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Summary of Contents for Glow-worm SUSTAIN 12S
- Page 1 The energy you need Installation and main- tenance instructions SUSTAIN ..s SUSTAIN 12s -A (H-GB) SUSTAIN 15s -A (H-GB) SUSTAIN 18s -A (H-GB)
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Page 2: Table Of Contents
Contents Contents Adapting the unit to the heating installation............20 Burner anti-cycling time ........20 Safety ..............3 Setting the pump output........20 Action-related warnings ......... 3 Setting the bypass valve........21 Risk caused by inadequate qualifications....3 Adjusting the hot water temperature ....21 Intended use ............ -
Page 3: Safety
Safety 1 – observance of accompanying operating, Safety installation and servicing instructions for Action-related warnings the product and any other system compon- ents Classification of action-related warnings – installing and fitting the product in accord- The action-related warnings are classified in ance with the product and system approval accordance with the severity of the possible –... - Page 4 1 Safety ▶ In order to operate the product, ensure that 1.4.7 Risk of death due to lack of safety devices the condensate siphon is always full. The schematic drawings included in this doc- 1.4.3 Risk of death due to blocked or ument do not show all safety devices re- leaking flue gas routes quired for correct installation.
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Page 5: Regulations (Directives, Laws, Standards)
Safety 1 ▶ Ensure that no chemical substances are steps and procedures to comply with Health and safety at work act and ensure safety of stored at the installation site. themselves and others with regard to manual ▶ Ensure that the combustion air is not handling and working at height requirements. - Page 6 1 Safety – BS EN 806 Parts 1 - 5. Additionally for gas boilers systems with out- – BS 8558 Guide to the design, installation, puts greater than 70KW. testing and maintenance of services sup- – BS 6644 Installation of gas boilers plying water for domestic use within build- between 60 kW and 2 MW (2nd and 3rd ings and their curtilages.
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Page 7: Notes On The Documentation
Max. flow temperature max. Article number Gas Council NOx class for the product Number Code (DSN) Specific product code SUSTAIN 12s -A (H- 0010015888 41-019-36 → "CE label" section SUSTAIN 15s -A (H- 0010015889 41-019-37 SUSTAIN 18s -A (H- 0010015890 41-019-38 Read the instructions. -
Page 8: Functional Elements: Pure Boiler
4 Installation Installation Functional elements: Pure boiler Transporting the unit Important: With regard to the regulations of 1992 concern- ing the manual handling of loads, the unit exceeds the weight that can be lifted by a single person. 4.1.1 General ▶... -
Page 9: Dimensions
Installation 4 Dimensions Minimum clearances Minimum clearance 150 mm 150 mm 5 mm 600 mm Clearance from combustible components It is not necessary to maintain a clearance between the product and components made of combustible materials. Using the installation template ▶... -
Page 10: Removing/Installing The Front Casing
4 Installation 4.10 Removing/installing the side section Conditions: The load-bearing capacity of the wall is not sufficient ▶ 4.10.1 Removing the side section Ensure that wall-mounting apparatus on-site has a suf- ficient load-bearing capacity. Use individual stands or Caution. primary walling, for example. ▶... -
Page 11: Installation
Installation 5 Installation Note We recommend that you provide the water pipes Danger! to the boiler outlet and to the system with thermal insulation. Risk of explosion or scalding caused by incorrect installation. Preliminary work Stresses in the supply line can cause leaks. Check that the system volume and the volumetric capa- ▶... -
Page 12: Connecting The Condensate Drain Pipework
If you cannot guarantee that the materials from which pipe pipe the drain lines are made are suitable, install a system for ≤ 10 m ≤ 25 m SUSTAIN 12s -A neutralising the condensate. (H-GB) ▶ Ensure that the connection between the condensate ≤ 10 m ≤... -
Page 13: Electrical Installation
Dia. 60/100 (L) Dia. 80/125 (L) C33 type air/flue C33 type air/flue pipe pipe ≤ 10 m ≤ 25 m SUSTAIN 12s -A (H-GB) ≤ 10 m ≤ 25 m SUSTAIN 15s -A (H-GB) ≤ 10 m ≤ 25 m... - Page 14 5 Installation 5.6.1 Opening the electronics box 5.6.4 Establishing the power supply ▶ Follow the instructions in the specified sequence. Observe all valid regulations. Ensure that the rated mains voltage is 230 V. 5.6.2 Cable route Set up a fixed connection and install a partition with a contact opening of at least 3 mm (e.g.
