Glow-worm ultrapower 100SXI Installation And Servicing Manual
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Glow-worm ultrapower 100SXI Installation And Servicing Manual

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Ultrapower sxi

Installation and Servicing

100sxi
G.C. No. 41-019-09
170sxi
G.C. No. 41-019-10
High Efficiency
System Store
Supplied By www.heating spares.co Tel. 0161 620 6677
www.glow-worm.co.uk

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  • Page 1: Installation And Servicing

    Ultrapower sxi Installation and Servicing 100sxi G.C. No. 41-019-09 170sxi G.C. No. 41-019-10 High Efficiency System Store www.glow-worm.co.uk Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 2: Guarantee Registration

    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.

  • Page 3: Table Of Contents

    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.

  • Page 4: Warnings

    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.

  • Page 5: Gas Supply

    British Standard Code of Practice. In IE, the installation must be carried out by a competent Any alteration not approved by Glow-worm, could invalidate person approved at the time by the Health and Safety the certification, boiler warranty and may also infringe the...

  • Page 6: Boiler Design

    Should there be any discharge from the pipes, isolate the conditions this may be due to the forming of ice in the boiler electrical supply and call your installer or Glow-worm’s condense drain external to the house. Release an ice...

  • Page 7: Boiler Specifications

    1 Boiler Specifications Data The data label is positioned inside the boiler module on the All dimensions are given in millimetres (except as noted). base. See diagram 1.1 and the Boiler Specification Table below. Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 8 1 Boiler Specifications Diagram 1.1 Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 9 1 Boiler Specifications Diagram 1.2 Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 10: Boiler Location, Clearances & Ventilation

    If the boiler is to be installed in a timber frame building it should be fitted in accordance with the Institute of Gas Engineers document IGE/UP/7/1998. If in doubt seek advice from local gas undertaking or Glow-worm. 2.4 Room Ventilation The boiler is room sealed so a permanent air vent is not required.

  • Page 11: Flue Options And Terminal Clearances

    3 Flue Options and Terminal Clearances 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 flue terminal positioning must be those detailed in I.S.813 “Domestic Gas Installations”.
  • Page 12 3 Flue Options and Terminal Clearances Ridge Tile Terminal Part No. A2043800 - Section 10, page 32 Top horizontal telescopic flue Ø60/100 Top horizontal standard flue Ø60/100 - page 23 Part No. A2043600 - page 27 Part No. A2043400 Vertical Flue - page 31 Vertical Flue Adapter, concentric flue Ø60/100 Part.

  • Page 13: Heating System

    4 Heating System General 4.7 ‘Hard’ Water Areas The boiler is for use only with sealed central heating systems. The temperatures within the heat exchanger are limited by the boiler control system to minimise scale formation within The digital readout on the controls fascia indicates the system the hot water pipework.

  • Page 14: Domestic Hot Water

    4 Heating System automatic bypass - closed automatic bypass - factory setting automatic bypass - open pump speed 1 pump speed 2 1000 1200 1400 1600 1800 Volumeflow (Litres/hr) Diagram 4.2 5 Domestic Hot Water General 5.4 Safety Valves All domestic hot water circuits, connections, fittings must be The safety valves are factory fitted and are an integral part of in accordance with the relevant standards and water supply this boiler and they must not be adjusted or used for any other...
  • Page 15 5 Domestic Hot Water NOTE: The tundishes are factory fitted during manufacture. 5.5 SYSTEM REQUIREMENTS – Domestic Hot The discharge pipe (D2) from the tundish should terminate in Water a safe place where there is no risk to persons in the vicinity of the discharge, preferably be of metal and: Domestic Hot Water Requirements a) Be at least one pipe size larger than the nominal outlet...

  • Page 16: Condensate Drain

    5 Domestic Hot Water NOTE: The discharge will consist of scalding water and steam. Asphalt, roofing felt and non-metallic rain water goods TABLE 1 may be damaged by such discharges. Valve outlet Worked example of discharge pipe sizing G 1/2 size The example given in diagram 5.2 is for a G1/2 temperature relief valve with a discharge pipe (D2) having 4 No.
  • Page 17 6 Condensate Drain INTERNAL SOIL BOILER BOILER EXTERNAL SOIL AND VENT STACK AND VENT STACK EXTERNAL MAX. 3M DIA. 22mm MIN. DIA. 22mm MIN. NO RESTRICTION NO RESTRICTION ON LENGTH ON LENGTH Internal Soil and Vent Pipe External Soil and Vent Pipe or Rainwater Pipe BOILER BOILER SINK...

