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Summary of Contents for Glow-worm Energy 25s
- Page 1 Installation and main- tenance instructions Energy 12s ‑A (H‑GB) Energy 15s ‑A (H‑GB) Energy 18s ‑A (H‑GB) Energy 25s ‑A (H‑GB) Energy 30s ‑A (H‑GB) Energy GB, IE...
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Page 2: Table Of Contents
Contents Contents Checking the factory setting ........ 30 Avoiding danger arising from insufficient water pressure............... 30 Safety ..............4 Switching on the product ........30 Intended use ............4 Filling and purging the heating installation ..30 Qualification ............4 9.10 Filling the domestic hot water circuit.... - Page 3 Contents Pipe lengths for the air/flue pipe ...... 59 Length of the C13 type air/flue pipe..... 59 Length of the C33 type air/flue pipe..... 59 Length of the C43 type air/flue pipe..... 59 Index ................... 60 0020300876_01 Energy Installation and maintenance instructions...
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Page 4: Safety
1 Safety Safety Qualification The person carrying out the work described Intended use here must have completed professional train- The product is intended as a heat generator ing. The competent person must demon- for sealed heating installations and for do- strably have all of the knowledge, skills and mestic hot water generation. - Page 5 Safety 1 ▶ Do not use naked flames (e.g. lighters, 1.3.3 Air supply matches). Unsuitable or insufficient combustion and ▶ Do not smoke. room air may lead to material damage, but ▶ Do not use any electrical switches, mains also to life-threatening situations. plugs, doorbells, telephones or other com- To ensure that the combustion air supply is munication systems in the building.
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Page 6: Regulations (Directives, Laws, Standards)
▶ You can find a list of relevant standards at To prevent material damage that is caused https://www.glow-worm.co.uk/standards. by heat transfer: ▶ Only solder connectors if the connectors are not yet screwed to the service valves. -
Page 7: Guarantee And Customer Service
To register your Glow-worm appliance visit: https://self-service.glow-worm.co.uk/warranty-registration Glow-worm is a licensed member of the Benchmark Scheme. Benchmark places responsibilities on both manufacturers and installers. The purpose is to ensure that customers are provided with the correct equipment for their needs, that it is installed, commissioned and serviced in accordance with the manufacturer’s instructions by a competent person approved at the time... -
Page 8: Technical Data
3 Technical data Technical data Technical data – General Energy7 12s ‑A Energy7 15s ‑A Energy7 18s ‑A Energy7 25s ‑A Energy7 30s ‑A (H‑GB) (H‑GB) (H‑GB) (H‑GB) (H‑GB) Gas category Diameter of the gas pipe 1/2 inch 1/2 inch 1/2 inch 1/2 inch 1/2 inch... - Page 9 Technical data 3 Energy7 12s ‑A Energy7 15s ‑A Energy7 18s ‑A Energy7 25s ‑A Energy7 30s ‑A (H‑GB) (H‑GB) (H‑GB) (H‑GB) (H‑GB) Maximum heat output 12 kW 15 kW 18 kW 25 kW 30 kW Effective output range (P) at 4.8 to 13.0 kW 4.8 to 16.2 kW 5.3 to 19.5 kW...
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Page 10: Notes On The Documentation
4 Notes on the documentation Notes on the documentation ▶ Always observe all operating instructions enclosed with the installation components. ▶ Store these instructions and all other applicable docu- ments for further use. These instructions apply only to: Product article number Article number Gas Council Number... -
Page 11: Product Description 5
Cat. Unit category Benchmark Condensing techno- Efficiency class of the boiler in accord- Glow-worm is a licensed member of the Benchmark logy ance with EC Directive 92/42/EEC Scheme. Type: Xx3(x) Permissible flue gas connections Benchmark places responsibilities on both manufacturers Maximum water pressure in heating and installers. -
Page 12: Functional Elements: System Boiler
5 Product description Functional elements: System boiler 5.5.2 Overheating Safety The boiler software is designed to recognise the potential for an overheat lockout and will shutdown before this happens. To restart the boiler, press the reset button on the boiler interface. -
Page 13: Set-Up
Set-up 6 Set-up Dimensions Unpacking the product Remove the product from its box. Remove the protective film from all of the product's components. Checking the scope of delivery ▶ Check that the scope of delivery is complete and intact. Number Designation Heat generator Unit mounting bracket... -
Page 14: Installation Site
6 Set-up Installation site Air/flue pipe 6.7.1 Regulation This boiler is not suitable for outdoor installation. This boiler may be installed in any room. However if the boiler is being Different flue outlet configurations can be carried out. installed in a room containing a bath or shower it must only be installed in zones 2 or 3. - Page 15 Set-up 6 A terminal guard is required if persons could come into con- tact with the terminal or the terminal could be subject to dam- age. If a terminal guard is required, it must be positioned to provide minimum of 50 mm clearance from any part of the terminal and be central over the terminal.
