diagrams 11.2 and 14.1.

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

An aid to test

Remove the tank module front panel to gain access to the boiler module front panel securing screws, see diagram

13.1. Hinge down the control box and unclip the cover. to gain access to the main PCB. Carry out the tests at connector plug X17, see diagram

14.1. Check chassis earth at a bare metal point on the boiler.

• Check that there is a gas supply to the boiler and the gas service isolation valve is turned on, see diagram 12.1.

• Check pressure at the gas service isolation valve, refer to section 12.6.

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

12.3.

• Check that all external controls are on.

• Check the functional ow diagram, 14.3.

13452

fault memory position

Fault code

Fault memory display

14.3 Diagnostic Menu

The Diagnostic Menu provides the ability to view and change certain parameters. See Diagram 14.5 for available parameters. To enter the diagnostic menu: a) Press and hold the ‘MODE’ button for 5 seconds. The display will change to ashing ‘0’. b) Use the ‘+’ or ‘-’ buttons to scroll to 96 (This is the installer level access password). c) Press ‘MODE’ to conrm, see diagnostic display 1.

13450

value

Diagnostic number

Diagram 14.1

14.2 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 ashing ‘0’ press ‘MODE’ button.

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

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

13845

Use the ‘+’ or ‘-’ buttons to view the appropriate diagnostic number, see diagram 14.4. If necessary the values can be changed by: a) Pressing the ‘MODE’ button. b) The diagnostic value ashes, see diagnostic display 2.

13451

c) Use the ‘+’ and ‘-’ buttons to cycle through available values. d) The change is saved by pressing ‘MODE’ once more. (NOTE: Only certain parameters can be adjusted) To exit the diagnostic menu press and hold the ‘MODE’ button for 5 seconds.

KEY

br BROWN b BLUE g/y GREEN/YELLOW gy GREY g GREEN bk BLACK y YELLOW r RED w WHITE or ORANGE p PURPLE pk PINK

14 Fault Finding

13119

bkbk

bk bk

r b

g/y

b r

g/y

Diagram 14.2

14 Fault Finding

CENTRAL HEATING

13012

START

Is there anything displayed

Yes

Is the display flashing 'F'?

Initiate a DHW demand.

Adjust DHW setpoint to

C and turn on a hot

water tap.

Does the boiler light?

DHW

No No

Yes

Is the power switched on?

Consult the Fault Table

Successful ignition

Yes

13411

Switch the power on

Check wires between

main PCB and display

PCB

Yes

Does the display flash 'F'

during or after a DHW

demand?

Consult the State List

Diagram 14.3

14 Fault Finding

Fault Codes

13412

Diagram 14.4

14 Fault Finding

Fault Codes (continued)

13447

Diagram 14.4a

14 Fault Finding

Diagnostic Menu - Level 1 Installer Access

Description Range

Domestic hot water flow temperature reading

Tank temperature

Heating temperature setpoint

Domestic hot water setpoint Tank setpoint

control

Domestic hot water demand

d.24 System water pressure in bar.

d.27 Option Relay 1 Reserved for future use

d.28 Option Relay 2 Reserved for future use

intelligent

13737

> 80 no flame < 40 good flame

Outside temperature

Minutes Ignitions / 100

Ignitions / 100

d.91 Internal Programmer type 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)

d.99 State List (see table opposite)

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

Diagram 14.5

14 Fault Finding

14.4 Status Codes

The status codes provide information about the current operating condition of the boiler and can be accessed through the diagnostic display, refer to diagram 14.6.

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

STATE LISTS

Central heating mode Description

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

Tank Loading

S.20 domestic hot water cycling mode active S.21 fan pre-run S.22 Pump pre run

S.23 ignition S.24 burner on S.25 pump / fan overrun S.26 fan overrun S.27 pump overrun S.28 Anticycling period

NORMAL OPERATING STATE FOR CH

NORMAL OPERATING STATE FOR TANK LOADING

13605

Special cases of status messages

S.30 No Heating demand from external controls 230V Check wiring in external controller.

Check wiring at Installer Interface.

S.31 summer mode Check CH setpoint / Check external controls S.32 Antifreeze active – fan speed variation too high Check fan connection. – waiting during blocking function S.34 frost protection active (Priority 4) Temperature below 8 connection if this is not true. S.36 No Heating demand from external controls 24V Check wiring in external controller.

Check wiring at Installer Interface.