  • Page 18: Installation Preparation

    7 Installation Preparation PLUMBING JIG TANK / BOILER MODULE CONNECTION WASHERS Retaining screws TANK / JIG stored in cartridge CONNECTION WASHERS LOOSE ITEMS PACK Installation booklet (not illustrated) 1 OFF User Instructions (not illustrated) 1 OFF Condensate Connection Pipe 1 OFF 22mm Copper Tails 4 OFF 15mm Copper Tail...

  • Page 19: Site Requirements

    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 floor, however slight adjustment can be made using the adjustable feet at the base of the tank module.

  • Page 20: Gas, Water & Boiler Connection

    8 Gas, Water & Boiler Connection 8.1 Systems Connection IMPORTANT: With regards to the Health and Safety Manual Handling requirements, two persons shall be required The water and gas isolation valve connections are on the jig. to lift the appliance. It should be noted that the appliance is The condense drain and safety discharges connections are made up of two modules each module requiring two persons not on the jig but their pipe runs are shown on the template.
  • Page 21 8 Gas, Water & Boiler Connection 8.3 Boiler Module Connection BOILER MODULE FRONT PANEL 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.

  • Page 22: Condensate & Safety Discharge Valve Connections

    9 Condensate & Safety Discharge Valve Connections 9.1 Safety Discharge Valve 9.2 Condensate Drain Connection The pipes must be extended, using not less than 22mm o.d. A flexible condensate hose runs from a push-fit connection at pipe, to discharge, in a visible position, outside the building, the bottom of the heat exchanger and terminates on the boiler facing downwards, preferably over a drain.
  • Page 23 10 Telescopic Flue - Length, Preparation and Installation 10.1 Flue Length When extension pipes are used the flue system must be designed to have a continuous fall to the boiler of at least 2.5 The maximum achievable rear and side flue length for a 44mm/metre to allow condensate to run back into the boiler telescopic flue, diagram 10.2, is as shown in diagram 10.1.
  • Page 24 10 Telescopic Flue - Length, Preparation and Installation A2043600 Top Outlet Horizontal telescopic flue pack FLUE ELBOW SECURING SCREW x 4 COLLAR SEALING SCREW x 2 TAPE (telescopic only) SCREW x 2 GASKET (fitted) TRIM RING SCREW x 1 TELESCOPIC TERMINAL ASSEMBLY SEALING Diagram 10.2...
  • Page 25 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 flue can be used without extensions. With the flue elbow temporarily fitted, measure the distance from the outside wall to the butt joint, see diagram 10.4.
  • Page 26 10 Telescopic Flue - Length, Preparation and Installation 10.5 Flue Fitting IMPORTANT:- The flue 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 flue system, ensure that debris such as mortar, filings or swarf are cleared from the flue system before completion.
  • Page 27 10 Standard Flue - Length, Preparation and Installation 10.6 Flue Length When extension pipes are used the flue system must be designed to have a continuous fall to the boiler of at least 2.5 o The maximum achievable rear and side flue length for a 44mm/metre to allow condensate to run back into the boiler standard flue, diagram 10.12, is as shown in diagram 10.11.
  • Page 28 10 Standard Flue - Length, Preparation and Installation Diagram 10.12 Diagram 10.13 Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 29 10 Standard Flue - Length, Preparation and Installation 10.7 Standard Horizontal Flue Refer to diagram 10.12 for kit contents. 10.8 REAR Flue With the flue elbow temporarily fitted, measure the distance from the outside wall to the butt joint, see diagram 10.14.
  • Page 30 10 Standard Flue - Length, Preparation and Installation Push the flue assembly into the wall, externally or internally, initially until the end of the assembly protrudes a short way from the inside face of the wall. This will enable the internal trim ring (if required) to be positioned and allow the flue assembly to be drawn back into the flue elbow.
  • Page 31 10 Vertical Flue - Length, Preparation and Installation 10.11 Vertical flue NOTE: 2x45º bends can replace 1x87.5º bend if necessary. When using 87.5º bends any horizontal extension pipe should The vertical flue system is available as an option where be inclined by a minimum of 44mm/metre (2.5°) towards the the boiler position does not permit the use of the top outlet boiler to facilitate condense removal, see (a) in diagram 10.19.