- Page 16 6 Set-up 6.7.3 Position of the air/flue terminal 6.7.3.1 Positioning the terminal of a fan-supported flue system Installation site Dimensions Adjacent to a boundary. 300 mm The dimension below eaves, balconies and car ports can be reduced to this value, as long as the flue terminal is 25 mm extended to clear any overhang.
- Page 17 Set-up 6 Installation site Dimensions Below eaves. 200 mm Below gutters, pipe and drains. 75 mm The dimension below eaves, balconies and car ports can be reduced to this value, as long as the flue terminal is 25 mm extended to clear any overhang. External flue joints must be sealed with suitable silicon sealant. Above adjacent ground or balcony.
- Page 18 6 Set-up 6.7.4.2 Vertical Concentric Flue ⌀ 60/100 mm or 6.7.4 Flue Configuration Description ⌀ 80/125 mm (C33 type installation) 6.7.4.1 Horizontal Concentric Flue ⌀ 60/100 mm or ⌀ 80/125 mm (C13 type installation) Gasket (fitted) Consult the separate installation manual for air/flue gas sys- Note tems supplied with your appliance for all possibilities and as- If the terminal is at less than 1.80 m from the...
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Page 19: Using The Mounting Template
Set-up 6 6.7.4.3 Multiple boiler chimney Flue ⌀ 60/100 mm Using the mounting template (C43 type installation) ▶ Use the mounting template to ascertain the locations at which you need to drill holes. 6.7.4.3.1 Multiple Boiler Chimney Flue Wall-mounting the product Note If you are using the rear air/flue connection, in- stall the air/flue pipe before you wall-mount the... -
Page 20: Removing/Installing The Front Casing
6 Set-up 6.10 Removing/installing the front casing 6.10.1 Removing the front casing 6.11.2 Installing the side section ▶ Refit the components in the reverse order. 6.10.2 Installing the front casing ▶ Refit the components in the reverse order. 6.11 Removing/installing the side section 6.11.1 Removing the side section Caution. -
Page 21: Installation
Installation 7 Installation Checking the gas meter ▶ Make sure that the existing gas meter is capable of Preparing for installation passing the rate of gas supply required. ▶ Make sure that the existing gas meter and the pipelines Checking the gas flow rate are capable of passing the rate of gas supply required. -
Page 22: Connecting The Drain Pipework For The Expansion Relief Valve
7 Installation Caution. Risk of material damage caused by corro- sion Due to non-diffusion-tight plastic pipes in the heating installation, air gets into the heating water. Air in the heating water causes corro- sion in the heat generator circuit and in the product. -
Page 23: Connecting The Condensate Discharge Pipe
Installation 7 Connecting the condensate discharge pipe to work incorrectly. Refer to BS5546 or BS6798 for further advice on disposal of boiler condensate. 7.7.1.1 Direct Connection to internal soil and vent stack Ø22mm ▶ Follow the instructions listed here and observe the legal and local regulations on condensate discharge. - Page 24 7 Installation 7.7.1.4 Internal termination into combined sink Open end of pipe direct into gulley below ground level but above water level waste Susceptible to siphonage, must terminate in a gulley 7.7.1.7 External termination into rain water down pipe 100mm ≥...