S.42 Accesory Module is blocking burner operation Check accessory module. S.53 waiting time: temperature difference flow

- return sensor too high (Check thermistor fit)

S.54 waiting time: no water in system, temperature (gradient error) rise flow / return sensor too high

S.76 Waiting period – pressure sensor Check system pressure - default display. S.96 Return-Sensor check is running, demand Check return thermistor connection to pipe. (DHW or heating) is blocked Check harness connection to thermistor. S.97 Water pressure sensor check is running, Check connection to pressure sensor. demand (DHW or heating) is blocked Check pump has not seized. S.98 Flow / Return - sensor check is running, demand (DHW or heating) is blocked

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

C - check thermistor

Diagram 14.6

15 Replacement of Parts

BRACKET

15.1 General

Replacement of parts must be carried out by a competent person approved at the time by the Health and Safety

Executive.

IMPORTANT:

in sections 15.7 to 15.12 and section 15.14 will require the removal of the burner module assembly and the replacement of seal and self locking nuts.

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

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 gas service isolation valve on the boiler, see diagram 12.1.

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

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

For replacement of parts the front casing panels will need to be removed.

The tank module front panel will need to be removed rst 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 13.2.

For ease of servicing, the control box and domestic expansion vessel can be moved into their service positions, this will improve access to hydraulic components, see diagrams 13.4 to 13.6.

The following replacement of parts described

Draining of Boiler Heating Circuit

To drain the boiler heating circuit, isolate the ow and return valves, see diagram 12.1.

Open the top tap on the lling loop to drain the boiler out through the lling loop hose.

After servicing or replacing parts open the heating ow and return isolating valves and rell, vent and pressurise the heating circuit, refer to section 12.3.

Close the drain valve and disconnect the hose.

Check for leaks.

Draining of Boiler Domestic Water Circuit

Drain the domestic water circuit by closing the cold-water 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 remove the expansion vessel slide forward out of its hanging bracket.

Remove the exible hose from the expansion vessel by undoing the union nut and lock nut, see diagram 15.1.

Fit a new rubber seal in union nut on exible hose.

Fit the replacement unit.

Rell, vent and pressurise the boiler.

Check for leaks.

15.3 Silencer assembly

For access, refer to section 15.1.

To aid access to the silencer and securing screw, slacken 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 t so no tools or xings are required for its removal or tting, see diagram 13.7.

13330

FLEXIBLE HOSE

UNION NUT

LOCK NUT

DOMESTIC EXPANSION VESSEL

Diagram 15.1

13341

SECURING

SCREW

(2 OFF)

ELECTRICAL CONNECTION

IGNITER

UNIT

BRACKET

IGNITION LEAD

Diagram 15.2

SPARK GAP

15 Replacement of Parts

SCREWS

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, gasket and two securing screws. Withdraw the spark electrode carefully from the combustion chamber, see diagram 15.3.

Fit new gasket when replacing.

ELECTRODE

SECURING SCREW (2 OFF)

GASKET

EARTH LEAD

FAN

13273

4mm

Diagram 15.3

13404

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 13.4 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 re-assembling.

Remove the two screws that secure the gas valve to the fan, see diagram 15.4.

Remove the gas valve.

Fit new gasket when replacing.

After re-tting 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”.

and adjust if

15.8 Fan

For access, refer to section 15.1.

Refer to section 13.4 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 replacing.

GASKET

GAS CONTROL VALVE

SECURING

Diagram 15.4

15 Replacement of Parts

GLASS

REAR

15.9 Burner

For access, refer to section 15.1.

Refer to section 13.4 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 13.4 for removal of the fan, gas valve and burner assembly.

Remove spark electrode, see section 15.6.

Remove burner as described in the appropriate section of

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 13.4 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.

WASHER

SECURING SCREW

HEAT EXCHANGER

13407

INSULATION

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 bre washer.

FIBRE WASHER

CIRCLIP

STEEL WASHER

Diagram 15.6

15 Replacement of Parts

SILENCER

SECURING

EXPANSION VESSEL CLAMP

CH PUMP

SCREW (2 OFF)

CH PUMP

FLEXIBLE HOSE CONNECTION

13354

BRACKET

IGNITION LEAD

IGNITER UNIT

CLAMP

SECURING SCREW (2 OFF)

HEAT EXCHANGER

EARTH LEAD

13351

NUT (4 OFF)

SECURING SCREW (2 OFF)

CLAMP

Diagram 15.8

Top view of CH pump

PRIMARY EXPANSION VESSEL

RETAINING CLIP

FLEXIBLE HOSE CONNECTION

RETAINING BRACKET

Diagram 15.7

15.13 Heating Expansion Vessel

For access, refer to section 15.1.

