Glow-worm Xtramax HE Installation And Servicing
  1. Manuals
  2. Brands
  3. Glow-worm Manuals
  4. Boiler
  5. Xtramax HE
  6. Installation and servicing

Glow-worm Xtramax HE Installation And Servicing

High efficiency condensing boilers
Hide thumbs Also See for Xtramax HE:
Table of Contents

Advertisement

Quick Links

See also: Instructions for Installation and Servicing , Instructions for Use Manual
Xtramax HE
G.C. No. 47-047-29

Installation and Servicing

High Effi ciency
Condensing
Boilers
www.glow-worm.co.uk
www.glow-worm.co.uk

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the Xtramax HE and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Glow-worm Xtramax HE

Summary of Contents for Glow-worm Xtramax HE

  • Page 1: Installation And Servicing

    Xtramax HE G.C. No. 47-047-29 Installation and Servicing High Effi ciency Condensing Boilers www.glow-worm.co.uk 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 and labour.

  • 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: Important Information

    - Use safety clothing where appropriate, e.g. gloves, safety without permission, in writing, by Glow-worm. footwear. Any alteration not approved by Glow-worm, could invalidate the Ensure safe lifting techniques are used certification, boiler warranty and may also infringe the current - Keep back straight.

  • Page 5: Statutory Requirements

    Statutory Requirements CE Mark Gas Supply This boiler meets the requirements of Statutory Instrument, The gas installation must be in accordance with the relevant No. 3083 The Boiler (Efficiency) Regulations, and therefore is standards. deemed to meet the requirements of Directive 92/42/EEC on In GB, this is BS6891.

  • Page 6: Safety Devices

    Glow-worm. If this appliance is installed in a rented property there is a duty of If a part is required contact Glow-worm’s own service organisation care imposed on the owner of the property by the current issue of using the telephone number on the inside front cover of this the Gas Safety (Installation and Use) Regulations, Section 35.

  • Page 7: Technical Information

    See diagrams 1.1, Table 1, Table 1 continued and Table 2. 3 0 1 8 9 0 4 8 0 7 0 0 Diagram 1.1 TABLE 1 Description Unit Xtramax HE Gas category ll2H3P SEDBUK rating 90.6% Band A Boiler flue type C13, C33, C53 Heating Heating output at 80°C/60°C (P)
  • Page 8 Class CE number 1312 BP 4108 TABLE 2 Technical data depending on the gas type Unit Xtramax HE Natural gas G 20 (1) Sanitary flow rate at maximum input 3.62 Heating flow rate at maximum input 3.02 Flow rate at minimum input 0.68...
  • Page 9 1 Technical Information Flue outlet 25 Heating isolating valve Main heat exchanger 26 Filter on cold water inlet Burner 27 Filling system Ignition and control electrode 28 Filter on heating circuit 29 Heating isolating valve Gas control valve 30 Domestic cold water isolating valve DHW storage vessel 31 Heating isolating valve Condensate drain...

  • Page 10: Boiler Location

    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 the local gas undertaking or Glow-worm. 2.4 Combustible Material The boiler and flue are suitable for installation onto and through...

  • Page 11: Flue Location And Ventilation

    L1 and L2, however, for every 90 or 45 elbows used the flue length MUST be reduced by 1 metre. 3.2 Flue Accessories Additional accessories are available. See Glow-worm “Flue Options Guide” for configurations available. Vertical concentric flue Diagram 3.2 1 8 8 Diagram 3.3...

  • Page 12: Terminal Position

    Increased siting flexibility can be achieved by using the Glow-worm Plume Management Kit. A2044000 (black) or A2044100 (white). NOTE: If the flue terminal is positioned near a light source HORIZONTAL FLUES insects may enter the flue system.

  • Page 13: Heating System

    4 Heating System 4.1 General 4.5 Filling the Sealed System The boiler is for use only with sealed central heating systems. NOTE: The water pressure at the boiler must be at least 1.2bar to enable filling the boiler to a minimum pressure. The boiler is The safety valve is an integral part of the boiler and it cannot supplied with a filling device.

  • Page 14: Installation Preparation

    6 Installation Preparation 6.1 Appliance Pack 6.5 Appliance Connection IMPORTANT: With regards to the Manual Handling Operations, Remove front panel, unscrew and remove the two retaining 1992 Regulations, the following lift operation exceeds the screws from the bottom of the front panel. recommended weight for a one man lift, refer to Manual Handling Remove front panel by lifting up and forward.