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Page 25: Flue Installation
Installation 7 7.9.2 Closing the electronics box Preferred option for external connection ▶ Follow the instructions in the reverse order. Flue installation 7.8.1 Installing and connecting the air/flue pipe 7.9.3 Cable route You can find out which air/flue pipes may be used by consulting the enclosed set-up instructions for the air/flue system. - Page 26 7 Installation 7.9.6 Connecting controls to the electronics Only strip inner conductors just enough to establish stable connections. Ensure that the product is voltage-free. To avoid short circuits resulting from loose individual wires, fit conductor end sleeves on the stripped ends of the conductors.
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Page 27: Operation
Operation 8 Operation Using check programmes By activating various check programmes, you can trigger Using diagnostics codes various special functions on the product. You can use the parameters marked as adjustable in the Check programmes – Overview table of diagnostics codes to adapt the product to the install- ation and customer requirements. -
Page 28: Start-Up
9 Start-up Start-up trance or window or any type of public access area, be clear of any electrical fittings and positioned so that any discharge can be seen. Carrying out the initial start-up A diaphragm type expansion vessel, conforming to the cur- Initial start-up must be carried out by a customer service rent issue of BS 4814 (see also BS 7074 Part 1 and 2) must technician or an authorised competent person using the... -
Page 29: Filling The Condensate Siphon
Start-up 9 Treating the filling and supplementary water Additives for cleaning measures (subsequent ▶ flushing required) Observe all applicable national regulations and technical – rules when treating the filling and supplementary water. Adey MC3+ – Adey MC5 Provided the national regulations and technical rules do not –... -
Page 30: Checking The Gas Type
9 Start-up Checking the gas type Switching on the product ▶ Make sure that the product is set up correctly by checking Switch on the product via the main switch installed on- the gas type. This ensures optimum combustion quality. site. -
Page 31: Checking The Gas Setting
Start-up 9 9.11 Checking the gas setting 9.11.2 Checking the gas connection pressure (gas flow pressure) Only a qualified competent person is authorised to imple- ment the settings on the gas valve assembly. Each destroyed seal must be replaced. The CO₂ adjusting screw must be sealed. Never modify the factory setting of the gas pressure regu- lator of the gas valve assembly. -
Page 32: Thoroughly Flushing The Heating Installation ("Hot")
9 Start-up Condition: Gas flow pressure in the permissible range Great Britain and Ireland ▶ Removed front casing / End the check programme P.01. installed front casing ▶ Allow the boiler to cool down allowing pump overrun to Natural gas operate for a minimum of two minutes. - Page 33 Start-up 9 Activate the display for the current operating mode. (→ Page 27) Status codes – Overview (→ Page 49) ◁ If the product is working correctly, the display shows S.04. 9.13.2 Checking the domestic hot water generation Activate the domestic hot water mode on the user interface.
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Page 34: 10 Adapting The Unit To The Installation
10 Adapting the unit to the installation 10 Adapting the unit to the installation Flow rate-pressure curves for 15 kW (pressure measured downstream of the valves) You can reset/change the system parameters (section "Us- ing diagnostics codes"). Overview of diagnostics codes (→ Page 46) 10.1 Setting the burner anti-cycling time To prevent frequent switching on and off of the burner and... -
Page 35: Setting The Bypass Valve
Handing over to the end user 11 Flow rate at maximum Available pressure Position of the adjusting Notes/application output (ΔT = 20K) (kPa) screw Flow rate in circuit (l/h) If the radiators do not heat up sufficiently at the factory Right-hand stop (screwed Flow rate-pressure curves for 30 kW setting. - Page 36 11 Handing over to the end user ▶ Inform the end user about measures taken to ensure the supply of combustion air and flue gas guiding, and instruct the operator that he must not make any changes. ▶ Inform the end user that they must not store or use explo- sive or highly flammable substances (such as petrol, pa- per or paint) in the installation room of the product.