Drain the boiler heating circuit, refer to section 15.1.

Remove the retaining clip from the exible hose at the central heating pump, see diagram 15.7.

Remove the exible hose from the pump, ensure the ‘O’ ring on the connection is seated correctly before re-tting.

Remove the expansion vessel clamp, see diagram 15.7.

Slide the expansion vessel forward and out from the retaining bracket.

Remove the exible hose union nut from the expansion vessel. When re-tting ensure that a new sealing washer is tted and that the elbow of the exible connection faces towards the front of the appliance.

15.14 Heat Exchanger

Refer to Manual Handling Operations, 1992.

For access, refer to section 15.1.

Drain the boiler heating circuit, see section 15.1.

Drain the boiler domestic water circuit, see section 15.1.

Disconnect the ue connection, refer to section 10.

Remove the silencer, refer to section 13.2.

Remove the igniter unit electrical connections, refer to diagram 15.2.

Refer to section 13.4 for removal of the fan, gas valve and burner assembly.

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

HEAT EXCHANGER

CONNECTION (push-fit)

Remove the two connection clips securing the ow 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 t condense pipe from the bottom of the heat exchanger, see diagram 15.10.

Carefully remove the heat exchanger and disconnect the ue overheat thermostat, see diagram 13.11.

CONNECTION

CLIPS

HEATING

FLOW

HEATING

RETURN

Diagram 15.9

13327

13444

13342

HEAT EXCHANGER CONDENSATE

Diagram 15.10

Diagram 15.11

15 Replacement of Parts

CONNECTION

TOP PUMP CONNECTOR

15.15 Central Heating Pump

For access, refer to section 15.1.

Drain the boiler heating circuit, see section 15.1.

Unscrew the union nut of the return pipe to the pump connection, see diagram 15.11.

Unscrew the union nut from the safety discharge valve.

Remove the exible connection from the CH pump, see diagram 15.7.

Disconnect the electrical connections inside the control box to the main PCB, see diagram 15.11.

Remove the securing screw from the pump retaining bracket and ease off the bracket from the spigot on the rear of the pump.

Remove the pump retaining clip.

The pump can now be pulled sidewards away from its three way valve connection.

When re-tting, ensure that all seals are in place.

Always vent the pump after re-tting.

15.16 Three Way Valve

For access, refer to section 15.1.

Remove the CH pump, refer to section 15.15.

Refer to diagram 15.12.

Remove the electrical plug.

Undo the CH inlet connection at the union nut between the boiler module and the tank module, remove the connector locknut.

Remove the retaining clip.

Remove the three securing screws.

Carefully remove the three way valve assembly.

15.17 Domestic Pump

For access, refer to section 15.1.

Drain the boiler domestic 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 from the main PCB, see diagram 15.13.

Unscrew the union nut at the pump top connector to the DHW pipe.

Unscrew the pipe union nut from the bottom pump connection, see diagram 15.13.

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-tting 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-tting any part, ensure that all seals and clips are in place.

Always vent the pump after re-tting.

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.

UNION NUT

ELECTRICAL

CONNECTION

13336

ELECTRICAL PLUG

3 WAY VALVE

CH INLET

SECURING SCREW (3 OFF)

RETAINING CLIP

CH PUMP

Diagram 15.12

13410

BOTTOM PUMP CONNECTOR

DOMESTIC PUMP

SECURING CLIP

UNION NUT

Diagram 15.13

HEAT EXCHANGER

15 Replacement of Parts

15.18 Safety Discharge Valve

For access, refer to section 15.1.

Refer to section 15.1 and drain the boiler heating circuit.

The safety discharge valve is situated towards the RH side of the boiler module, refer to diagram 15.14.

Unscrew the pipework union nut from the safety discharge valve.

Remove the securing clip and withdraw the safety discharge valve.

Fit new ‘O’ ring.

15.19 Domestic 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 15.15.

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 controls.

13442

LOW WATER

PRESSURE

SENSOR

DOMESTIC

WATER

THERMISTOR

Diagram 15.15

13328

15.20 Heating Flow Thermistor

For access, refer to section 15.1.

The primary ow thermistor is situated underneath the heat exchanger, refer to diagram 15.16.

Remove the electrical connections from the thermistor.

Remove the thermistor noting its position on the ow pipe.

NOTE: When reconnecting, the polarity of the wiring to thermistors is not important.