  • Page 32: Flue Terminal Installation

    10 Vertical - Flue Length, Preparation and Installation Long lengths of flues must be secured to the walls or ceilings they run against. Use at least one fixing bracket for every flue extension that is used. After cutting inner flue tubes ensure that you de-burr and chamfer the male tube end to prevent damage.
  • Page 33 10 Vertical Flue - Length, Preparation and Installation Completion of Installation Carefully push the terminal assembly upwards to allow room for fitting the final flue piece. Fit a fixing bracket to the terminal With the flue terminal positioned in the roof the length of the assembly.
  • Page 34 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 WALL SEAL Diagram 10.26 Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 35: Terminal Position

    10 Twin Flue - Length, Preparation and Installation 10.12 Twin flue The twin flue system is available as an option when the top outlet horizontal concentric rear or vertical flue system is not appropriate, see diagram 10.26. The system is made up of accessories. The accessories include terminal assembly, bends 45º...
  • Page 36 10 Twin Flue - Length, Preparation and Installation Do not stress the flue connections during the installation this can damage the flue seals. Horizontal Terminal Installation NOTE: The air inlet terminal and the flue outlet terminals must never be installed on the opposite sides of a property. Termination must only be on the same wall or adjacent walls.

  • Page 37: Electrical Connection

    2 x 45 bends the maximum length of the Plume Management Kit must be reduced by 1m. For more information contact Glow-worm, refer to page 2. The Plume Management Kit is supplied with installation instructions. Refer to BS5546 or BS6798 for advice on disposal of boiler condensate.
  • Page 38 11 Electrical Connection 11.1 Electrical Connection ELECTRICAL Take the previously laid electrical cable and route along the CARTRIDGE 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.
  • Page 39 11 Electrical Connection 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 fitted in accordance with the rules in force.

  • Page 40: Commissioning

    12 Commissioning Diagram 12.1 IMPORTANT: At the time of commissioning, complete all relevant sections of the Benchmark Checklist located in the DOMESTIC centre pages of this document. PUMP VENT 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.

  • Page 41: Initial Lighting

    QUICK DOUBLE As an option, a chargeable boiler only commissioning service RELEASE CHECK can be provided by Glow-worm Service by calling telephone No. 01773 828100. INLET VALVE Light the appliance by following the procedure below: Refer to diagram 12.4 and repeatedly press the “MODE”...

  • Page 42: Water Systems

    12 Commissioning 12.5 Re-pressurising System (if required) 12.7 Range Rating 1. Ensure that the filling loop flexible hose is securely The boilers are fully modulating for central heating, and it is connected to the double check inlet valve, see diagram therefore not necessary to range rate the boiler.

  • Page 43: Instruct The User

    12 Commissioning ● Advise the User if the mains electricity and gas are to be turned off for any long periods during severe weather, it is AUTOMATIC recommended that the whole system, including the boiler, AUTOMATIC BYPASS should be drained to avoid the risk of freezing. AIR VENT Note: Sealed System: Contact your installation/servicing company as draining, refilling and pressurising MUST be...

  • Page 44: Servicing

    When replacing a part on this appliance, use only spare parts that you can be assured conform to the safety and performance specification that we require. Do not use reconditioned or copy parts that have not been clearly authorised by Glow-worm. If 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.
  • Page 45 CONTROL BOX appliance must be disconnected until the CO/CO2 ratio is acceptable. Advice can be sought from the Glow-worm Technical Helpline. 13.1 Servicing NOTE: If the Combustion CO2, CO/CO2 ratio and Gas rate...
  • Page 46 13 Servicing 13.2 Silencer For access to the heat exchanger the silencer will need to be removed, see diagram 13.7. SILENCER Remove the securing screw and pull the silencer from the gas valve, this is a push fit. SECURING SCREW HEAT EXCHANGER Diagram 13.7...

  • Page 47: Heat Exchanger

    13 Servicing 13.4 Burner SILENCER HEAT BRACKET NOTE: EXCHANGER ● 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 IGNITION diagram 13.6.
  • Page 48 13 Servicing BURNER FRONT INSULATION BURNER DOOR FLEXIBLE SECURING CONDENSATE GASKET SCREW (4) HOSE SPARK ELECTRODE Turn anti-clockwise GAS VALVE to remove AND FAN Diagram 13.12 13.6 Condense Trap and Siphonic Drain SERVICE The condensate trap & siphonic drain does not normally need FILL LEVEL servicing unless material deposits exceed beyond the service fill level, see diagram 13.14.

