Glow-worm ULTRACON 18SXI Installation And Servicing Manual
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Glow-worm ULTRACON 18SXI Installation And Servicing Manual

High efficiency condensing combination boilers
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Ultracom

Installation and Servicing

18sxi
G.C. No. 41-019-07
30sxi
G.C. No. 41-019-08
High Efficiency
Condensing Combination
Boilers
www.glow-worm.co.uk
1

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Summary of Contents for Glow-worm ULTRACON 18SXI

  • Page 1: Installation And Servicing

    Ultracom Installation and Servicing 18sxi G.C. No. 41-019-07 30sxi G.C. No. 41-019-08 High Efficiency Condensing Combination Boilers www.glow-worm.co.uk...

  • Page 2: Guarantee Registration

    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

    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

    Glow- worm. - Grip the boiler at its base Any alteration not approved by Glow-worm, could invalidate - Be physically capable the certification, boiler warranty and may also infringe the - Use safety clothing where appropriate, e.g. gloves, safety current issue of the statutory requirements.

  • Page 5: Statutory Requirements

    Statutory Requirements CE Mark NOTE: For further information, see the current issue of the Building Regulations, approved document L1 ( in the UK) and This boiler meets the requirements of Statutory Instrument, the following current issues of: No. 3083 The Boiler (Efficiency) Regulations, and therefore 1) Central heating system specification (CheSS) is deemed to meet the requirements of Directive 92/42/EEC on the efficiency requirements for new hot water boilers fired...

  • Page 6: Boiler Design

    This valve must not be touched. Should there be any discharge from the pipe, 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.

  • Page 7: Boiler Specification

    1 Boiler Specification BOILER SPECIFICATION 18sxi 30sxi Lift weight 36kg (80Ib) 39kg (86Ib) Total weight (installed) 41kg (90Ib) 44.5kg (98Ib) Gas connection 15mm copper 15mm copper Heating flow & return connection Ø O.D. 22mm. copper 22mm. copper Condensate connection Ø I.D. 21.5mm.

  • Page 8: Boiler Dimensions & Hydraulic Schematic

    2 Boiler Dimensions and Hydraulic Schematic BOILER CONDENSATE CONNECTION Diagram 2.2 outlet 2.1 Boiler Dimensions & Hydraulic Schematic All dimensions are given in millimetres (except as noted). The general arrangment of the boiler is shown in diagram 2.1. and the hydraulic and gas schematic, diagram 2.2. Diagram 2.1 The data label is positioned on the front of the inner casing panel.

  • Page 9: Boiler Location, Clearances 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 local gas undertaking or Glow-worm. 3.4 Combustible Material Diagram 3.1 The boiler and flue are suitable for installation onto and...

  • Page 10: Flue Options And Terminal Clearances

    4 Flue Options and Terminal Clearances Top horizontal telescopic flue (Ø60/100) Top horizontal standard flue (Ø60/100) Part No. A2043600 - Section 10, page 20 Part No. A2043400 - Section 10, page 24 Plume Management Kit basic set, white, concentric flue (Ø60/100) - Part No.

  • Page 11: Flue Terminal Position

    4 Flue Options and Terminal Clearances 4.1 Flue Options There are various flue options to choose from as illustrated in diagram 4.1. The flue lengths and installation are described in section 10. 4.2 Flue Terminal Position In GB the minimum acceptable siting dimensions for the terminal from obstructions, other terminals and ventilation openings are shown in diagram 4.2.

  • Page 12: Water System 5

    5 Water System 5.1 General This boiler is designed for use as part of a sealed water central heating system with fully pumped circulation. The pump, expansion vessel and associated safety devices are all fitted within the boiler. An options board accessory is available to link the internal programmer with a Honeywell S or Y plan system.

  • Page 13: Water System

    5 Water System SUPPLY PIPE BOILER BOILER CONTROL VALVE TYPE CA BACKFLOW DOUBLE PREVENTION DEVICE CHECK VALVE FLOW RETURN FLOW RETURN HOSE CONTROL CONTROL UNION VALVE VALVE SUPPLY PIPE HEATING TEMPORARY HEATING CONTROL HOSE CIRCUIT CONNECTION CIRCUIT AIR GAP VALVE UNION DRAIN DRAIN...

