Related Manuals for Glow-worm Ultracom2 sxi
Summary of Contents for Glow-worm Ultracom2 sxi
- Page 1 condens Installation and Servicing Ultracom 12sxi G.C. No. 41-019-12 18sxi G.C. No. 41-019-13 30sxi G.C. No. 41-019-14...
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Page 3: Table Of Contents
TAbLE Of CONTENTS I NT R O D U C T I O N Instructions guidance .........................3 1.1 Product documentation................... 3 1.2 Associated documents ..................3 1.3 Explanation of symbols................... 3 1.4 Guarantee registration .................... 3 Appliance description .........................3 2.1 Safety devices .......................3 2.2 Data label .......................4 2.3 Gas category ......................4 2.4 Regulation and statutory requirements ..............4 2.5 Hydraulic schematic .................... - Page 4 TAbLE Of CONTENTS Commissioning ..........................24 12.1 Switching on ......................24 12.2 Filling the CH system (Central heating) ..............24 12.3 Filling the Condensate Trap ................. 24 12.4 Initial lighting ......................24 12.5 Gas rates ......................25 12.6 Testing heating system ..................26 12.7 Testing domestic hot water system............... 26 12.8 Completion ......................26 Specific adjustment .........................26 13.1 Heating circuit adjustment ..................26 13.2 Appliance technical settings and parameter list ........... 27 13.3 CO2 measurement ....................30 13.4 Re-check and restart ....................
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Page 5: Instructions Guidance
Instructions guidance 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 Product documentation still benefit from a 12 month warranty from the date of issue by the manufacturer. The instructions are an integral part of the appliance and must be handed to the user on completion of the installation in order We recommend you complete and return as soon as possible to comply with the current regulation. your guarantee registration card. If your guarantee registration card is missing you can obtain a copy or record your registration • Carefully read the manual, to understand all the information by telephoning the Glow-worm Customer Service number to enable safe installation, use and servicing. No liability can 01773 828100. be accepted in the event of damage for not complying with the guidance in this instruction manual. These instructions consist of, Installation, Servicing, Fault Finding, Appliance description 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 Safety devices the user on completion of the installation. 2.1.1 Overheating safety Associated documents The appliance is designed to recognise the potential for an - 1 Instructions for use overheat lockout and will shutdown before this happens. -
Page 6: Data Label
Installers are required to carry out installation, commissioning - The electrical protection class and servicing work in accordance with the Benchmark Code of Practice which is available from the Heating and Hotwater - The minimum and maximum heat input (Q) Industry Council who manage and promote the Scheme. - The minimum and maximum power output (P) Visit www.centralheating.co.uk for more information. • - The CE number and logo The appliance shall only be connected to the gas type(s) indicated on the data label. Gas category This boiler is for use only on G20, but can be converted for use on G31 (except 12sxi). • To adapt the appliance to another type of gas, see the chapter "Gas conversion". 0020112600_02 - 10/12 - Glow-worm - 4 -... -
Page 7: Hydraulic Schematic
Condensate trap 17 Pump Ignition and control electrode 18 filling taps burner Heating flow Main heat exchanger Pipe for heating safety valve Thermal fuse flue outlet Heating return 10 Silencer Condensate drain Heating expansion vessel 12 fan 0020112600_02 - 10/12 - Glow-worm - 5 -... -
Page 8: Safety Instructions And Regulations
“Domestic Gas Installations”, the current Building Regulations The basic safety instructions must be followed before and reference should be made to the current ETCI rules for attempting to maintain or replace spare parts: Electrical Installation. • Stop the appliance. GB: the following Codes of Practice apply: BS4814, BS6798, BS5440 Part 1 and 2, BS5546 Part 1, BS5449, BS6891, • Electrically isolate the appliance from the power supply. BS6700, BS7074 Part 1 and 2, BS7593, BS7671. IE: I.S.813, BS5546, BS 5449, BS 7074, BS 7593. • Turn off the appliance gas isolation valve. NOTE: For further information, see the current issue of the • Hydraulically isolate the appliance using the isolation valves Building Regulations, approved document L1 ( in the UK) and if provided. the following current issues of: 1) Central heating system specification (CheSS) and • Should you need to replace hydraulic components, drain the 2) Controls for domestic central heating system and hot water. appliance. BRECSU. • Protect all the electrical components from water while working on the appliance. • Use only original spare parts. 0020112600_02 - 10/12 - Glow-worm - 6 -... -
