Glow-worm Ultrapower 100sxi Installation And Servicing
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Glow-worm Ultrapower 100sxi Installation And Servicing

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Ultrapower sxi

Installation and Servicing

100sxi
G.C. No. 41-019-09
170sxi
G.C. No. 41-019-10
High Efficiency
System Store
www.glow-worm.co.uk

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Summary of Contents for Glow-worm Ultrapower 100sxi

  • Page 1: Installation And Servicing

    Ultrapower sxi Installation and Servicing 100sxi G.C. No. 41-019-09 170sxi G.C. No. 41-019-10 High Efficiency System Store www.glow-worm.co.uk...

  • Page 2: Guarantee Registration

    12 month warranty from the date of issue by the manufacturer. We recommend you complete and return as soon as possible your guarantee registration card. If your guarantee registration card is missing you can obtain a copy or record your registration by telephoning the Glow-worm Customer Service number 01773 828100.

  • Page 3: Table Of Contents

    These instructions consist of, Installation, Servicing, Fault Finding, Replacement of Parts and Spares. The instructions are an integral part of the appliance and must, to comply with the current issue of the Gas Safety (Installation and Use) Regulations, be handed to the user on completion of the installation.

  • Page 4: Warnings

    WARNINGS Gas Leak or Fault Turn off the gas emergency control valve immediately. Eliminate all sources of ignition, i.e.smoking, blowlamps, hot air guns etc. Do not operate electrical lights or switches either on or off. Open all doors and windows, ventilate the area. Metal Parts This boiler contains metal parts (components) and care should be taken when handling and cleaning, with particular regard to edges.

  • Page 5: Gas Supply

    Regulations and reference should be made to the current worm. ETCI rules for Electrical Installation. Any alteration not approved by Glow-worm, could invalidate In GB, the following Codes of Practice apply: the certification, boiler warranty and may also infringe the BS4814, BS6798, BS5440 Part 1 and 2, BS5546 Part 1, current issue of the statutory requirements.

  • Page 6: Boiler Design

    Should there be any discharge from the pipes, isolate the conditions this may be due to the forming of ice in the boiler electrical supply and call your installer or Glow-worm’s condense drain external to the house. Release an ice...

  • Page 7: Boiler Specifications

    1 Boiler Specifications Data The data label is positioned inside the boiler module on the All dimensions are given in millimetres (except as noted). base. See diagram 1.1 and the Boiler Specification Table below. 82°C Max / 28°C Min 82°C Max / 28°C Min SEDBUK rating % 2005 91.5...
  • Page 8 1 Boiler Specifications Diagram 1.1...
  • Page 9 1 Boiler Specifications Diagram 1.2...

  • Page 10: Boiler Location, Clearances & Ventilation

    If the boiler is to be installed in a timber frame building it should be fitted in accordance with the Institute of Gas Engineers document IGE/UP/7/1998. If in doubt seek advice from local gas undertaking or Glow-worm. 2.4 Room Ventilation The boiler is room sealed so a permanent air vent is not required.

  • Page 11: Evacuation Of Combustion Gas

    If the flue terminal is positioned near a light source insects may enter the flue system. Where safe and practical to do so advise the Only flue accessories supplied by Glow-worm homeowner to check the flue outlet and clear must be used.
  • Page 12 3 Evacuation of Combustion Gas Diagram 3.2 Position Position of the flue terminal Position Position of the flue terminal Horizontal flues from opening (door/window) in car port 1200 into dwelling directly below an opening, air brick, opening windows vertical from a terminal 1500 above an opening, air brick, opening windows horizontally from a terminal...
  • Page 13 3 Evacuation of Combustion Gas Flue configuration description Type Max length Ø 60/100 3.2.1 Horizontal concentric flue Ø 60/100 mm Ø 80/125 25 m or Ø 80/125 mm (C13 type installation) Each time an additional 90° bend is necessary (or 2 at 45°), If the terminal is at less than 1.80 m from the the length (L) must be reduced by 1 m.

  • Page 14: Heating System

    4 Heating System General The boiler is for use only with sealed central heating systems. The digital readout on the controls fascia indicates the system pressure when there is no demand. The circulation pump is integral with the boiler. 4.1 Safety Valves The safety valves are factory fitted and are an integral part of the boiler and must not be adjusted or used for any other purpose.

  • Page 15: Domestic Hot Water

    4 Heating System automatic bypass - closed automatic bypass - factory setting automatic bypass - open pump speed 1 pump speed 2 1000 1200 1400 1600 1800 Volumeflow (Litres/hr) Diagram 4.2 5 Domestic Hot Water General 5.4 Safety Valves All domestic hot water circuits, connections, fittings must be The safety valves are factory fitted and are an integral part of in accordance with the relevant standards and water supply this boiler and they must not be adjusted or used for any other...
  • Page 16 5 Domestic Hot Water NOTE: The tundishes are factory fitted during manufacture. 5.6 SYSTEM REQUIREMENTS – Domestic Hot The discharge pipe (D2) from the tundish should terminate in Water a safe place where there is no risk to persons in the vicinity of the discharge, preferably be of metal and: Domestic Hot Water Requirements a) Be at least one pipe size larger than the nominal outlet...

