Glow-worm Xtramax HE Installation And Servicing Instructions
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- Installation and servicing (48 pages) ,
- Instructions for use manual (12 pages) ,
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Summary of Contents for Glow-worm Xtramax HE
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Page 1: Installation And Servicing
02******A.05.05 INSTALLATION AND SERVICING Xtramax HE G.C. No. 47-047-29 High Efficiency Condensing Combination Boiler Glow-worm, Nottingham Road, Belper, Derbyshire. DE56 1JT www.glow-worm.co.uk www.high-efficiency.info Supplied By www.heating spares.co Tel. 0161 620 6677... -
Page 2: Heating
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. -
Page 3: Table Of Contents
The instructions consist of two parts, Installation and Servicing Instructions. 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: Important Information
I.E.E. wiring regulations. without permission, in writing, by Glow-worm. External wiring must be correctly earthed, polarised and in Any alteration not approved by Glow-worm, could invalidate the accordance with the relevant standards. certification, boiler warranty and may also infringe the current In GB this is BS 6891. -
Page 5: Heating
Do not use the compartment or cupboard for storage. Glow-worm has specially designed different accessories for your appliance depending on your installation. Clearances If you want to have a detailed list, please contact your supplier If fixtures are positioned close to the boiler, space must be... -
Page 6: Appliance Safety Devices
Servicing/maintenance should be carried out by a competent person in accordance with the rules in force in the countries of destination. To obtain service, please call your installer or Glow-worm’s own service organisation using the telephone number on the inside front cover of this literature. -
Page 7: Technical Information
1 Technical Information 1.1 IMPORTANT NOTICE This boiler is for use only on G20 natural gas, but may be converted for use on G31 gas (propane L.P.G.). Where no British Standards exists, materials and equipment 3 0 1 should be fit for their purpose and of suitable quality and workmanship. -
Page 8: Boiler Type C13, C33, C53
1 Technical Information TABLE 1 Boiler type C13, C33, C53 Description Unit Xtramax HE Gas category ll2H3P Heating Heating output at 80°C/60°C (P) 7.6 - 28 Efficiency calculated on net calorific value at 80/60°C 95.8 - 97.8 Heating output at 50°C/30°C (P) 8.6 - 30.6... -
Page 9: Heating
Class CE number 1312 BP 4108 TABLE 2 Technical data depending on the gas type Unit Xtramax HE Natural gas G 20 (1) Sanitary flow rate at maximum input 3.62 Heating flow rate at maximum input 3.02 Flow rate at minimum input 0.68... -
Page 10: Heating
1 Technical Information SCHEMATIC DIARGRAM Supplied By www.heating spares.co Tel. 0161 620 6677... -
Page 11: Boiler Location And 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 the local gas undertaking or Glow-worm. 2.4 Room Ventilation The boiler is room sealed so a permanent air vent is not required. -
Page 12: Flue Location And Ventilation
L1 and L2, however, for every 90 or 45 elbows used the flue length MUST be reduced by 1 metre. 3.2 Flue Accessories Additional accessories are available. See Glow-worm “Flue Options Guide” for configurations available. Vertical concentric flue Diagram 3.2 1 8 8 Twin flue Diagram 3.3... -
Page 13: Heating
3 Flue Location and Ventilation 3.4 Terminal Position The minimum acceptable siting dimensions for the terminal from obstructions, other terminals and ventilation openings are shown in diagram 3.5. For Ireland the minimum distances for flue terminal positioning must be those detailed in I.S.813 “Domestic Gas Installations”. -
Page 14: Heating System
4 Heating System 4.1 General 4.5 Filling the Sealed System The boiler is for use only with sealed central heating systems. NOTE: The water pressure at the boiler must be at least 1.2bar to enable filling the boiler to a minimum pressure. The boiler is The safety valve is an integral part of the boiler and it cannot supplied with a filling device. -
Page 15: Heating
6 Installation Preparation 6.5 Appliance Connection 6.1 Appliance Pack Remove front panel, unscrew and remove the two retaining IMPORTANT: With regards to the Health and Safety Manual screws from the bottom of the front panel. Handling requirements, two persons shall be required to lift the appliance. -