Page 9: Recycling
By complying with this directive, you will contribute Connection of the whole electrical system of the boiler, including to the preservation of natural resources and the any heating controls, to the electrical supply MUST be through protection of human health. one common isolator and must be fused 3 Amp maximum. Packaging Isolation should be by a double pole switched fused spur box, with a minimum gap of 3mm for both poles. The fused spur We recommend that you recycle the packaging of the appliance in a responsible fashion. box should be readily accessible and preferably adjacent to the appliance. It should be identified as to its use. • Sort the waste in order to separate those elements which can be recycled (cardboard, plastics ...) and those which Alternatively connection can be made through an unswitched cannot be recycled. shuttered socket and 3A fused 3-pin plug both to the current issue of BS 1363, provided they are not used in a room • Eliminate the waste in accordance with existing regulations. containing a bath or shower. Wiring to the boiler must be PVC 85OC insulated cable, not less than 0.75mm2 (24/0.20mm). 0020112600_02 - 10/12 - Glow-worm - 7 -... -
Page 10: Technical Data
Gas connection Ø O.D. (copper) (copper) (copper) Heating flow and return connection Ø O.D. (copper) (copper) (copper) 21.5 21.5 21.5 Condensate connection Ø I.D. (plastic) (plastic) (plastic) Safety valve discharge connection Ø O.D. (copper) (copper) (copper) 37.1 37.1 38.3 Lift weight 81.8 81.8 84.5 Total weight (installed) 1312 1312 1312 Number of CE certificate 5333 5334 5336 0020112600_02 - 10/12 - Glow-worm - 8 -... -
Page 11: Installation
- The minimum clearances from the boiler case are BUILDING REGULATIONS. maintained. In IE reference should be made to the current edition of I.S.813 “Domestic Gas Installations” and the current ETCI rules. Ventilation Timber Frame Buildings If the boiler is to be installed in a timber frame building it should 6.3.1 Room Ventilation be fitted in accordance with the Institute of Gas Engineers document IGE/UP/7/1998. The boiler is room sealed so a permanent air vent is not required. 6.3.2 Cupboard or Compartment Ventilation Clearances Due to the high efficiency and low casing temperature of this • To allow periodic maintenance, ensure the distances boiler, cupboard or compartment ventilation is not necessary. indicated on the diagram. • Existing ventilation should be investigated for its purpose Additional clearances may be beneficial around the boiler for before removing. installation and servicing. For flue installations where external access is not practicable, consideration should be given for the space required to insert 0020112600_02 - 10/12 - Glow-worm - 9 -... -
Page 12: Appliance Installation
- In GB, Guidance on vessel sizing is also given in the current Documents bag (x1) issue of BS5449 and BS7074 Part 1. Installation and servicing manual (x1) flue book (x1) - In IE, current edition of I.S.813 “Domestic Gas Installations”. Instructions for use (x1) Extended guarantee leaflet (x1) Guarantee envelope pack (x1) Magnetic lighting instruction label (x1) Gas conversion label (x1) 0020112600_02 - 10/12 - Glow-worm - 10 -... -
Page 13: Dimensions
Heating return circuit 3 4 4 boiler Double check valve assembly Domestic cold water supply in Temporary filling loop (remove immediately after filling) Drain point back flow prevention device Tundish The system should be pressurised to 0.8bar, indicated on the digital display with no heating demand. Drain points Drain taps must be provided at all low points of the system, which will allow the entire system to be drained. Drain taps shall be to the current issue of BS2879. 0020112600_02 - 10/12 - Glow-worm - 11 -... -
Page 14: Mounting
80/125 flue • Drill the holes for the fixing screws in accordance with the wall template. • Take the wall template and place in the desired position on the wall, giving due consideration to the required boiler • Fix the hanging bracket on the wall. clearances, see chapter "Appliance location ► Clearances", and the flue you are fitting. 7.4.1 fixing to the wall 1 3 0 9 0 ° Wall template Standard flue length horizontal 2.5° 44mm/metre inclined extended flue length Wall plug 0020112600_02 - 10/12 - Glow-worm - 12 -... -
Page 15: Hydraulic Connection
Gas service isolating valve with pressure test point + sealing washer ½" Heating flow isolating valve + sealing washer ¾" Connection Ø O.D. 22 mm Connection Ø O.D. 15 mm • Use only the original gas service isolation valve type GER/1 DN15, CE-0085 CL 0082 • Use only the olive which is delivered with the gas isolation valve • Use only original sealing washers • Remove the protective caps from the boiler connections. • Flush out the domestic hot water and the heating systems. 0020112600_02 - 10/12 - Glow-worm - 13 -... -
Page 16: Safety Discharge Valve