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Page 37: 12 Inspection And Maintenance
Inspection and maintenance 12 ▽ 12 Inspection and maintenance The value is not OK; you cannot start up the product. ▶ 12.1 Using original seals Set the CO₂ content. If you replace components, use only the enclosed original 12.5 Removing the gas-air mixture unit seals;... -
Page 38: Cleaning The Heat Exchanger
12 Inspection and maintenance 12.7 Checking the burner Check the surface of the burner for possible damage. If you see any damage, replace the burner. Install the two new burner seals. 12.8 Checking the ignition electrode Remove the gas-air mixture unit (6). Disconnect the connection (2) and the earth cable (1). -
Page 39: 12.10 Installing The Gas-Air Mixture Unit
Inspection and maintenance 12 12.10 Installing the gas-air mixture unit Install the burner. Install two new burner seals in the burner hood. Install the gas-air mixture unit. Tighten the screws on the gas-air mixture unit. – Ideally to 7 Nm if a torque spanner is available. Install the flue pipe. -
Page 40: 13 Troubleshooting
13 Troubleshooting 13 Troubleshooting operation of the product. To receive information about the available original spare parts, contact the contact address provided on the back page of these instructions. 13.1 Eliminating faults ▶ If you require spare parts for maintenance or repair ▶... - Page 41 Troubleshooting 13 13.6.4 Replacing the pump head Remove the upper clip (1). Disconnect the pump cables from the electronics box. Remove the lower clip (3). Undo the four screws (1). 10. Remove the return pipe (2). Remove the pump head (2). Replace the O-ring.
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Page 42: Checking The Product For Leak-Tightness
13 Troubleshooting 13.6.6 Replacing the main PCB 13.6.8 Replacing the expansion relief valve Remove the clip (2). Remove the expansion relief valve. Fit the new expansion relief valve with a new O-ring. Reattach the clip (2). 13.6.9 Replace the pressure sensor Open the electronics box. -
Page 43: Decommissioning The Product 14
Close the gas stopcock. ▶ Close the cold-water stopcock. 15 Recycling and disposal Disposing of the packaging ▶ Dispose of the packaging correctly. ▶ Observe all relevant regulations. ▶ For detailed information refer to www.glow-worm.co.uk. 0020300876_01 Energy Installation and maintenance instructions... -
Page 44: Appendix
Appendix Appendix Inspection and maintenance work 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. Each time inspection and maintenance work is carried out, carry out the required preparatory and com- pletion work. -
Page 45: B Check Programmes - Overview
Appendix Maintenance work Interval Reassemble the product After each time maintenance work is carried out Open the service valves, carry out the required leak-tightness test Annually Fill the product/heating installation to the filling pressure specified for the Annually system Connect the product to the electrical installation Annually Run the test operation on the product/heating installation including hot Annually... -
Page 46: C Overview Of Diagnostics Codes
Appendix Overview of diagnostics codes Note Since the code table is used for various products, some codes may not be visible for the product in question. Dia- Values Default set- gnostics Parameter Unit Increment, select, explanation Own setting ting Min. Max. - Page 47 Appendix Dia- Values Default set- gnostics Parameter Unit Increment, select, explanation Own setting ting Min. Max. code – d.18 Pump overrun operat- 1 = Continuous (pump runs per- Adjustable ing mode manently) 3 = Eco (intermittent pump oper- ation – for the dissipation of the residual heat after domestic hot water generation at an extremely low heat demand)
- Page 48 Appendix Dia- Values Default set- gnostics Parameter Unit Increment, select, explanation Own setting ting Min. Max. code – – d.35 Position of the priorit- Current value 0 = Heating ising diverter valve adjustable 40 = Mid-position (parallel opera- tion) 100 = Domestic hot water –...
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Page 49: D Status Codes - Overview
Appendix Dia- Values Default set- gnostics Parameter Unit Increment, select, explanation Own setting ting Min. Max. code – – – d.77 Max. cylinder post- Adjustable heating → Section "Technical data" – d.80 Running time in heat- Current value Running time = Display value x ing mode adjustable –... -
Page 50: E Overview Of Fault Codes
Appendix Status code Meaning S.13 Domestic hot water mode: Burner ignition S.14 DHW mode: Burner on S.15 DHW mode: Pump/fan overrun S.16 DHW mode: Fan overrun S.17 DHW mode: Pump overrun Display in comfort mode with warm start or domestic hot water mode with cylinder S.20 Domestic hot water mode: Requirement S.21... - Page 51 Appendix Fault code Meaning Possible cause F.12 and Short circuit: Cylinder temperature NTC sensor defective, short circuit in the cable harness, cable/housing F.91 sensor F.13 Short circuit: Temperature sensor for the NTC sensor defective, short circuit in the cable harness, cable/housing domestic hot water cylinder F.20 Safety shutdown: Overheating temperat-...