SECURING

CLIP

UNION

NUT

SAFETY

DISCHARGE

VALVE

Diagram 15.14

HEATING

FLOW

THERMISTOR

13252

Diagram 15.16

15.21 Heating Return Thermistor

For access, refer to section 15.1.

Refer to diagram 15.17.

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.

15.22 Automatic Air Vent

For access, refer to section 15.1.

Refer to section 15.1 and drain the boiler heating circuit.

Refer to diagram 15.18.

Remove the retaining clip to release the automatic air vent.

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

15 Replacement of Parts

AUTOMATIC

FAN

PLATE TO PLATE

15.23 Water Pressure Sensor

For access, refer to section 15.1.

Refer to section 15.1 and drain the boiler heating circuit.

Refer to diagram 15.19.

Disconnect the electrical lead and withdraw the lead plug.

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

Fit new ‘O’ ring.

15.24 Plate-to-Plate Heat Exchanger

For access, refer to section 15.1.

Refer to section 15.1 to drain the boiler heating circuit.

Refer to section 15.1 and drain the boiler domestic water circuit.

Refer to diagram 15.20.

Remove the four screws securing the plate-to-plate heat exchanger to the hydroblock.

There will still be water present so carefully pull the plate-toplate heat exchanger upwards to remove.

When replacing the plate-to-plate heat exchanger ensure that the four rubber seals are tted into the hydroblock.

NOTE: The plate-to-plate heat exchanger only ts one way.

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.

Open the heating circuit isolation valves, re-pressurise the system as necessary.

LOW WATER

PRESSURE

SENSOR

RETAINING

CLIP

13304

AIR VENT

RETAINING

CLIP

Diagram 15.18

13315

ELECTRICAL

LEADS

HEATING RETURN

THERMISTOR

Diagram 15.17

13310

HYDROBLOCK

SECURING SCREWS (4)

Diagram 15.19

13348

HEAT EXCHANGER

Diagram 15.20

15 Replacement of Parts

SPIGOT (4 OFF)

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 heating circuit and the boiler domestic water circuit.

Isolate the gas supply at the gas service isolation valve, see diagram 12.1.

Remove the silencer, refer to section 15.3.

Remove the plate to plate heat exchanger, refer to section

15.24.

Remove the low water pressure sensor from the LH hydroblock, refer to section 15.23.

Remove clips from the plastic LH and RH hydroblocks retaining the DHW, DCW and primary ow pipes, see diagram

15.21.

Remove the heating ow pipe from the LH hydroblock.

Remove the CH lter from the heating ow pipe port in the LH hydroblock. The lter is a push-t in the hydroblock port.

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

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

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

Remove the 3 screws which retain the three way valve, refer to section 15.16.

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

NOTE: Before removing the bypass tube from the hydroblocks, take note of the tube position and orientation.

Fit the new bypass tube with new ‘O’ ring seals and reassemble to hydroblocks.

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

Lower the assembly onto the bracket ensuring that the brass washers on the DHW and DCW pipes are not displaced. Check also that the seals on the front of the RH hydroblock remain in place as it slides past the three way valve body. Before retting the plate to plate heat exchanger ensure that the four rubber seals are in place, two in the LH and two in the RH hydroblock.

Fit new ‘O’ rings to pipes.

HEATING FLOW PIPE

LH HYDROBLOCK

RETAINING CLIP

CH FILTER

(in Hydroblock)

RH HYDROBLOCK

MOUNTING BRACKET

PLATE TO PLATE RUBBER SEAL (4 OFF)

BYPASS TUBE

CH OUTLET

PIPE

13409

3 WAY VALVE SEALS

DHW PIPE

DCW PIPE

Diagram 15.21

15 Replacement of Parts

TANK

BOILER / TANK MODULE

GRUB SCREW

6 bar SAFETY

15.26 Filling Loop

For access, refer to section 15.1.

Refer to section 15.1 and drain the boiler domestic water circuit.

Refer to diagram 12.3.

Undo the union nuts on the lling loop valve and the double check inlet valve to remove the lling loop.

Fit new ‘O’ rings.

After replacing the lling 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: To comply with the water regulations the exible hose must be disconnected from the double check inlet valve - undo the nut and pull the exible hose from the valve.

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 15.22.

Remove the retaining clip to remove the bypass valve.

Fit new ‘O’ rings.

Replace the bypass valve, rell, vent and pressurise the boiler.

Adjust the bypass as described in commissioning, see section

12.8.