  • Page 14: Installation Preparation

    6 Installation Preparation 6.1 Appliance Pack 6.3 Wall Template Please check the contents of packs as shown in diagram 6.1. Take the wall template from the document pack located The packs are located in the top polystyrene packing. within the top polystyrene packing and place in the desired position on the wall, giving due consideration to the required Remove the carton sleeve and top pack then lift the boiler and...

  • Page 15: Boiler Fixing

    6 Installation Preparation 6.4 Flue Hole Cutting External access flue installation can use a 105mm diameter 44mm/metre WALL core drill. inclined extended TEMPLATE Internal access only flue installation will need a 125mm flue length Preferred diameter core drill. fixing points NOTE: The flue is designed with an internal fall of 44mm/ metre (2.5°), therefore the hole can be drilled horizontally.

  • Page 16: Gas/Water Connection

    8 Gas / Water Connection 8.1 Systems Connection Remove the protective caps from the boiler connections. NOTE: The appliance may contain a small amount of water, place a water container beneath the boiler connections. Assemble and secure the pre formed copper tails to their respective isolation valves making sure of their correct orientation, see diagram 8.1.

  • Page 17: Safety Discharge Valve And Condensate Connections

    9 Safety Discharge Valve and Condensate Connections 9.1 Safety Discharge Valve Take the safety discharge pipe, supplied in the pipe pack and the union nut and seal, supplied in the loose items pack and fit as shown in diagram 9.1. This must be extended, using not less than 15mm o.d.
  • Page 18 9 Safety Discharge Valve and Condensate 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 SINK (CONSTITUTES...

  • Page 19: Flue Length Preparation And Installation

    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 The maximum permissable horizontal flue length is 10 metres 2.5 o 44mm/metre to allow condensate to run back into the plus the flue terminal assembly, this can be achieved by use boiler and out via the condensate drain.
  • Page 20 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 COLLAR...
  • Page 21 10 Telescopic Flue - Length, Preparation and Installation 10.2 Horizontal Telescopic Flue - A2043600 Refer to diagram 10.2 for kit contents. 10.3 REAR Flue BUTT JOINT If a wall thickness is between 203mm min. to 413mm 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 22 10 Telescopic Flue - Length, Preparation and Installation 10.5 Flue Fitting With the air duct seams aligned and the flue set to the required length ‘Y’, mark the securing hole position in the air duct. Drill a 3mm diameter hole at this position, take care not to pierce the inner flue duct.
  • Page 23 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 The maximum permissable horizontal flue length is 10 metres 2.5 o 44mm/metre to allow condensate to run back into the plus the flue terminal assembly, this can be achieved by use boiler and out via the condensate drain.
  • Page 24 10 Standard Flue - Length, Preparation and Installation A2043400 Top Outlet Standard Horizontal Concentric Flue Pack FLUE ELBOW SECURING SCREW x 4 COLLAR SCREW x 2 SCREW x 2 GASKET (fitted) TRIM RING STANDARD TERMINAL ASSEMBLY SEALING Diagram 10.11 COLLAR Diagram 10.12...
  • Page 25 10 Standard Flue - Length, Preparation and Installation 10.7 Standard Horizontal Flue - A2043400 Refer to diagram 10.11 for kit contents. 10.8 REAR Flue BUTT JOINT With the flue elbow temporarily fitted, measure the distance from the outside wall to the butt joint, see diagram 10.13. If the measurement ‘Y’...
  • Page 26 10 Standard Flue - Length, Preparation and Installation 10.10 Flue Fitting Remove the flue elbow. Separate the flue duct from the terminal by twisting to release the terminal catch, then pull out of the retaining seal, refer to diagram 10.16. The flue duct cutting length (L + 11mm.) is shown in diagram 10.16.
  • Page 27 10 Vertical Flue - Length, Preparation and Installation 10.11 Vertical flue The terminal siting should be as shown in diagram 4.2. The vertical flue system is available as an option where the Measure the distance of flue length required for the boiler position does not permit the use of the top horizontal installation.

  • Page 28: Flue Installation

    10 Vertical - Flue Length, Preparation and Installation Flue Installation Refer to diagram 10.20 and secure the flue adapter in position on top of the boiler with four screws supplied, making sure the nib fits into the locating slot in the boiler casing to ensure correct orientation.
  • Page 29 10 Vertical Flue - Length, Preparation and Installation Completion of Installation With the flue terminal positioned in the roof the length of the final pipe can be determined. If a telescopic length cannot be used, then a standard flue length can be cut to make the correct length.
  • Page 30 10 Twin Flue - Length, Preparation and Installation Diagram 10.24...