  • Page 15: Gas/Water And Appliance Connection

    7 Gas / Water and Appliance Connection 7.1 Gas Connection 7.2 Water & Appliance Connections Before connection check supply of local gas. Before undertaking any operation, carefully clean the pipes Refer also to statutory requirements. with an appropriate product in order to remove impurities such as filings, welds, oils and greases that may be present.

  • Page 16: Safety Discharge, Condensate And Tundish Connection

    8 Safety Discharge, Condensate and Tundish Connections Domestic hot water safety valve Drain cock Filling loop extension knob Gasket Discharge valve for PRV (BLUE) on domestic hot water circuit Nut (x2) Gasket (x2) Gasket (x2) 10 Union coupling 12 Olive 15mm. 13 Tundish 14 Olive 22mm.
  • Page 17 8 Safety Discharge, Condensate and Tundish Connections Valve outlet size Minimum size Minimum size of Maximum resistance Resistance of discharge to discharge pipe D2 allowed expressed as created by tundish D1 from tundish a length of straight pipe i.e. each elbow no elbows or bends or bend G 1/2”...

  • Page 18: Condensate Drain Connection

    8.3 Tundish discharge Any fault arising from incorrect wiring cannot be put right under the terms of the Glow-worm guarantee. All system components must be of an approved type. The internal safety valves, 24 and 36 have been tee’d to-...
  • Page 19 8 Safety Discharge, Condensate and Tundish Connections Diagram 8.4...

  • Page 20: Electrical Connection

    Any fault arising from incorrect wiring cannot be ALL electrical connections to the boiler put right under the terms of the Glow-worm guarantee. must be permanently fixed to a wall or a ● All system components must be of an approved type.

  • Page 21: Commissioning

    10 Commissioning IMPORTANT At the time of commissioning, complete all relevant sections of the Benchmark Checklist located in the FLUE ELBOW centre pages of this document. 10.1 Preliminaries - All Systems Do Not operate the boiler without water. The commissioning should be carried out by a competent person approved at the time by the Health and Safety Executive and in accordance with the current issue of BS6798.

  • Page 22: Initial Lighting

    10 Commissioning Commissioning should only be carried out by a competent person approved at the time by the Health and Safety Executive. 10.4 Initial Lighting NOTE: The combustion for this appliance has been checked, adjusted and preset at the factory for operation on natural gas (G20) as defined on the appliance data label.
  • Page 23 10 Commissioning Check the gas rate using the gas meter test dial and stop The fan should start and after a few seconds the ignition will commence. watch, at least 10 minutes after the burner has lit, see table below for approximate rates. If the burner fails to light the fan will stop.

  • Page 24: Instruct The User

    10 Commissioning 10.7 Completion Adjust the boiler temperature control and any system controls to their required settings. GB: It is a requirement that the “Benchmark” Installation, Commissioning and Service Record is completed and left with the user. IE: it is necessary to complete a “Declaration of Conformity” to indicate compliance to I.S.813.
  • Page 25 As an option, a chargeable boiler only commissioning service temperature. Check that the CO combustion remains between can be provided by Glow-worm Service by calling telephone 9.8% and 10.8% CO . Further adjustment should not be No. 01773 828100.

  • Page 26: 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.

  • Page 27: Servicing 11

    Wait until the CO2 value is stable and check that the value must be disconnected until the CO/CO2 ratio is acceptable. is within the range specified in Table 3. If adjustment is Advice can be sought from the Glow-worm Technical Helpline. necessary, proceed as follows:- 11.1 Servicing...

  • Page 28: Draining Of The Appliance

    11 Servicing 11.3 Draining of the appliance Heating circuit, see diagram 11.3. Turn on the drain cock (1) provided at the system low point. Provide an air intake by opening a radiator bleed screw.In order to drain only the water in the boiler, first shut off the heating flow and return isolating valves.
  • Page 29 11 Servicing DHW pump retaining screws DHW pump motor Heating pump retaining screws Heating pump motor Cold water filter retaining clip Cold water filter Filling tap retaining clip “Foaming” filter retaining clip “Foaming” filter 10 Low water pressure sensor retaining clip 11 Low water pressure sensor 12 Sanitary exchanger retaining screws...