  • Page 17: Condensate Connection

    5 Domestic Hot Water NOTE: The discharge will consist of scalding water and steam. Asphalt, roofing felt and non-metallic rain water goods TABLE 1 may be damaged by such discharges. Valve outlet Worked example of discharge pipe sizing G 1/2 size The example given in diagram 5.2 is for a G1/2 temperature relief valve with a discharge pipe (D2) having 4 No.

  • Page 18: Condensate Drain

    6 Condensate Drain INTERNAL SOIL BOILER BOILER EXTERNAL SOIL AND VENT STACK AND VENT STACK EXTERNAL MAX. 3M DIA. 22mm MIN. DIA. 22mm MIN. NO RESTRICTION NO RESTRICTION ON LENGTH ON LENGTH Internal Soil and Vent Pipe External Soil and Vent Pipe BOILER BOILER SINK...

  • Page 19: Installation Preparation

    7 Installation Preparation PLUMBING JIG TANK / BOILER MODULE CONNECTION WASHERS Retaining screws TANK / JIG stored in cartridge CONNECTION WASHERS LOOSE ITEMS PACK Installation booklet (not illustrated) 1 OFF User Instructions (not illustrated) 1 OFF Condensate Connection Pipe 1 OFF 22mm Copper Tails 4 OFF 15mm Copper Tail...

  • Page 20: Site Requirements

    The floor strength should be suitable for the combined weight of appliance and water: 100sxi 175kg 170sxi 225kg 1331 (100sxi) NOTE: Due to the varied site conditions we do not supply...

  • Page 21: Gas, Water & Boiler Connection

    8 Gas, Water & Boiler Connection 8.1 Systems Connection IMPORTANT: With regards to the Health and Safety Manual Handling requirements, two persons shall be required The water and gas isolation valve connections are on the jig. to lift the appliance. It should be noted that the appliance is The condense drain and safety discharges connections are made up of two modules each module requiring two persons not on the jig but their pipe runs are shown on the template.
  • Page 22 8 Gas, Water & Boiler Connection 8.3 Boiler Module Connection BOILER MODULE FRONT PANEL Unpack the boiler module from its carton. Position the boiler on top of the tank ensuring the correct engagement of the locating pins, see diagram 8.3. Remove the front panel securing screws and lift the panel off at the top locating bracket, see diagram 8.2.

  • Page 23: Condensate & Safety Discharge Valve Connections

    9 Condensate & Safety Discharge Valve Connections 9.1 Safety Discharge Valve 9.2 Condensate Drain Connection The pipes must be extended, using not less than 22mm o.d. A flexible condensate hose runs from a push-fit connection at pipe, to discharge, in a visible position, outside the building, the bottom of the heat exchanger and terminates on the boiler facing downwards, preferably over a drain.

  • Page 24: Electrical Connection

    Any fault arising from incorrect wiring cannot be being inoperable, it MUST be wired separately from the boiler put right under the terms of the Glow-worm guarantee. electrical connections. ● All system components must be of an approved type.
  • Page 25 10 Electrical Connection 10.1 Electrical Connection ELECTRICAL Take the previously laid electrical cable and route along the CARTRIDGE left hand side of the tank module through the two grommets and the cable ties and across to the installers interface as shown in diagram 10.1.
  • Page 26 10 Electrical Connection 10.2 System Controls 24V WARNING: UNDER NO CIRCUMSTANCES MUST ANY MAINS VOLTAGE BE APPLIED TO ANY OF THE TERMINALS ON THE 24V CONNECTION PLUG. Connect the mains supply and system heating controls e.g. room thermostat as diagram 10.4. External controls should be fitted in accordance with the rules in force.

  • Page 27: Commissioning

    11 Commissioning Diagram 11.1 IMPORTANT: At the time of commissioning, complete all relevant sections of the Benchmark Checklist located in the DOMESTIC inside back pages of this document. PUMP VENT 11.1 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 in accordance with the current issue of BS6798.

  • Page 28: Initial Lighting

    QUICK DOUBLE RELEASE CHECK As an option, a chargeable boiler performance and function service can be provided by Glow-worm Service by calling INLET telephone No. 01773 828100. VALVE Light the appliance by following the procedure below: Refer to diagram 11.4 and repeatedly press the “MODE”...
  • Page 29 11 Commissioning 11.7 Range Rating 11.5 Re-pressurising System (if required) 1. Ensure that the filling loop flexible hose is securely The boilers are fully modulating for central heating, and it is connected to the double check inlet valve, see diagram therefore not necessary to range rate the boiler.