The pipe should have a fall of a least 2.5° 44mm/ metre away from the boiler. The pipe must have a continuous fall and be routed to a position so that any discharge of water, possibly boiling, Condensate should, if possible be discharged into the or steam cannot create any danger to persons, damage to household internal drainage system. property or external electrical components and wiring. • If this is not practicable, discharge can be allowed into the external household drains or a purpose designed soak away, refer to diagram overleaf. It is recommended that any external condensate drain pipe is protected and also preferably of 32mm diameter, to prevent freezing in adverse weather conditions. • Always ensure the pipe is installed with the correct fall • Connect the boiler condensate drain (1) to a condensate discharge pipe which should be minimum of 19 mm internal diameter and be made of an acid resistant material (e.g. plastic overflow pipe). Do not use metal pipes. It is permissible to use a condensate neutraliser providing that it is checked for correct operation. 0020112600_02 - 10/12 - Glow-worm - 14 -... - Page 17 INSTALLATION 0020112600_02 - 10/12 - Glow-worm - 15 -...
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Page 18: Evacuation Of Combustion Gas
Where safe and practical to do so advise the Regulation homeowner to check the flue outlet and clear visible insects from the terminal end. Only flue accessories supplied by Glow-worm must be used. Different flue outlet configurations can be carried out. • Consult your supplier for more information about the other possibilities and associated accessories. - Page 19 Position Position of the flue terminal Horizontal flues from surface or a boundary facing the terminal directly below an opening, air brick, from opening (door/window) in car port 1200 opening windows into dwelling above an opening, air brick, opening windows vertical from a terminal 1500 horizontally to an opening, air brick, opening horizontally from a terminal windows Vertical flues below gutter, drain/soil pipe from another terminal below eaves above roof level below a balcony or car port from adjacent opening window 1000 from vertical drain pipes and soil pipes from adjacent wall to flue from internal/external corners to a boundary alongside the terminal (*) These dimensions comply with the building regulations, above adjacent ground or balcony level but they may need to be increased to avoid wall staining and nuisance from pluming depending on site conditions. 0020112600_02 - 10/12 - Glow-worm - 17 -...
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Page 20: Flue Configuration Description
C43 flue systems must not be a 'pressurised system' but act under natural draught principles C43 type flue systems must have their own condensate drain fitted and not allow condensate to mix into other appliances 1 Gasket (fitted) 0020112600_02 - 10/12 - Glow-worm - 18 -... -
Page 21: Remove The Front Panel
Model 12sxi 18sxi 30sxi The appliance must be connected directly to an accessible, Exhaust mass rate (g/s) fixed, switched, electrical outlet. At min thermal load (40°C/30°C) The external wiring must be earthed, with correct polarity and in At max thermal load (80°C/60°C) 13.8 accordance with current standards. Exhaust temperature (°C) The manufacturer declines any responsibility for damages to At min thermal load (40°C/30°C) persons or others caused by the incorrect installation of the At max thermal load (80°C/60°C) 65.7 71.4 appliance earthing. This includes failure to comply with current standards. Electrical components have been tested to meet the equivalent requirements of the BEAB. • Do not use cable greater than 10 mm in diameter for the electrical connections. All system components must be of an approved type. • Do not interrupt the mains supply with a time switch or programmer. The boiler is suitable for installation in bathroom zones 2 and 3. 0020112600_02 - 10/12 - Glow-worm - 19 -... -
Page 22: Access To Main Board
Terminal blocks for 230 V connection 230 V access cover 11.2 Main board 30mm Connector Electrical wires Insulation When you connect the electrical wires to a connector on the electronic board: Power supply cable • Keep a distance of a maximum of 30 mm between connector • Connect the appliance's power cable to the 230 V single- (1) and the start of the insulation (3). phase network + earth. • If using single core wires are used(2) ensure that the are • Connect the appliance correctly to the live and neutral wrapped together in an insulating sheath. connections. • Fix the cables in the cable-clamp on the eBox. 0020112600_02 - 10/12 - Glow-worm - 20 -... - Page 23 Double pole connector RT = Switch live (230V) = Mains earth • Connect mains supply as described. N = Mains neutral L = Mains live Junction box fuse Double pole connector • Connect the mains supply and system heating controls e.g. room thermostat as described. • When installing a 230V controller, the link fitted to the 24V terminals (RT/24V) must be removed. RT 24V T° ext 0020112600_02 - 10/12 - Glow-worm - 21 -...