  • Page 30: Combustion Check

    11 Servicing 11.6 Combustion Block, refer to diagram NOTE: Make sure that the water is kept away from electrical components. Ensure that the Condensate trap is operating 11.8. correctly. 11.7 Combustion Check Ignition and control electrode Remove the ignition and control electrode connector (8). With the appliance operational connect the CO combustion analyser to the test point, see diagram 10.2.
  • Page 31 11 Servicing S 1 0 4 1 5 26 Gas valve connector 13 Mixing arm Heat exchanger retaining screws retaining plate 14 Heat exchanger hanging brackets Gasket 27 Burner retaining screws 15 Burner assembly retaining screws Viewing window gasket 28 Gas valve connector 16 Insulation Viewing window circlip 29 Gas valve retaining clip...
  • Page 32 11 Servicing Diagram 11.9 SECURING SCREW FRONT (4 OFF) INSULATION BURNER GASKET SPARK ELECTRODE Diagram 11.10...

  • Page 33: Fault Finding

    12 Fault Finding TANK OVERHEAT THERMISTOR THERMOSTAT IGNITION AND CONTROL ELECTRODE VALVE HEATING IGNITION RETURN MODULE THERMISTOR HEATING FLOW THERMISTOR WATER FLOW DOMESTIC HOT SENSOR WATER SENSOR THREE WAY VALVE WATER PRESSURE SENSOR 24V CONNECTION TO EXTERNAL CONTROLS IF REQUIRED USER INTERFACE MAIN...
  • Page 34 You will find the list of some fault codes in the operating instructions. The faults described in this chapter should be carried out by a skilled professional and if need be by Glow-worm’s After Sales Service. Important: a central heating system cannot operate efficiently if it is not filled with water and if the air it contains at first has not been completely removed.
  • Page 35 12 Fault Finding...

  • Page 36: Replacement Of Parts

    13 Replacement of Parts Remove the safety valve (15)/(20). 13.1 General Filling device Replacement of parts must be carried out by a competent Disconnect the drain connection (5) located under the filling person approved at the time by the Health and Safety Executive. device (18).
  • Page 37 13 Replacement of Parts DHW pump retaining screws 16 Heating safety valve retaining clip DHW pump motor 17 Low water pressure sensor retaining clip Heating pump retaining screws 18 Filling device Heating pump motor 19 DHW safety valve retaining clip Cold water filter retaining clip 20 DHW safety valve Cold water filter...
  • Page 38 13 Replacement of Parts 13.3 Combustion Block, refer to diagram Ignition and control electrode Remove the connector from the ignition and control electrode 13.2. connector (8). Remove the 2 ignition and control electrode retaining screws Mixing arm (11). Remove the 2 mixing arm retaining screws (23) bolted on the Fit the new ignition and control electrode and the new gasket fan (33) and the burner door.
  • Page 39 13 Replacement of Parts S 1 0 4 1 5 25 Gas valve connector 13 Mixing arm Heat exchanger retaining screws retaining screw 14 Heat exchanger hanging brackets Gasket 26 Gas valve connector 15 Burner assembly retaining screws Viewing window gasket retaining plate 16 Insulation Viewing window circlip...
  • Page 40 13 Replacement of Parts 13.4 DHW expansion vessel, refer to dia- 13.3 DHW storage vessel, refer to diagrams grams 13.3 and 13.4. 13.3 and 13.4. Relieve the DHW expansion vessel coupling (8). Heating expansion vessel Relieve the DHW expansion vessel retaining screw (9). Relieve the heating expansion vessel coupling (6).
  • Page 41 13 Replacement of Parts 13.6 Condensate trap, refer to diagram RETAINING 13.5. LATCHES Disconnect the connector flexible (5) located under the condensate trap. Remove the inner front panel. Loosen both retaining screw (3) of the condensate trap (4). Remove the condensates recovery equipment by loosening flexibles (1);...

  • Page 42: Main Pcb

    13 Replacement of Parts 13.10 Main PCB MAINS/RESET For access, refer to section 13.7. SWITCH Hinge down the control box. KNOB Remove TORX screws and unhook the rear panel. RETAINING Remove the electrical connections to the PCB. CLIPS Prise back the two PCB retaining clips and withdraw the PCB, see diagram 13.6.

  • Page 43: Spare Parts

    14.1 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 44 14 Spare Parts Diagram 15.1...

  • Page 45: Manual Handling

    15 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. Regulations, the following lift operation exceeds the recommended Fit bracket securely onto wall before lifting appliance into position. weight for a one man lift.

  • Page 47: Declaration Of Conformity

    16 Declaration of Conformity...
  • Page 48 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 www.high-efficiency.info...

Table of Contents