  • Page 49: Fault Finding

    14 Fault Finding 14.1 Preliminary fault finding Indicates fault memory The following checks should be performed before proceeding position onto specific diagnostics: • Check the external electrical supply to the boiler is on and a supply of 230V is present at the ‘L’ and ‘N’ terminals at Fault code the installer interface.
  • Page 50 14 Fault Finding BROWN BLUE GREEN/YELLOW GREY GREEN BLACK YELLOW WHITE ORANGE PURPLE PINK bk bk br g/y Diagram 14.2 Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 51: Central Heating

    14 Fault Finding CENTRAL HEATING START Is there anything displayed Is the power switched on? Switch the power on Check wires between main PCB and display Is the display flashing 'F'? Consult the Fault Table Initiate a DHW demand. Does the display flash 'F' Successful ignition during or after a DHW demand?
  • Page 52 14 Fault Finding Fault Codes Diagram 14.4 Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 53 14 Fault Finding Fault Codes (continued) Diagram 14.4a Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 54 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 intelligent control Domestic hot water demand d.24 System water pressure in bar. d.27 Option Relay 1 Reserved for future use...

  • Page 55: Status Codes

    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...

  • Page 56: Replacement Of Parts

    15 Replacement of Parts 15.1 General 15.3 Silencer assembly Replacement of parts must be carried out by a competent For access, refer to section 15.1. person approved at the time by the Health and Safety To aid access to the silencer and securing screw, slacken Executive.
  • Page 57 15 Replacement of Parts 15.4 Ignition Lead SPARK GAP For access, refer to section 15.1. GASKET 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.
  • Page 58 15 Replacement of Parts 15.9 Burner REAR For access, refer to section 15.1. INSULATION WASHER Refer to section 13.4 for removal of the fan, gas valve and burner assembly. SECURING Remove the four screws that secure the burner, see diagram SCREW 13.12.
  • Page 59 15 Replacement of Parts SECURING SECURING SILENCER HEAT SCREW (2 OFF) NUT (4 OFF) BRACKET EXCHANGER SECURING SCREW IGNITION (2 OFF) LEAD IGNITER UNIT EXPANSION VESSEL CLAMP CLAMP CLAMP EARTH LEAD CH PUMP CH PUMP SECURING SCREW (2 OFF) FLEXIBLE HOSE CONNECTION Diagram 15.8 15.13 Heating Expansion Vessel...
  • Page 60 15 Replacement of Parts Remove the two connection clips securing the flow and return pipes to the heat exchanger, see diagram 15.9. Move the pipes away from the heat exchanger. Remove the four heat exchanger securing screws and clamps, see diagram 15.8. CAUTION: There will be water in the heat exchanger.

  • Page 61: Central Heating Pump

    15 Replacement of Parts 15.15 Central Heating Pump 15.17 Domestic Pump For access, refer to section 15.1. 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. Unscrew the union nut of the return pipe to the pump Remove the domestic expansion vessel and place in its connection, see diagram 15.11.
  • Page 62 15 Replacement of Parts 15.18 Safety Discharge Valve For access, refer to section 15.1. LOW WATER Refer to section 15.1 and drain the boiler heating circuit. PRESSURE The safety discharge valve is situated towards the RH side of SENSOR the boiler module, refer to diagram 15.14. Unscrew the pipework union nut from the safety discharge valve.
  • Page 63 15 Replacement of Parts 15.23 Water Pressure Sensor AUTOMATIC AIR VENT For access, refer to section 15.1. Refer to section 15.1 and drain the boiler heating circuit. RETAINING Refer to diagram 15.19. CLIP Disconnect the electrical lead and withdraw the lead plug. Remove the retaining clip to remove the low water pressure sensor.
  • Page 64 15 Replacement of Parts 15.25 Hydroblock and Bypass Tube Grip the LH and RH hydroblocks simultaneously and lift clear of the spigots on the mounting bracket. The RH hydroblock For access, refer to section 15.1. should be drawn upwards past the plastic three way valve IMPORTANT: To replace the bypass tube the LH and RH body.

  • Page 65: Filling Loop

    15 Replacement of Parts 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 filling loop valve and the double check inlet valve to remove the filling loop.
  • Page 66 15 Replacement of Parts 15.31 Immersion Heater IMMERSION For access, refer to section 15.1. HEATER Refer to section 5.3 and drain the hot water storage tank. Remove the flexible condensate hose from the condensate trap and siphonic drain, see diagram 13.14. Isolate any electrical connections to the immersion heater.
  • Page 67 15 Replacement of Parts 15.33 Access to Control Box Internals For access, refer to section 15.1. RETAINING CLIPS 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.

  • Page 68: 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.
  • Page 69 16 Spare Parts Diagram 16.1 Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 70: Declaration Of Conformity

    17 Declaration of Conformity Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 71 Notes Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 72 Because of our constant endeavour for improvement, details may vary slightly from those shown in these instructions. Glow-worm, Nottingham Road, Belper, Derbyshire. DE56 1JT www.high-efficiency.info Supplied By www.heating spares.co Tel. 0161 620 6677...

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