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Page 24: External Accessories
Ebus room thermostat connector or Ebus radio receiver/Smart wiring centre Outdoor sensor connector Overheating safety connector for heating floor • Fit external controls in accordance with the rules in force. • When installing a non eBus controller, the link fitted to the 24V terminals (RT/24V) must be removed. 11.5 Testing the electrical connections Carry out preliminary electrical system checks as below: • Resistance to earth (<1 Ohm) • Short circuit test (L-N) • Resistance to earth (L-E) • Polarity check 0020112600_02 - 10/12 - Glow-worm - 22 -... -
Page 25: Wiring Diagram
13 Heating return temperature sensor Location for 24V option card 14 Gas valve Location for external programmer 15 fan User interface 16 Thermal fuse fuse 2A 17 Water pressure sensor Connector for 230 V option Main supply 230V 0020112600_02 - 10/12 - Glow-worm - 23 -... -
Page 26: Commissioning
• Test for gas soundness and purge air from the gas supply. • Press the on/off button to activate the appliance. • Make sure that the domestic hot water and heating functions on your appliance are not activated. filling trap 12.2 filling the CH system (Central heating) Condensate trap • Make sure that the installation's cold-water inlet isolating • Fill the trap 3/4 full with water (1). valve is open. • Activate the Heating and, if Glow-worm intelligent controls • Open the isolating valves located on the connections: they are fitted, Domestic Hot Water functions. must be positioned in the direction of the flow. • Run the appliance for at least 15 minutes, with a heating If the Central Heating (C.H.) pressure falls below 0.4 bar, the temperature set to greater than or equal to 50°C (not display will flash the current pressure and the boiler will not applicable for an installation with underfloor heating). operate. To increase the pressure, the CH circuit requires • Vent air from each radiator again until the water flows "Topping up". -
Page 27: Gas Rates
Do not use the reset button to purge the installation - never press reset more than 3 times. 12.5.2 Gas Rate • Press the central heating water temperature button and the factory setting temperature will be displayed. • Make sure that all other gas burning appliances and pilot lights are off. • Press or buttons to adjust. • Check the gas rate using the gas meter test dial and stop • If Glow-worm intelligent controls are fitted, press the watch, at least 10 minutes after the burner has lit, see table hot water temperature button and the factory setting below for approximate rates. To check the settings in the sxi temperature will be displayed. range activate P.03 in the diagnostic menu and ensure that in the diagnostic codes d.00 are set at the maximum setting for • Press or buttons to adjust. the appliance. 12.5 Gas rates... -
Page 28: Testing Heating System
Available pressure between heating flow and return (kPa) 13.1 Heating circuit adjustment Heating circuit flow rate (l/h) Speed min, bypass closed It may be necessary to adjust the by-pass to the design of the Speed max, bypass closed system. The boiler is delivered pre-set open 1/2 turn (1). Speed max, bypass middle position Speed max, bypass opened 0020112600_02 - 10/12 - Glow-worm - 26 -... -
Page 29: Appliance Technical Settings And Parameter List
Functioning mode: 0 = Automatic: maximum speed when the burner is switched on d.19 Speed of the pump 1 = Minimum speed 2 = Automatic: automatic speed when the burner is switched on 3 = Maximum speed Maximum temperature setting for The recommended maximum temperature setting for domestic hot d.20 °C domestic hot water water is 60°C. Choose a value suitable for your needs. The following 2 menus are displayed if an option card (not supplied) is installed on the appliance. d.27 Function relay 1 Reserved for future use d.28 Function relay 2 Reserved for future use 0020112600_02 - 10/12 - Glow-worm - 27 -... - Page 30 Pump status 1 = on 0 = open (no heating), d.16 Current state of the 24V room thermostat °C 1 = closed (heating mode) Temperature regulation on flow (radiator) or return d.17 Flow or Return temperature control °C (under-floor heating) temperature sensor. 0 = DHW function disabled d.21 DHW status 1 = DHW activated 0 = off d.22 DHW mode (eBus and direct connection to board) 1 = on 0 = CH not available (summer mode) d.23 Central heating mode 1 = CH available (winter mode) DHW loading enabled or disabled by Appliance d.25 DHW mode Interface or Ebus or external controls. Fan speed is displayed between 0 and 99. d.33 Speed setpoint of fan Multiply the displayed value by 100. d.44 Digitalized ionisation voltage Display the digitalized ionisation voltage 0020112600_02 - 10/12 - Glow-worm - 28 -...