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Page 15: Operation
Operation 6 Operation 5.6.5 Connecting controllers to the electronic system Using diagnostics codes You can use the parameters marked as adjustable in the table of diagnostics codes to adapt the product to the system and customer requirements. 24 V Overview of diagnostics codes (→ Page 28) 6.1.1 Activating diagnostics codes –... -
Page 16: Using Check Programmes
7 Start-up ◁ Start-up The display switches to the basic display. Using check programmes Carrying out the initial start-up By activating various check programmes, you can trigger Initial start-up must be carried out by a customer service various special functions on the product. technician or an authorised competent person using the first- commissioning-checklist. -
Page 17: Avoiding Danger Arising From Insufficient Water Pressure
Start-up 7 ▶ Ensure that oxygen cannot get into the heating water. No incompatibility with our products has been detected to (→ Page 20) date with proper use of the following additives. ▶ When using additives, follow the manufacturer's instruc- Checking the filling and supplementary water ▶... -
Page 18: Filling And Purging The Heating Installation
7 Start-up Filling and purging the heating installation Filling the condensate siphon Preliminary work ▶ Rinse the heating installation through. Loosen the purging valve cap (1) on the pump and on the automatic air vents. Fill with water until the required filling pressure is reached. - Page 19 Start-up 7 7.9.2 Checking the leak-tightness of the flue gas system and for flue gas recirculation Check that the flue gas system is intact, in accordance with British Gas TB 200. If the flue gas installation is longer than 2 m, a flue gas recirculation test is strongly recommended.
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Page 20: Checking Function And Leak-Tightness
8 Adapting the unit to the heating installation Status codes – Overview (→ Page 32) Settings Unit G20 natural ◁ If the product is working correctly, the display shows CO₂ after 5 minutes in full S.04. 9.2 ± 1.0 load mode with front casing Vol.–% closed 7.10.2 Checking the hot water generation... -
Page 21: Setting The Bypass Valve
Adjusting the hot water temperature 9 Adjusting the hot water temperature Overview of diagnostics codes (→ Page 28) 8.2.1 Pump diagrams You can reset/change the system parameters (→ section "Using diagnostics codes"). Overview of diagnostics codes (→ Page 28) PWM 5% Setting the hot water temperature PWM 20% Danger! -
Page 22: Procuring Spare Parts
The original components of the product were also certified as part of the declaration of conformity. If you do not use certified Glow-worm original spare parts for maintenance or repair work, this voids the conformity of the product. We therefore strongly recommend that you install Glow-worm original spare parts. -
Page 23: Cleaning The Heat Exchanger
Inspection and maintenance 11 11.4 Cleaning the heat exchanger 11.7 Cleaning the condensate siphon Protect the folded down electronics box against sprayed water. Clean the ribs of the heat exchanger (1) with water. ◁ The water runs out into the condensate tray. 11.5 Checking the burner Search the surface of the burner for possible damage. -
Page 24: Checking The Admission Pressure Of The Expansion Vessel
12 Troubleshooting 11.10 Checking the admission pressure of the 12.4 Resetting parameters to factory settings expansion vessel Reset all parameters to the factory settings using the diagnostics code d.96. Drain the product. (→ Page 23) Set the diagnostics code. (→ Page 15) Measure the pre-charge pressure of the expansion ves- sel at the vessel valve. - Page 25 Troubleshooting 12 Remove the temperature sensor (3). 13. Lift the heat exchanger up slightly and remove it to- gether with the condensate tray (1). Remove the upper clip (1). 14. Undo the four screws (3). Remove the lower clip (4). 15.
- Page 26 12 Troubleshooting 12.6.7 Replacing the PCB for the user interface Undo the nut (3). Remove both screws on the support plate (1). Remove the support plate. Pull out the expansion vessel (2) towards the front. Insert the new expansion vessel into the product. Screw the new expansion vessel to the water connec- tion.
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Page 27: Completing Repair Work
Drain the product. (→ Page 23) 14 Customer service For contact details for our customer service department, you can write to the address that is provided on the back page, or you can visit www.glow-worm.co.uk. 0020200967_00 SUSTAIN ..s Installation and maintenance instructions... -
Page 28: Appendix
Appendix Appendix Check programmes – Overview Note Since the programme table is used for various products, some programmes may not be visible for the product in question. Display Meaning P.01 Start up the burner at the adjustable heat input: The product is operated after a successful ignition with the set heat input between "0" (0% = Pmin) and "100"... - Page 29 Appendix Dia- Values Default set- User-spe- gnostics Parameter Unit Increment, select, explanation ting cific setting Min. Max. code d.02 Maximum burner anti- Adjustable cycling time in heating mode ℃ – – d.04 Water temperature in the Current value cylinder adjustable ℃...
- Page 30 Appendix Dia- Values Default set- User-spe- gnostics Parameter Unit Increment, select, explanation ting cific setting Min. Max. code ℃ d.20 Maximum hot water set Adjustable target temperature – – d.21 Status of the warm start Current value off = Function deactivated for hot water adjustable on = Function activated and...
- Page 31 Appendix Dia- Values Default set- User-spe- gnostics Parameter Unit Increment, select, explanation ting cific setting Min. Max. code – d.45 Value for the base point Adjustable of the heating curve ℃ – – d.47 Outside temperature Current value adjustable d.50 Correction of the min- 3000 Adjustable...