- Page 52 Appendix Fault code Meaning Possible cause F.78 Interruption to DHW outlet sensor at UK link box is connected, but domestic hot water NTC not bridged external control F.83 Fault: Dry fire When the burner starts, the temperature change registered at the flow or return temperature sensor is non-existent or too small: Insufficient water in the product, the flow or return temperature sensor is not in the correct position on the pipe...
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Page 53: F Wiring Diagram: System Boiler
Appendix Wiring diagram: system boiler Burner off RT 24V X106 eBUS – Burner 24V= 230V~ RT 230Vac 230Vac Main PCB Pressure sensor Interface PCB External ignition transformer Temperature sensor on the heating flow Heating pump Temperature sensor on the heating return Ionisation and ignition electrode Main power supply and connection for 230 V control Gas valve assembly... -
Page 54: G Wiring Diagram: System Boiler (30 Kw)
Appendix Wiring diagram: system boiler (30 kW) Burner off X106 eBUS – Burner 24V= 230V~ RT 230Vac 230Vac Main PCB Gas valve assembly 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 Energy... -
Page 55: H Commissioning Checklist
Appendix Commissioning Checklist Benchmark Commissioning & Warranty Validation Service Record It is a requirement that the boiler is installed and commissioned to the manufacturers’ instructions and the data fields on the commissioning checklist completed in full. To instigate the boiler warranty the boiler needs to be registered with the manufacturer within one month of the installation. - Page 56 Appendix GAS BOILER SYSTEM COMMISSIONING CHECKLIST & WARRANTY VALIDATION RECORD Address: Boiler make and model: Boiler serial number: Commissioned by (PRINT NAME): Gas Safe registration number: Company name: Telephone number: Company email: Company address: Commissioning date: Heating and hot water system complies with the appropriate Building Regulations? Time, temperature control and boiler interlock provided for central heating and hot water Boiler Plus requirements (tick the appropriate box(s)) Weather compensation...
- Page 57 Appendix SERVICE & INTERIM BOILER WORK RECORD It is recommended that your boiler and heating system are regularly serviced and maintained, in line with manufacturers’ instructions, and that the appropriate service / interim work record is completed. Service provider When completing a service record (as below), please ensure you have carried out the service as described in the manufacturers’ instructions. Always use the SERVICE/INTERIM WORK ON BOILER SERVICE/INTERIM WORK ON BOILER Date:...
- Page 58 Appendix SERVICE & INTERIM BOILER WORK RECORD It is recommended that your boiler and heating system are regularly serviced and maintained, in line with manufacturers’ instructions, and that the appropriate service / interim work record is completed. Service provider When completing a service record (as below), please ensure you have carried out the service as described in the manufacturers’ instructions. Always use the SERVICE/INTERIM WORK ON BOILER SERVICE/INTERIM WORK ON BOILER Date:...
- Page 59 Appendix Pipe lengths for the air/flue pipe Length of the C13 type air/flue pipe Validity: C13 type air/flue pipe Diameter of the air/flue pipe Dia. 60/100 (L) Dia. 80/125 (L) C13 type air/flue C13 type air/flue pipe pipe Energy7 12s ‑A ≤...
- Page 60 Index Index Kammerbelüftung ..............14 Kundendienst ................ 7 Air/flue pipe, horizontal wall duct......... 18 Air/flue pipe, installing ............25 Leak-tightness ............32, 39, 42 Air/flue pipe, type C13 ............18 Maintenance work ............... 37 Air/flue pipe, type C33 ............18 Minimum clearance .............
- Page 64 Nottingham Road ‒ Belper-Derbyshire ‒ DE56 1JQ Telephone 01773 824639 ‒ Technical helpline 0330 100 7679 After sales service 0330 100 3142 0020300876_01 www.glow-worm.co.uk 0020300876_01 ‒ 09.11.2020 © These instructions, or parts thereof, are protected by copyright and may be reproduced or distributed only with the manufacturer's written consent.
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