Glow-worm Ultrapower sxi Range User Manual

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

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