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Page 32: C Status Codes - Overview
Appendix Dia- Values Default set- User-spe- gnostics Parameter Unit Increment, select, explanation ting cific setting Min. Max. code d.84 Maintenance in 3000 Number of hours = Display value x 10 adjustable – – – d.85 Increase in the min. out- Adjustable put (heating and hot wa- →... -
Page 33: D Overview Of Fault Codes
Appendix Status code Meaning S.17 DHW mode: Pump overrun Display in Comfort mode with warm start or hot water handling mode with cylinder S.20 Hot water handling mode: Requirement S.21 Hot water handling mode: Advance fan operation S.22 Hot water handling mode: Pump pre-run S.23 Hot water handling mode: Burner ignition S.24... - Page 34 Appendix Fault code Meaning Possible cause F.20 Safety switch-off: Overheating temperat- Incorrect earth connection between cable harness and product, flow or return ure reached NTC defective (loose connection), black discharge via ignition cable, ignition plug or ignition electrode F.22 Safety switch-off: Low water pressure in No or insufficient water in the product, water pressure sensor de- the boiler fective, cable to the pump or to the water pressure sensor loose/not...
- Page 35 Appendix Fault code Meaning Possible cause F.77 Fault: Condensate or smoke No response, flue non-return flap defective F.78 Interruption to DHW outlet sensor at UK link box is connected, but hot water NTC not bridged external controller F.83 Fault: Burner temperature sensor Burner temperature sensor is defective When the burner starts, the temperature change registered at the flow or return temperature sensor is non-existent or too small: Insufficient water...
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Page 36: E Connection Diagram: Pure Boiler
Appendix Connection diagram: Pure boiler Burner off X106 eBUS – Burner 24V= 230V~ RT 230Vac 230Vac Main PCB Gas valve Interface PCB Pressure sensor Control system Ionisation electrode Temperature sensor in the heating flow Heating pump Temperature sensor in the heating return Ignition electrode Main power supply Installation and maintenance instructions SUSTAIN ..s 0020200967_00... -
Page 37: F Inspection And Maintenance Work - Overview
Appendix Inspection and maintenance work – Overview The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals. If na- tional regulations and directives require shorter inspection and maintenance intervals, you should observe these instead of the intervals listed in the table. -
Page 38: G Opening In The Air/Flue Pipe
Appendix Opening in the air/flue pipe D, E Positioning of the opening of a fan-supported flue gas pipe Minimum dimen- Installation site sions Directly below an opening, air bricks, opening windows, etc., that can be opened. 300 mm Above an opening, air bricks, opening windows, etc., that can be opened. 300 mm Horizontally to an opening, air bricks, opening windows, etc., that can be opened. -
Page 39: Text From Bs 5440-1 On Fan-Supported Flue Gas Pipes
Appendix Text from BS 5440-1 on fan-supported flue gas pipes BS 5440–1: It is recommended that the fanned flue gas system terminal is positioned as follows: – At least 2 m from an opening in the building directly opposite, and –... -
Page 40: H Commissioning Checklist
Appendix Commissioning Checklist Benchmark Commissioning and Servicing Section It is a requirement that the boiler is installed and commissioned to the completed in full. www.centralheating.co.uk © Heating and Hotwater Industry Council (HHIC) Installation and maintenance instructions SUSTAIN ..s 0020200967_00... - Page 41 Appendix GAS BOILER SYSTEM COMMISSIONING CHECKLIST This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference. CONTROLS Optimum start control Fitted...
- Page 42 Appendix SERVICE RECORD It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed. Service Provider SERVICE 01 SERVICE 02 ² % ² % ² % ² % SERVICE 03 SERVICE 04 ²...
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Page 43: I Combustion Chart
Appendix Combustion chart PRIOR TO CO AND COMBUSTION RATIO CHECK NOTE The boiler manufacturer’s installation instructions should have been followed, gas type verified and gas THE AIR GAS RATIO VALVE IS FACTORY supply pressure/rate checked as required prior to commissioning. SET AND MUST NOT BE ADJUSTED As part of the installation process, especially where a flue has been fitted by persons other than the DURING COMMISSIONING UNLESS THIS... -
Page 44: J Technical Data
Appendix Technical data Technical data – Heating SUSTAIN 12s -A (H- SUSTAIN 15s -A (H- SUSTAIN 18s -A (H- 10 … 80 ℃ 10 … 80 ℃ 10 … 80 ℃ Max. flow temperature adjustment range (default setting: 75 °C) Maximum permissible pressure 0.3 MPa... - Page 45 Appendix SUSTAIN 12s -A (H- SUSTAIN 15s -A (H- SUSTAIN 18s -A (H- Flue gas mass rate in hot water 6.9 g/s 8.3 g/s 11.6 g/s handling mode at P max. 55 ℃ 55 ℃ 60 ℃ Flue gas temperature (80 °C/60 °C) at P max.
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Page 46: Index
Index Index Leak detection spray ............. 5 Air index setting..............20 Mains connection ..............14 Maintenance work ............21, 37 Air/flue pipe, installed ............4 Minimum clearance ............... 9 Burner anti-cycling time............20 Bypass valve ............... 21 Power supply............... 14 Preparing the repair work ............ - Page 48 Publisher/manufacturer Glow-worm Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JQ Telephone 016 34 29 23 00 ‒ Fax 016 34 29 01 66 Technical helpline 084 4 736 00 59 ‒ After sales service 017 73 82 81 00 www.glow-worm.co.uk 0020200967 The energy you need We reserve the right to make technical changes.
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