Page 16: Gas/Water And Appliance Connection
7 Gas / Water & Appliance Connection 7.1 Gas Connection, refer to diagram 7.1 Flush out the domestic hot water and the heating systems before connecting to the boiler. Before connection check supply of local gas. Take care when soldering pipes as the heat could damage the Refer also to section 1.2. -
Page 17: Safety Discharge, Condensate And Tundish Connection
8 Safety Discharge, Condensate & Tundish Connections Domestic hot water safety valve Drain cock Filling loop extension knob Gasket Discharge valve for PRV (BLUE) on domestic hot water circuit Nut (x2) Gasket (x2) Gasket (x2) 10 Union coupling 12 Olive 15mm. 13 Tundish 14 Olive 22mm. -
Page 18: Heating
Any fault arising from incorrect wiring cannot be put right under hand bottom of the boiler (see chapter Block diagram). the terms of the Glow-worm guarantee. The tundish (supplied) must be used with this outlet within the All system components must be of an approved type. -
Page 19: Heating
8 Safety Discharge, Condensate & Tundish Connections Valve outlet size Minimum size of Minimum size of Maximum resistance allowed Resistance created discharge to tundish discharge pipe D2 from expressed as by each elbow tundish a length of straight pipe i.e. no or bend elbows or bends G 1/2”... -
Page 20: Heating
8 Safety Discharge, Condensate & Tundish Connections INTERNAL SOIL EXTERNAL SOIL AND VENT STACK AND VENT STACK BOILER BOILER EXTERNAL MAX. 3M MIN. DIA. 21MM MIN. DIA. 21MM NO RESTRICTION NO RESTRICTION ON LENGTH ON LENGTH Internal Soil and Vent Pipe External Soil and Vent Pipe or Rainwater Pipe BOILER SINK... -
Page 21: Electrical Connection
9 Electrical Connection 9.1 Mains Supply Cable IMPORTANT NOTE The appliance mains supply cable should be permanently connected to a cable anchorage. The cable anchorage shall ALL electrical connections to the boiler relieve conductors from strain, including twisting, at the terminals must be permanently fixed to a wall or a and protect the insulation of the conductors from abrasion. -
Page 22: Heating
9 Electrical Connection WIRING DIARGRAM 12 Main reset switch Overheat thermostat 13 Chassis earth 14 Fuse Gas valve 15 Three way valve Heating return thermistor 16 Ignition module Heating flow thermistor 17 DHW temperature sensor Water pressure sensor 18 Ignition and control electrode Water flow sensor DHW pump Heating pump... -
Page 23: Commissioning
NOTE: Steps 10.2 to 10.4 will need to be completed before the appliance can be converted. 10.2 Reactivation The Xtramax HE can be converted to run on LPG-Propane After setting and reassembly, restore the maximum heating power (G31). to its initial value (20 kW). -
Page 24: Heating
10 Commissioning The system pressure is displayed on the controls panel fascia of the appliance, see diagram 1 of the User Instructions. FLUE ELBOW Open the auto air vent on the pump as well as the automatic bleeders of the system. Open the blue filling loop valve situated under the boiler until you obtain a 2 bars pressure on the indicator. -
Page 25: Heating
Allow the system to reach maximum temperature then switch from Glow-worm should be used when repairing and servicing off the boiler by isolating from the electrical supply. the appliance. -
Page 26: Heating
10 Commissioning Bypass screw Diagram 10.2 PUMP SPEEDS Speed III By-pass fully shut Open 1/4 turn Open 1/2 turn Open 2 turns Speed II By-pass fully shut Open 1/4 turn Open 1/2 turn Speed I By-pass fully shut Open 1/2 turn Speed III Speed II Speed I... -
Page 27: Instructions To User
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. Supplied By www.heating spares.co Tel. 0161 620 6677... -
Page 28: Servicing
12 Servicing 12.2 Casing Panels Front panel Remove the 2 front panel retaining screws (4) Remove the front panel (5). Right side panel Remove the front panel (5). Remove the right side panel retaining screws (7). Remove the right side panel (6). Inner front panel Remove the inner front panel retaining screws (3). -
Page 29: Heating
12 Servicing 12.3 Draining of the appliance Heating circuit, see diagram 12.2 Turn on the drain cock (1) provided at the system low point. Provide an air intake by opening a radiator bleed screw.In order to drain only the water in the boiler, first shut off the heating flow and return isolating valves. -