- Page 31 Domestic hot water heating- ebus only smart wiring 13.2.4 Test modes Status centre S.20 Pre-run pump By activating these various test modes, you can enable special S.21 Pre-run fan functions on the appliance. S.23 Ignition • Press the on/off button to switch off the appliance. S.24 Burner lit S.25 Post run pump/fan • While keeping the button pressed for more than 5 S.26 Post run fan seconds, press the on/off button. S.27 Post run pump The screen displays the first test mode "P01" and "Off". S.28 The boiler blocks warmstart after a reheating cycle. 0020112600_02 - 10/12 - Glow-worm - 29 -...
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Page 32: Co2 Measurement
CO2 measurement • Advise the user that the permanent mains electrical supply The combustion for this appliance has been pre-set at the should not be switched off, as the built in frost protection and factory for operation on Natural Gas G20 as defined on the pump exercise program will not operate. appliance data label. • Advise the User if the mains electricity and gas are to be No adjustment of the combustion is necessary. turned off for any long periods during severe weather, it is recommended that the whole system, including the boiler, If you wish to check the combustion then follow the instructions should be drained to avoid the risk of freezing. in the Servicing section. Sealed system: The system must be refilled and to the correct pressure as indicated in these instructions • Leave these instructions and the ‘Benchmark’ Installation, Commissioning and Service Record with the user. 0020112600_02 - 10/12 - Glow-worm - 30 -... -
Page 33: Maintenance
Check the electrical installation 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 and usage, but in general once a year should be enough. It is the Law that any servicing is carried out by a competent person approved at the time by the Health and Safety Executive. • Before commencing with a service or replacement of parts isolate the boiler from the electrical supply and turn off the gas supply at the gas isolation valve. • 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 chapter "Trouble-shooting ► Fault diagnosis ► Check the electrical installation". • After servicing, complete the relevant Service Interval Record Main board section of the Benchmark Checklist located in this document. Neutral Live Multimeter 15 Trouble-shooting • Remove the front casing panel • 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... -
Page 34: Fault Memory
• Check the wiring harness. Flow heating temperature sensor fault Sensor short-circuit • Check the sensor. Return heating temperature sensor Return heating temperature sensor fault shorted. • Check the operation of the pump. Overheating safety device activated • Check the wiring harness. Overheating fault (97°C) • Check that the flow and return heating isolation valves are open. • Fill the installation. • Purge the installation. Return water valve closed • Check the pump connections. Water pressure of the installation (<0.3 bar) Pump disconnected • Check the flow and return heating sensor Leak in the installation connections. • Check that there are no leaks. • Check the flow and return heating sensor Maximum temperature difference reached Water circulation fault connection. between return and flow heating • Check the pump speed. Malfunction of the pump (excessively • Check that the flow and return heating isolation Water circulation fault rapid temperature increase) valves are open. 0020112600_02 - 10/12 - Glow-worm - 32 -... - Page 35 • Check the operation of the gas valve. Defective condensate pump (option) • Check the operation of the condensate pump (option). • Fill the installation. • Purge the installation. Return water valve closed No water in the installation : the temperature • Check the pump connections. Pump disconnected does not increase when the burner is lit • Check the flow and return heating sensor Leak in the installation connections. • Check that there are no leaks. Inverted or disconnected flow and Permanent temperature difference between • Check temperature sensors connections. return heating temperature sensors flow and return heating sensors • Replace faulty sensors. Defective temperature sensors Flow and return heating temperature Flow and return heating sensors fault • Check temperature sensors connections. sensor connected to same tube • Check the sensor connections. Floor heating contact open Underfloor heating contact fault • Check that the sensor is connected to the main Sensor disconnected or defective board and the shunt is removed. • Check connection from user interface PCB to main User interface fault Defective user interface PCB. • Replace user interface. 0020112600_02 - 10/12 - Glow-worm - 33 -...
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Page 36: Functional Flow Diagram
MAINTENANCE 15.4 functional flow diagram 15.4.1 Central Heating 16 Gas conversion adjustments In order to operate with a gas other than that provided from the factory, it is necessary to some adjustments to the gas valve. This conversion should only be carried out by a competent person approved at the time by the Health and Safety Executive. • During the conversion to Propane, use of a suitable flue gas analyser is necessary. The person carrying out a combustion measurement should have been assessed as competent in the use of a flue gas analyser and the interpretation of the results. The flue gas analyser used should be one meeting the requirements of BS7927 or BS-EN50379-3 and be calibrated in accordance with the analyser manufacturers’ requirements. Competence can be demonstrated by satisfactory completion of the CPA1 ACS assessment, which covers the use of electronic portable combustion gas analysers in accordance with BS 7967, parts 1 to 4. 0020112600_02 - 10/12 - Glow-worm - 34 -... -
Page 37: Settings
2b Vertical flue adaptor Serial number stickers • Remove the front panel first. Data label location • Remove the cap (3) and connect a CO2 analyser to effect • Firmly attach the gas conversion label to the appliance in the the measurement (2). corresponding location (1) on the electrical box. 16.1.1 Adjusting the gas valve 16.2 Restart - re-check commissioning • Press the on/off button to turn the appliance off. • Before putting the appliance into operation, follow the instructions within the chapter Specific adjustment. • Turn the screw in the direction and the number of times indicated in the following table. 0020112600_02 - 10/12 - Glow-worm - 35 -... -
Page 38: Draining
• Check that there are no leaks in the joints and the safety If this appliance is installed in a rented property there is a duty valves. of care imposed on the owner of the property by the current issue of the Gas Safety (Installation and Use) Regulations, • Check that there are no gas leaks. Section 35. • Verify that the flue system is sound and complete. • Servicing/maintenance should be carried out by a competent person approved at the time by the Health and • Check the appliance’s electrical safety. Safety Executive in accordance with the rules in force in the countries of destination. 18.1.3 Cleaning of the components • To obtain service, please call your installer or Glow-worm’s • Clean the following components: own service organisation. PLEASE NOTE: During routine servicing, and after any - The condensate trap maintenance, we recommend that the following must be - The heat exchanger. checked: 0020112600_02 - 10/12 - Glow-worm - 36 -... -
Page 39: Casing Removing
• Select the “ ”, constant central heating function by pressing the “ ” button repeatedly, refer to commissioning section. The boiler should fire automatically. Safe combustion can only be verified by measuring CO/CO2 ratio. This must not exceed the value shown in the table opposite. front panel front panel retaining screw • Undo the two screws (2) on the underside of the front panel and remove the front panel (1). 0020112600_02 - 10/12 - Glow-worm - 37 -... - Page 40 Remember to replace the sample point cap on completion of the test. 18.3.4 Gas rate check • Check the gas rates as described in the commissioning Throttle section. Combustion analyser sample point 2A flue elbow 18.3.5 Completion 2b Vertical flue adaptor If it is not possible to achieve the required results for either the combustion or gas rates, it will be necessary to complete a full service of the appliance and then repeat the combustion check procedure. 0020112600_02 - 10/12 - Glow-worm - 38 -...
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Page 41: Servicing
MAINTENANCE If after servicing and adjustment of the appliance the • Repeat the operation in reverse order to replace the silencer. combustion values are still unacceptable and after further 30sxi remedial work has been carried out, the appliance must be disconnected until the CO/CO2 ratio is acceptable. • Advice can be sought from the Glow-worm Technical Helpline. 18.4 Servicing If the annual check of combustion CO2, CO/CO2 ratio checks did not require adjustment and the inspections described in "Preliminaries" were satisfactory then it will not be necessary to complete a full service. -
Page 42: Expansion Vessel
Technical Data » chapter) by means of the pressure inlet located on the expansion vessel. Adjust the pressure if necessary. • Following the installation of a new expansion vessel, fill and The condensate trap purge the appliance or installation, if necessary. Condensate outlet pipe Siphon Condensate trap retaining clips Hose • Place a container under the condensate trap (1). • Remove the siphon (3) from the condensate trap and clean. • Disconnect the condensation discharge (2). • Disconnect the heat exchanger hose (5). • Remove the condensate trap (1) using the clips (4). • Clean the hose, the trap and the siphon, remove any accumulated dirt. • Reassemble the components, taking care to position the gaskets correctly. • Start the siphon (3) and fill with water. 0020112600_02 - 10/12 - Glow-worm - 40 -... -
Page 43: Combustion Block
Spark electrode inlet 13 burner Spark electrode retaining screw. 14 Gas valve Spark electrode gasket 15 fan Spark electrode 16 fan connection burner retaining nut 17 Gas pipe burner retaining screw Thermal fuse connection 0020112600_02 - 10/12 - Glow-worm - 41 -... -
Page 44: Service Completion
18.8.2 Dismantling the burner 19 Replacement of Parts Warning: The burner door seal (12) must be • Do not use reconditioned or copy parts, only use original replaced each time the burner is dismantled. parts supplied by Glow-worm. • Disconnect the spark electrode connector (6) from the igniter • If a part is required, contact the Glow-worm service unit. organisation. • Remove the gas pipe (17). • Please quote the name of the appliance, this information will be on the name badge on the front of the appliance. • Remove the connectors from the gas valve (1) and the fan (15). -
Page 45: General
Upper support bracket Retaining screw Gasket • Drain the boiler heating circuit as described in the appropriate chapter "Draining". • Remove the two screws (4). • Undo the connector (1) at the base of the vessel. • Remove upper support bracket (3). • Remove the expansion vessel (2). • Fit a new gasket between the expansion vessel and connector. • Refill, vent and pressurise the boiler. fibre washer Steel washer Glass Steel washer Circlip • Remove the circlip (5). • Remove the steel washer (4). • Remove fibre washer (1). • Remove the glass (3). 0020112600_02 - 10/12 - Glow-worm - 43 -... -
Page 46: Hydraulic Block
20 Pump head connector screws 21 Pump head retaining screws 8 Heating flow pipe retaining clip 22 Pump head 9 Heating flow pipe 23 Automatic air vent retaining clipc air vent retaining clip 10 Heating return pipe 0020112600_02 - 10/12 - Glow-worm - 44 -... -
Page 47: Automatic Air Vent
• Remove the retaining clip (29). • Remove the automatic air vent (20). • Fit the new automatic air vent and ‘O’ ring ensuring the vent cap is left loose. • Refill, vent and pressurise the boiler. 19.4.4 Low water pressure sensor • Drain the boiler heating circuit as described in the appropriate chapter "Draining". • Disconnect the electrical lead (15). • Remove the retaining clip (17), remove the low water pressure sensor (16). • Fit the new low water pressure sensor. • Refill vent and pressurise the boiler. 19.4.5 bypass • Drain the boiler heating circuit as described in the appropriate chapter "Draining". • Remove the retaining clip (23) to remove the bypass screw (24). • After replacing the bypass, refill, vent and pressurise the boiler. 0020112600_02 - 10/12 - Glow-worm - 45 -... -
Page 48: Combustion Block
MAINTENANCE 19.5 Combustion block 0020112600_02 - 10/12 - Glow-worm - 46 -... - Page 49 • Remove the gasket (9). • Remove the thermal fuse connector (20). • Check that the distance between the 2 electrodes is between 3.5 and 4.5 mm. • Remove the 2 heating pipe retaining clips (25) and (29). • Install the electrode and a new gasket. • Release the heating pipes (24) and (27) from the heat exchanger. 19.5.2 Igniter unit • Release the condensate trap pipe from the heat exchanger. • Remove the ignition lead (2). • Remove the combustion/burner door assembly (11) refering to chapter "Removing the combustion/burner door • Remove electrical connections (4). assembly". • Loosen the screws (3) located on the igniter unit (2). • Unscrew the 4 retaining screws (17) and (23) and remove • Remove the igniter unit (2). the 2 retaining plates (18) and (22) from the heat exchanger. • Pull the heat exchanger towards you to extract it from its 2 side rails. 0020112600_02 - 10/12 - Glow-worm - 47 -...