  • Page 31: 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 horizontal or vertical flue system is not appropriate. The system can provide an independent horizontal air inlet and flue outlet, horizontal air inlet and vertical flue outlet or vertical air inlet and flue outlet via a concentric terminal.

  • Page 32: Installation Details

    10 Twin Flue - Length, Preparation and Installation Installation Details The parts available for a twin flue system installation are shown in diagram 10.25. Boiler Connection Push the twin flue adaptor onto the outlet of the boiler with the air inlet to the left hand side, see diagram 10.26. Secure the adaptor to the top panel with the screws provided.
  • Page 33 For each 90 bend or 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 AIR BRICK instructions.

  • Page 34: Electrical Connection

    The boiler is suitable for installation in bathroom zones 2 and 3. 11.1 Electrical Wiring If you are fitting the Glow-worm Options Board Kit, please refer to the instructions supplied with the kit for the system wiring. Remove the electrical cartridge from the fittings pack.
  • Page 35 11 Electrical Connection 11.2 System Controls 24V WARNING: UNDER NO CIRCUMSTANCES MUST ANY MAINS VOLTAGE BE APPLIED TO ANY OF THE TERMINALS ELECTRICAL ON THE 24V CONNECTION PLUG. CARTRIDGE Connect the mains supply and system heating controls e.g. room thermostat as diagram 11.2. External controls should be fitted in accordance with the rules in force.

  • Page 36: Commissioning

    Diagram 12.1 12.4 Initial Lighting NOTE: If you have fitted a Glow-worm Options Board Kit, please refer to the instructions supplied with the kit for completion of commissioning.
  • Page 37 12 Commissioning 12.6 Gas Rate The gas valve is factory set for natural gas (G20) and should need no adjustment. Should any doubt exist about the gas rate, check it using the gas meter test dial and stop watch, at least 10 minutes after the burner has lit, see diagram 12.3 for approximate rates.

  • Page 38: Instruct The User

    12 Commissioning 12.8 Completion Fit the base coverplate, see diagram 12.4. Ensure that the magnetic lighting instruction label is placed on the surface of the boiler casing. GB: It is a requirement that the “Benchmark” Installation, Commissioning and Service Record is completed and left with the user.
  • Page 39 As an option a chargeable boiler only commissioning service THROTTLE can be provided by Glow-worm Service by calling telephone No. 01773 828100. Tools required to make the conversion are a 2mm Allen key and an electricians screwdriver.

  • Page 40: 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 41 13 Servicing 13.3 Servicing Note: If the Combustion & Gas rate checks did not require adjustment then it will not be necessary to service the Combustion Chamber, Heat Exchanger or Burner. RETAINING Complete this section, 13.4 and then proceed to 13.9. STRAP All routine servicing requirements can be achieved by the removal of the front and inner panels, see diagram 13.1.
  • Page 42 13 Servicing Diagram 13.7 Disconnect the electrical plug from the fan. BURNER FRONT SECURING Disconnect the spark electrode plug and earth lead, refer to INSULATION SCREW (4) diagram 13.6. Remove the five combustion chamber/burner door securing nuts, see diagram 13.7, these should be discarded and replaced with the new nylocs nuts supplied in the burner door seal kit.

  • Page 43: Combustion Check

    13 Servicing 13.7 Combustion Check FLUE ELBOW With the appliance operational connect the CO combustion analyser to the test point, see diagram 13.9. IMPORTANT: Remember to replace the cap on completion of the test. Check the burner %CO , at maximum rate(open a hot water tap fully to generate a demand).

  • Page 44: Fault Finding

    14 Fault Finding 14.1 Preliminary fault finding RETAINING SECURING The following checks should be performed before proceeding SLOTS SCREW 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 on the installer interface, refer to section 11.5 for access and diagram 14.4.
  • Page 45 14 Fault Finding CONTROL VALVE IGNITION HEATING ELECTRODE RETURN IGNITER THERMISTOR UNIT HEATING FLOW THERMISTOR WATER PRESSURE SENSOR PUMP CHASSIS EARTH MAIN CONTROL BOARD BROWN BLUE GREEN/YELLOW GREY BLACK APPLIANCE YELLOW INTERFACE BOARD WHITE ORANGE PURPLE Diagram 14.4...
  • Page 46 14 Fault Finding CENTRAL HEATING Diagram 14.5...
  • Page 47 14 Fault Finding Fault Codes If -9 C is displayed, check that the thermistor wires are unconnected, faulty or trapped. Diagram 14.6...
  • Page 48 14 Fault Finding Fault Codes (continued) Diagram 14.6...
  • Page 49 14 Fault Finding Diagnostic Menu The Diagnostic Menu provides the ability to view and change certain parameters. See Diagram 14.5 for available parameters. To enter the diagnostic menu: a) Press and hold the ‘MODE’ button for 5 seconds. The display will change to flashing ‘0’. b) Use the ‘+’...
  • Page 50 14 Fault Finding Diagnostic Menu - Level 1 Installer Access Description Range - 99 will be displayed. Reserved for future use. Tank temperature Flow temperature setpoint Flow target temp. from external intelligent control (Option) d.24 System water pressure in bar. d.27 Option Relay 1 Reserved for future use...
  • Page 51 14 Fault Finding State list - Accessed through Diagnostic Codes - Level 1, Installer Access d.99 STATE LISTS Central heating mode (Priority 3) Possible Causes S.00 no heating required S.01 fan pre-run S.02 pump pre-run S.03 ignition S.04 burner on S.05 pump / fan overrun S.06...

  • Page 52: Replacement Of Parts

    15 Replacement of Parts 15.1 General IGNITER BRACKET IGNITER UNIT IMPORTANT: The replacement parts described in sections SECURING SCREW 15.5 to 15.9 and section 15.12, will require the removal of the burner module assembly and the replacement of the burner IGNITER door seal and self locking nuts.
  • Page 53 15 Replacement of Parts 15.5 Gas Valve For access, refer to section 15.1. Refer to section 13.5 for removal of the fan, gas valve and burner assembly. Before removing the gas valve note its orientation in relationship to the fan. Remove the three securing screws, which also secures the plastic swirl plate to the venturi on the fan, see diagram 15.2.

  • Page 54: Expansion Vessel

    15 Replacement of Parts 15.10 Viewing Window 15.13 Flue Hood For access, refer to section 15.1. For access, refer to section 15.1. Refer to diagram 15.5. Remove heat exchanger as per section 15.12. Remove circlip. Remove the two securing screws and pull the flue hood down and away from the flue hood bracket and flue elbow, see Remove steel washer.
  • Page 55 15 Replacement of Parts 15.14 Heating Flow Thermistor Remove the securing clip from the heat exchanger adapter, then disconnect the adapter and flexible hose. For access, refer to section 15.1. Lift the siphon adapter and hose out of the condensate trap Refer to diagram 15.10.

  • Page 56: Automatic Air Vent

    15 Replacement of Parts 15.17 Pump (head only) For access, refer to section 15.1. CAP HEAD SCREW (4) Drain the boiler heating circuit as described in the appropriate paragraph of 15.1. Refer to diagram 15.12. Remove the four cap head screws. Carefully remove the pump head together with cable.

  • Page 57: Maintenance

    15 Replacement of Parts 15.20 Low Water Pressure Sensor MAINTENANCE For access, refer to section 15.1. COVER RETAINING AUTOMATIC Drain the boiler heating circuit as described in the appropriate CLIP AIR VENT section of 15.1. Refer to diagram 15.15. Disconnect the electrical leads. Remove the retaining clip, remove the low water pressure sensor.
  • Page 58 15 Replacement of Parts 15.22 Hydroblock and Bypass Tube Remove the 3 screws which retain the automatic bypass housing, refer to section 15.21. For access, refer to section 15.1. Grip the LH and RH hydroblocks simultaneously and lift clear IMPORTANT: To replace the bypass tube the LH and of the spigots on the mounting bracket.
  • Page 59 15 Replacement of Parts 15.23 Access User Interface and Main PCB For access, refer to section 15.1. RETAINING SECURING Remove control box retaining screw, see diagram 15.18. SLOTS SCREW Hinge down the control box. Release the control box cover by carefully pressing the four retaining clips, see diagram 15.18.

  • Page 60: 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 61: Spare Parts 16

    16 Spare Parts Diagram 15.21...

  • Page 62: Manual Handling

    17 Manual Handling Positioning of Appliance for Final Installation – no obstructions. IMPORTANT. With regards to the Manual Handling Operations, 1992 Recommend 2 persons lift appliance to position into place. Fit brack- Regulations, the following lift operation exceeds the recommended et securely onto wall before lifting appliance into position.
  • Page 64 0020020821-02 02.07 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...

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