Page 30: Heating
12 Servicing “Foaming” filter 10 Low water pressure sensor retaining clip DHW pump retaining screws 11 Low water pressure sensor DHW pump motor 12 Sanitary exchanger retaining screws Heating pump retaining screws 13 Sanitary exchanger Heating pump motor 14 Flow sensor Cold water filter retaining clip 15 Flow sensor retaining clips Cold water filter... -
Page 31: Heating
12 Servicing Heat exchanger 12.5 Condense Trap, refer to diagram 12.6 Remove the 2 mixing arm retaining screws (23) bolted on the Disconnect the connector flexible (5) located under the fan (33). condensate trap. Remove the 5 heat exchanger retaining nuts (17). Remove the inner front panel. -
Page 32: Heating
12 Servicing S 1 0 4 1 5 12 Fan connector 25 Gas valve connector Heat exchanger retaining screws retaining screw 13 Mixing arm Gasket 26 Gas valve connector 14 Heat exchanger hanging brackets Viewing window gasket retaining plate 15 Burner assembly retaining screws Viewing window circlip 27 Burner retaining screws 16 Insulation... -
Page 33: Fault Finding
You will find the list of some fault codes in the operating instructions. The faults described in this chapter should be carried out by a skilled professional and if need be by Glow-worm’s After Sales Service. Important: a central heating system cannot operate efficiently if it is not filled with water and if the air it contains at first has not... - Page 34 13 Fault Finding Supplied By www.heating spares.co Tel. 0161 620 6677...
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Page 35: Heating
14 Replacement of Parts Fit the new automatic air vent and ‘O’ ring ensuring the vent 14.1 General cap is left loose. Replacement of parts must be carried out by a competent Refill, vent and pressurise the boiler. person. Check for leaks. Before replacing any parts the boiler should be isolated from the mains electric supply and the gas should be turned off at Filling tap... -
Page 36: Heating
14 Replacement of Parts DHW pump retaining screws 16 Heating safety valve retaining clip DHW pump motor 17 Low water pressure sensor retaining clip Heating pump retaining screws 18 Filling device Heating pump motor 19 DHW safety valve retaining clip Cold water filter retaining clip 20 DHW safety valve Cold water filter... -
Page 37: Heating
14 Replacement of Parts Ignition and control electrode 14.3 Combustion Block, refer to diagram 14.2 Remove the connector from the ignition and control electrode Mixing arm connector (8). Remove the 2 mixing arm retaining screws (23) bolted on the Remove the 2 ignition and control electrode retaining screws fan (33) and the burner door. -
Page 38: Heating
14 Replacement of Parts S 1 0 4 1 5 25 Gas valve connector 13 Mixing arm Heat exchanger retaining screws retaining screw 14 Heat exchanger hanging brackets Gasket 26 Gas valve connector 15 Burner assembly retaining screws Viewing window gasket retaining plate 16 Insulation Viewing window circlip... -
Page 39: Heating
14 Replacement of Parts 14.4 DHW expansion vessel, refer to diagrams 14.3 DHW storage vessel, refer to diagrams 14.3 and 14.4 14.3 and 14.4 Relieve the DHW expansion vessel coupling (8). Heating expansion vessel Relieve the DHW expansion vessel retaining screw (9). Relieve the heating expansion vessel coupling (6). -
Page 40: Heating
14 Replacement of Parts 14.5 Condensate trap, refer to diagram 14.5 RETAINING Disconnect the connector flexible (5) located under the LATCHES condensate trap. Remove the inner front panel. Loosen both retaining screw (3) of the condensate trap (4). Remove the condensates recovery equipment by loosening flexibles (1);... -
Page 41: Heating
14 Replacement of Parts 14.8 Main PCB MAINS/RESET For access, refer to section 14.6. SWITCH Hinge down the control box. Remove TORX screws and unhook the rear panel. KNOB RETAINING Remove the electrical connections to the PCB. CLIPS Prise back the two PCB retaining clips and withdraw the PCB, see diagram 14.6. -
Page 42: Heating
Supplied By www.heating spares.co Tel. 0161 620 6677... -
Page 43: Heating
Supplied By www.heating spares.co Tel. 0161 620 6677... -
Page 44: Heating
Supplied By www.heating spares.co Tel. 0161 620 6677...
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