13234

Diagram 15.22

13345

RELIEF VALVE

15.28 Pressure Reducing Valve

For access, refer to section 15.1.

Refer to diagram 15.23.

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 remove the reduced pressure zone valve.

Fit new ‘O’ rings.

15.29 Safety Relief Valve

For access, refer to section 15.1.

Refer to diagram 15.23.

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 15.24.

Undo the union nut on the right hand side of the valve and disconnect pipe, unscrew the valve body to remove.

Apply the sealant supplied before replacing the relief valve.

SAFETY RELIEF VALVE PIPE

3.5 bar PRESSURE REDUCING VALVE

CONNECTIONS

UNION NUTS

TEMPERATURE AND PRESSURE RELIEF VALVE

Diagram 15.23

13334

UNION NUT

CYLINDER

Diagram 15.24

15 Replacement of Parts

15.31 Immersion Heater

For access, refer to section 15.1.

Refer to section 5.3 and drain the hot water storage tank.

Remove the exible condensate hose from the condensate trap and siphonic drain, see diagram 13.14.

Isolate any electrical connections to the immersion heater.

Unscrew the large locknut holding the immersion heater in place on the hot water tank, see diagram 15.25.

Remove immersion heater and gasket.

When replacing the immersion heater a new gasket is also supplied.

15.32 Condense Trap & Siphonic Drain

For access, refer to section 15.1.

Remove the exible condensate hose by pulling out of condense trap and siphonic drain, see diagram 13.14.

Refer to diagram 15.26.

Remove the securing screw holding the trap/drain.

Remove the oat to clean it. When replacing, ensure that the oat is inserted correctly as shown in diagram 15.26.

Flush water through the trap/drain to remove any remaining solids.

Check for any debris in the outlet pipe of the condense trap and siphonic drain and clean as necessary.

Reassemble and ret.

IMMERSION HEATER

SECURING SCREW

13333

Diagram 15.25

13332

FLOAT

CONDENSE TRAP & SIPHONIC DRAIN

Diagram 15.26

15 Replacement of Parts

RETAINING

APPLIANCE

15.33 Access to Control Box Internals

For access, refer to section 15.1.

Carefully pull the control box forwards so that it lies horizontally in its hinges.

Do not allow the front of the control box to swing down and be loosely held by its electrical connections.

Release the four retaining clips, see diagram 15.27, to remove the rear cover and gain access to the electrical connections, main PCB and appliance interface PCB.

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 15.28.

When retting 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 15.28.

FUSE

RETAINING

CLIPS

CONTROL

BOX

CLIP (4 OFF)

13446

Diagram 15.27

13372

MAIN PCB

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 15.29.

Withdraw the board.

When replacing the board refer to instructions supplied with replacement PCB.

15.37 Boiler Module Front Casing Panel Seal

Remove the seal and thoroughly clean the casing surface before tting the new seal, see diagram 13.15.

Ret the casing panel.

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

RETAINING LUG (2 OFF)

RETAINING CLIPS

ELECTRICAL CONNECTION

INTERFACE PCB

ELECTRICAL CONNECTION

Diagram 15.28

13355

Diagram 15.29

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 0020038232 Plate to Plate Heat Exchanger H52-547 2 0020020763 Igniter Unit H42-773 3 0020014160 DHW Thermistor H36-325 4 2000801840 Burner E88-867 5 0020014161 Automatic Air Vent H42-754 6 0020018812 Burner Door Seal Kit H49-385 7 0020020781 Flow/Return Thermistor H42-792 8 0020014171 Central Heating Pump H42-760 9 0020014173 Safety Discharge Valve H42-758 11 0020037668 Main PCB H52-597 12 0020038183 Primary Expansion Vessel H52-505 13 0020038257 Domestic Expansion Vessel H52-591 14 0020038167 Temperature & Pressure Relief Valve H52-529 15 0020038209 NTC H52-540 16 0020038275 Water Pressure Switch H52-545 17 0020038166 Immersion Heater H52-507 18 0020038182 6 bar Safety Relief Valve H52-532 19 0020038071 Gas Valve H52-565 20 0020038069 Fan H52-563 21 0020038061 Appliance Interface H52-596 22 0020018810 Electrode H49-383 23 0020038245 Domestic Pump H52-554 24 0020038175 Bypass H52-492

16 Spare Parts

13325

Diagram 16.1

17 Declaration of Conformity

Notes

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

0020048525-04 09.09

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

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Glow-worm Ultrapower sxi Range User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual