Glow-worm XTRAMAX Instructions For Use Installation And Servicing
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Glow-worm XTRAMAX Instructions For Use Installation And Servicing

Unvented hot water storage fanned flue combination boiler
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Installation and Servicing

XTRAMAX
G.C. No. 47-047-15
Unvented Hot Water Storage
Fanned Flue Combination Boiler
This is a Cat II
The instructions consist of three parts, User, Installation and Servicing Instructions, which include the Guarantee Registration Card.
The instructions are an integral part of the appliance and must, to comply with the current issue of the Gas Safety (Installation and Use)
Glow-worm appliances' are manufactured to the very highest standard so we are pleased to offer our customers' a
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 second year of the parts guarantee, from the beginning of the 13th month onwards after installation, is conditional upon
the boiler having been serviced by a CORGI registered gas installer, 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 benefit from a 12 month warranty
We recommend you complete and return as soon as possible your guarantee registration return literature, supplied in the
If your guarantee registration return literature is missing you can obtain a copy by telephoning the Heatcall Customer Service

Instructions for Use

To b e l e f t w i t h t h e u s e r
Appliance
2H3+
Regulations, be handed to the user on completion of the installation.

Guarantee Registration

Thank you for installing a new Glow-worm appliance in your home.
Comprehensive Guarantee.
the date of manufacture, whichever is shorter, for labour.
from the date of issue from the manufacturer.
document envelope.
number 01773 828100.
REGISTER YOUR GLOW-WORM APPLIANCE
CALL 0208 247 9857
Hepworth Heating Ltd.,
Nottingham Road, Belper, Derbyshire. DE56 1JT
General/Sales enquiries:
Tel: (01773) 824141 Fax: (01773) 820569
4000116705-2.10.02

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  • Page 1: Instructions For Use

    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 2: Table Of Contents

    Contents CONTENTS DESCRIPTION SECTION PAGE No. Important Information Appliance Introduction INSTRUCTION Appliance Safety Devices FOR USE Service and Maintenance Operating the Appliance Xtracom Remote Control Technical Data General Information Heating System Design Domestic Hot Water System Design Boiler Schematic Boiler Location, Flue and Ventilation Safety Discharge INSTALLATION Fixing Jig...

  • Page 3: Important Information

    Important Information Gas safety (Installation and use) Regulations Control of Substances Hazardous to Health The adhesives and sealants used in this appliance are cured In your interests and that of gas safety, it is the law that ALL gas and give no known hazard in this state. appliances are installed and serviced by a competent person in accordance with the above regulations.

  • Page 4: Appliance Introduction

    Call your Installation/Servicing company. Appliance Introduction The XTRAMAX boiler is a wall mounted modulating combination The installation of this boiler must be carried out by a competent boiler with electronic ignition providing central heating and person in accordance with the rules in force in the countries of stored hot water.

  • Page 5: Appliance Safety Devices

    Appliance Safety Devices Air flow rate safety device Heating safety valve If the flue is obstructed, even partially, the built in safety system CAUTION: A heating safety valve with a discharge pipe is fitted will turn the boiler OFF, the fan will continue to run. The boiler to this boiler.

  • Page 6: Operating The Appliance

    Operating the Appliance Controls The control panel, located at the lower front of the boiler casing, see diagram 1, allows the boiler to be started, shut down, controlled and monitored during use. 1 - On/Off button 5 - Graphic display 2 - Summer/Winter mode selector 6 - Heating temperature adjuster 3 - Hot water temperature adjuster...

  • Page 7: Lighting The Boiler

    Operating the Appliance Lighting the boiler : Make sure that: The boiler is connected to the electrical supply. The gas service cock is open. Then follow the instructions below : Press the On/Off button (1) The pressure must be between 1 and 2 bar. If not, the system must be filled by a competent person. mode To stop the boiler : Press button (1) Setting to the SUMMER position...

  • Page 8: Xtracom Remote Control

    Xtracom Remote Control Xtracom programmable, roomstat and boiler remote control Setting the Time panel part No. A20077. • Press button 14. • Press + or - to set the correct hour. PROGRAMME/ • Press OK. THERMOSTAT DISPLAY • Press + or - to set the correct minutes. •...

  • Page 9: Technical Data

    Electrical supply 230 V Maximum absorbed power 235 W Level of protection IP44 Fuse rating WEIGHT 71 kg The XTRAMAX is delivered in three separate packages: • The boiler • The fixing jig • The flue system Diagram 1.1 4000116705-2...

  • Page 10: General Information

    BS5440 Part 1 and 2, BS5449, BS5546, BS6700, BS6798, BS6891 and BS7074 Part 1 and 2, BS7478, BS7593, BS7671. 3 Heating System Design • The XTRAMAX is for use ONLY with sealed central heating • Pipe sectional areas shall be determined in accordance with systems.

  • Page 11: Heating System Design 3

    3 Heating System Design • The piping system shall be routed so as to avoid any air 3.1 Bypass pockets and facilitate permanent venting of the installation. • The boiler is fitted with an adjustable automatic bypass. Bleed fittings must be provided at every high point of the system Ensure that under no circumstances does the flow rate drop and on all radiators.

  • Page 12: Domestic Hot Water System Design

    4 Domestic Hot Water System Design • Copper tubing or plastic Hep 0 may be used for the domestic hot water system. Unnecessary pressure losses should be avoided. • A flow restrictor limiting the flow through the boiler to a maximum of 16 l/min is fitted to the boiler.

  • Page 13: Boiler Location, Flue And Ventilation

    6 Boiler Location, Flue and Ventilation 6.1 Boiler Location 25mm The boiler may be installed in any room although particular attention is drawn to the requirements of the current issue of above BS7671 with respect to the installation of a boiler in a room elbow containing a bath or a shower.
  • Page 14 6 Boiler Location, Flue and Ventilation 6.4 Terminal position The minimum acceptable spacings from the terminal to obstructions and ventilation openings are shown in diagram 6.2. The boiler must be installed so that the terminal is exposed to the external air. Warning: Do not obstruct the outside terminal of the boiler.

  • Page 15: Safety Discharge

    7 Safety Discharge Resistance created Maximum resistance allowed Minimum size of Minimum size of discharge Valve outlet by each elbow expressed as a length of straight discharge to tundish pipe D2 from tundish size or bend pipe i.e. no elbows or bends G 1/2 15 mm 22mm...

  • Page 16: Piping System Installation

    9.5 Tundish discharge temperature to prevent the risk of scalding). To be able to do this, a thermostatic mixing valve is supplied with the Xtramax The internal safety valves, 24 and 27, have been tee’d together boiler (factory set to 43°C) and can be fitted during the installation and the discharge pipe run so that it exits at the right hand procedure.
  • Page 17 9 Piping System Installation There are 2 options for the domestic hot water supply : • The supply from the governed gas meter must be of adequate size to provide a constant inlet working pressure of 20 mbar (8 1 - Piping the hot water supply without the use of the mixing in w.g.).

  • Page 18: Boiler Installation

    10 Boiler Installation 10.1 Warning to the installer This installation is subject to building regulation approval, notify the Local Authority of intention to install. 10.2 Installing the boiler Prior to starting work, the system must be thoroughly flushed using a propriety cleanser such as Sentinel X300 to eliminate any foreign matter and contamination e.g.

  • Page 19: Horizontal Telescopic Top Flue Installation

    11 Horizontal Telescopic Top Flue Installation The Horizontal Telescopic Top Flue, Kit No. A2004500 is suitable for installations that require a flue length from 425 minimum to 659.5 maximum. If longer flueing is required extensions and bends are available, see note below.

  • Page 20: Horizontal Top Flue Installation

    11a Horizontal Top Flue Installation The Horizontal Top Flue , Kit No. 86285H is suitable for installations that require a flue length from 190 minimum to 667 maximum (without extensions). If a shorter flue length is required the flue can be cut to suit, see diagrams 11a.1 and 11a.2 for minimum flue length.
  • Page 21 11a Horizontal Top Flue Installation 11a.4 Installation of flue assembly Important: If the flue has been cut, ensure that there are no burrs that could damage the ‘O’ ring. • For flue systems less than 0,5 m long, leave the restrictor (a) fitted in the fan outlet, see diagram 11a.5.

  • Page 22: Electrical Connection

    12 Electrical Connection WARNING: This appliance must be earthed and must be wired Test the polarity of the mains. in accordance with these instructions. Any fault arising from Please ensure the “Benchmark” logbook is completed and left incorrect wiring cannot be put right under the terms of the Glow- with the user.

  • Page 23: Commissioning

    13 Commissioning Please ensure the “Benchmark” logbook is completed and left with the user. The commissioning and first firing of the boiler must only be done by a competent person. Gas installation It is recommended that any air is purged from the supply at the gas inlet test point on the gas valve, see diagram 13.1.
  • Page 24 13 Commissioning The pressure must be between 1 and 2 bar Open the system filling loop and fill the system until the pressure indicated on the display is between 1 and 2 bar. Bleed each radiator to Leave the cap on the Open various hot water remove the air, re-tighten pump auto air vent open.
  • Page 25 13 Commissioning OPERATING PARAMETERS MODE FAULT HISTORY MODE HEATING HEATING mode 5 secs FUNCTIONS CODE FAULT CODE PARAMETERS FUNCTIONS CODE • Press the display light button and keep pressed for 5 seconds and this will give you access to both the operating parameters or fault history modes.

  • Page 26: Safety Devices

    3 - Intermittent (with room thermostat) 14 Safety Devices General safety devices The XTRAMAX incorporates a visual display that indicates fault conditions, should they occur. In the event of a fault, the display will indicate, by means of 14.4 Air flow rate safety device...

  • Page 27: Changing Gas Type

    Conversion natural Gas (G20) to G30/G31 Part No. 86631. 16 Settings Bypass The XTRAMAX boiler has a built-in bypass, see diagram 16.1. The boiler is supplied with the bypass open half a turn. It should not be necessary to adjust the bypass, but if required ensure that under no circumstances does the flow rate fall below the figures specified, refer to diagram 1.1.

  • Page 28: Routine Cleaning And Inspection

    17 Routine Cleaning and Inspection To ensure the continued efficient and safe operation of the boiler it is recommended that it is checked and serviced at regular intervals. The frequency of servicing will depend upon the particular installation conditions and usage, but in general once a year should be enough.
  • Page 29 17 Routine Cleaning and Inspection 17.9 Heat exchanger, refer to diagram 17.4. 17.8 Burner, refer to diagram 17.3. • Disconnect electrical connections from fan. • Undo main gas supply nut from under the sealed chamber. • Unscrew and remove two fan retaining screws from the right Note: The washer between main burner and main burner gas hand side edge of fan mounting plate.
  • Page 30 17 Routine Cleaning and Inspection 17.10 Spark and Sense Gaps • Check that the spark and sense gaps as shown in diagram 17.5. 17.11 Domestic hot water discharge (Annual Check) Refer to diagram 5.1. Open expansion valve (24) and temperature/pressure release valve (27) and check that the discharge outlet is not blocked (D2) and that the valves close, SPARK GAP check the pressure reducing valve and strainer and clean if...

  • Page 31: Fault Finding

    Between terminals B2.4 and B2.2 Display 5V + 0.5V Between terminals B2.4 and B4.2 The XTRAMAX has an on-board fault diagnostic system. Should a fault occur on the boiler, the warning LED at the top of the user display will illuminate and the LCD display will indicate the precise area where the fault has occurred.
  • Page 32 18 Fault Finding TO AID FAULT FINDING REFER TO DIAGRAMS 5.1 and 19.1. CODE TYPE OF FAULT DISPLAY SYMBOL CHECK NO FAULT NO FAULT THIS SYMBOL IS NOT INSTANTANEOUS BUT IF IT APPEARS AFTER 40 SECONDS, CHECK • THE FLUE SYSTEM FOR A BLOCKAGE, EXCESS LENGTH. AIR FLOW SAFETY •...
  • Page 33 19 Wiring Diagram IGNITION SENSE IGNITION ELECTRODES ELECTRODE MODULE g/y br SENSOR AIR PRESSURE SWITCH WATER PRESSURE SENSOR CONTROL VALVE THERMISTOR OVERHEAT THERMISTOR CHASSIS EARTH THERMISTOR FLOW SENSOR THREE-WAY VALVE PLUG STORAGE VESSEL THERMISTOR PUMP CH PUMP DHW 230V~50Hz CHASSIS PERMANENT EARTH MAINS SUPPLY...

  • Page 34: Replacement Of Parts

    20 Replacement of Parts To drain the domestic hot water circuit (DHW) of the boiler Close isolating valve/throttle (m) Note: This valve is closed when screwed fully clockwise. Open the DHW drain point (z) located below the DHW pump. To drain the central heating circuit (CH) of the boiler Close isolating valves (q) and (v) Note: These valves are closed when slots are at right angles to direction of flow.
  • Page 35 20 Replacement of Parts 20.3 Domestic hot water storage vessel INSULATION thermistor PLUG Before starting refer to the front of Section 20 Important information. • Remove the front panel, refer to Section 17.3. • Lower the control panel, refer to Section 17.5. •...
  • Page 36 20 Replacement of Parts • Fit replacement pump. 20.6 Domestic water flow sensor • Open isolating valves on flow and return connections, refill, Before starting refer to the front of Section 20 Important and pressurise boiler. information. • Check for leaks. •...
  • Page 37 20 Replacement of Parts 20.10 Three-way valve head 20.13 System water pressure sensor Before starting refer to the front of Section 20 Important Before starting refer to the front of Section 20 Important information. information. • Remove the front panel, refer to Section 17.3. •...
  • Page 38 20 Replacement of Parts 20.14 Gas control valve stepper motor, refer to SPARK IGNITION UNIT diagram 20.11. Before starting refer to the front of Section 20 Important information. • Remove the front panel, refer to Section 17.3. • Lower the control panel, refer to Section 17.5. •...
  • Page 39 20 Replacement of Parts • Release flue hood as follows: 20.16 Gas safety valve, refer to diagram 20.11. From front of boiler carefully unclip wire spring retainers from Before starting refer to the front of Section 20 Important side of flue hood. information.
  • Page 40 20 Replacement of Parts 20.21 Overheat thermostat Before starting refer to the front of Section 20 Important information. • Remove the front panel, refer to Section 17.3. • Remove sealed chamber cover, refer to Section 17.4. • Locate high limit thermostat on heating flow pipe on left hand side of boiler, see part of diagram 17.4.
  • Page 41 20 Replacement of Parts • Unclip side clips and hinge up control panel cover, see 20.24 Burner injectors, refer to diagram 20.13. diagram 13.2. Before starting refer to the front of Section 20 Important • Carefully pull off electrical connection from the user interface information.
  • Page 42 20 Replacement of Parts 20.29 Domestic hot water pump, refer to ELECTRICAL diagram 20.15. CONNECTION BOX Before starting refer to the front of Section 20 Important information. • Remove the front panel, refer to Section 17.3. • Lower the control panel, refer to Section 17.5. •...
  • Page 43 20 Replacement of Parts DOMESTIC HOT WATER EXPANSION VALVE TOP SIDE PANELS SUPPORT DOMESTIC HOT WATER STORAGE VESSEL UNION NUT Diagram 20.18 20.33 Domestic Hot water storage vessel, refer to diagram 20.19. Before starting refer to the front of Section 20 Important information.

  • Page 44: Spare Parts

    21 Spare Parts When ordering spare parts, quote the part number and description, stating the appliance model number and serial number from the data badge. Short parts list No..Description ............ Part No........... G.C. No. 1 ..Domestic hot water thermistor ....57213 ..........E37381 2 ..

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