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Page 50: Condensate Trap
• Place a container under the condensate trap (1). operations in reverse. • Remove the condensate (3) from the reservoir. • After assembly test for gas tightness and purge in • Disconnect the condensation discharge (2). accordance with the current issue of BS6891or in IE, the current edition of I.S.813 “Domestic Gas Installations”. • Disconnect the heat exchanger hose (5). • Check the combustion CO2. The condense trap will contain water, lift taking care not to spill the water. 19.5.10 • Remove the condensate trap (1) using the clips (4). • Remove the burner door (11) refering to chapter "Dismantling the burner door". • IMPORTANT: Partially fill the condensate trap with water before replacing. Start the siphon (3) and fill with water. • Remove the gas valve (31) (see previous paragraph). • Loosen the 3 screws (38) located on the burner door (11). • Remove the fan (33) and the gasket (35). • Fit the new gasket (35). • Screw the new fan to the burner door (11). 0020112600_02 - 10/12 - Glow-worm - 48 -... -
Page 51: Pcb
• When refitting the rear panel, ensure the leads are not chapter "Electrical connection". trapped. 19.7.2 fuse Rating 20 Spare parts • For access, refer to chapter "Main PCB". In order to guarantee the safe and prolonged life of the product, • The fuse is located at top right hand side of the PCB, see manufacturers genuine spare parts must be used. chapter "Electrical connection ►Wiring diagram". This appliance displays a CE Mark of conformity. Only use the manufacturer’s genuine, new spare parts. • Ensure that spare parts are correctly mounted in the right position and direction. After fitting any spare part or servicing, the appliance must be tested for its safe operation. 0020112600_02 - 10/12 - Glow-worm - 49 -... - Page 52 MAINTENANCE Short List of Parts • When ordering spare parts, contact Glow-worm’s own service organisation. • 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. number of the part. Part No. Description GC Part No. 0020097277 Fan A000035144 Spark igniter 2000801935 Thermistor (flow and return) 0020097279 Gas valve 18sxi 0020097280 Gas valve 12sxi 0020038071 Gas valve 30sxi 0020038441 Electrode assembly 0020097299 User interface PCB 0020097216 Pump (head assembly) 12sxi / 18sxi 0020097220 Pump (head assembly) 30sxi A000024135 Low water pressure sensor...
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Page 53: Manual Handling
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 bracket Regulations, the following lift operation exceeds the recommended securely onto wall before lifting appliance into position. Obtain firm weight for a one man lift. grip on front and sides of appliance, lift upwards, ensure stable bal- ance achieved and lift upwards to position in place on bracket. Ensure General recommendations when handling safe lifting techniques are used – keep back straight – bend using Clear the route before attempting the lift. legs - when lifting load from floor level. Do not twist – reposition feet Ensure safe lifting techniques are used – keep back straight – bend instead. Keep boiler as close as possible to body throughout lift to using legs. Keep load as close to body as possible. Do not twist – minimise strain on back. Ensure co-ordinated movements to ensure reposition feet instead. If 2 persons performing lift, ensure co-ordinated equal spread of weight of load. Always use assistance if required. movements during lift. Avoid upper body/top heavy bending - do not Recommend wear suitable cut resistant gloves with good grip to protect lean forward/sideways. Recommend wear suitable cut resistant gloves against sharp edges and ensure good grip when handling appliance. with good grip to protect against sharp edges and ensure good grip. Always use assistance if required. Positioning of Appliance for final Installation – above worktop, foreseeable obstructions etc. - Page 57 Failure to install and commission according to the manufacturer’s instructions and complete this Benchmark Commissioning Checklist will invalidate the warranty. This does not affect the customer’s statutory rights. If yes, and if required by the manufacturer, has a water scale reducer been fitted? Condensing Boilers only The condensate drain has been installed in accordance with the manufacturer’s instructions and/or BS5546/BS6798 If the condensate pipe terminates externally has the pipe diameter been increased and weatherproof insulation fitted?
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Page 58: Service Record
service record It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed. service Provider Before completing the appropriate Service Record below, please ensure you have carried out the service as described in the manufacturer’s instructions. - Page 60 Glow-worm Nottingham Road, Because of our constant endeavour for Belper, Derbyshire. improvement, details may vary slightly DE56 1JT from those shown in these instructions. www.glow-worm.co.uk...
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