  • Page 30: Instruct The User

    11 Commissioning ● Advise the User if the mains electricity and gas are to be turned off for any long periods during severe weather, it is AUTOMATIC recommended that the whole system, including the boiler, AUTOMATIC BYPASS should be drained to avoid the risk of freezing. AIR VENT Note: Sealed System: Contact your installation/servicing company as draining, refilling and pressurising MUST be...

  • Page 31: Servicing

    When replacing a part on this appliance, use only spare parts that you can be assured conform to the safety and performance specification that we require. Do not use reconditioned or copy parts that have not been clearly authorised by Glow-worm. If any electrical connections have been disconnected and after their connection, checks to the earth continuity, polarity, short circuit and resistance to earth must be repeated using a suitable multimeter, as described in section 13.
  • Page 32 CONTROL BOX appliance must be disconnected until the CO/CO2 ratio is acceptable. Advice can be sought from the Glow-worm Technical Helpline. 12.1 Servicing NOTE: If the Combustion CO2, CO/CO2 ratio and Gas rate...
  • Page 33 12 Servicing 12.2 Silencer For access to the heat exchanger the silencer will need to be removed, see diagram 12.7. SILENCER Remove the securing screw and pull the silencer from the gas valve, this is a push fit. SECURING SCREW HEAT EXCHANGER Diagram 12.7...

  • Page 34: Heat Exchanger

    12 Servicing 12.4 Burner SILENCER HEAT BRACKET NOTE: EXCHANGER ● The following procedure will require that you replace the burner door seal and nyloc nuts. ● Removal of the burner is not necessary during a normal service, but if it is removed it will require a new gasket, see IGNITION diagram 12.12.
  • Page 35 12 Servicing BURNER FRONT INSULATION BURNER DOOR FLEXIBLE SECURING CONDENSATE GASKET SCREW (4) HOSE SPARK ELECTRODE Turn anti-clockwise GAS VALVE to remove AND FAN Diagram 12.12 12.6 Condense Trap and Siphonic Drain SERVICE The condensate trap & siphonic drain does not normally need FILL LEVEL servicing unless material deposits exceed beyond the service fill level, see diagram 12.14.

  • Page 36: Fault Finding

    13 Fault Finding 13.1 Preliminary fault finding Indicates fault memory The following checks should be performed before proceeding position onto specific diagnostics: • Check the external electrical supply to the boiler is on and a supply of 230V is present at the ‘L’ and ‘N’ terminals at Fault code the installer interface.
  • Page 37 13 Fault Finding BROWN BLUE GREEN/YELLOW GREY GREEN BLACK YELLOW WHITE ORANGE PURPLE PINK bk bk br g/y Diagram 13.2...

  • Page 38: Central Heating

    13 Fault Finding CENTRAL HEATING START Is there anything displayed Is the power switched on? Switch the power on Check wires between main PCB and display Is the display flashing 'F'? Consult the Fault Table Initiate a DHW demand. Does the display flash 'F' Successful ignition during or after a DHW demand?
  • Page 39 13 Fault Finding Fault Codes Diagram 13.4...
  • Page 40 13 Fault Finding Fault Codes (continued) Diagram 13.4a...
  • Page 41 13 Fault Finding Diagnostic Menu - Level 1 Installer Access Description Range Domestic hot water flow temperature reading Tank temperature Heating temperature setpoint Domestic hot water setpoint Tank setpoint intelligent control Domestic hot water demand d.24 System water pressure in bar. d.27 Option Relay 1 Reserved for future use...

  • Page 42: Status Codes

    13 Fault Finding 13.4 Status Codes The status codes provide information about the current operating condition of the boiler and can be accessed through the diagnostic display, refer to diagram 13.6. State list - Accessed through Diagnostic Codes - Level 1, Installer Access d.99 STATE LISTS Central heating mode Description...

  • Page 43: Replacement Of Parts

    14 Replacement of Parts 14.1 General 14.3 Silencer assembly Replacement of parts must be carried out by a competent For access, refer to section 14.1. person approved at the time by the Health and Safety To aid access to the silencer and securing screw, slacken Executive.
  • Page 44 14 Replacement of Parts 14.4 Ignition Lead SPARK GAP For access, refer to section 14.1. GASKET Refer to diagram 12.9. Pull the spark plug style connector off the spark electrode and the ignition lead connected to the igniter unit, see diagram 14.2.
  • Page 45 14 Replacement of Parts 14.9 Burner REAR For access, refer to section 14.1. INSULATION WASHER Refer to section 12.4 for removal of the fan, gas valve and burner assembly. SECURING Remove the four screws that secure the burner, see diagram SCREW 12.12.
  • Page 46 14 Replacement of Parts SECURING SECURING SILENCER HEAT SCREW (2 OFF) NUT (4 OFF) BRACKET EXCHANGER SECURING SCREW IGNITION (2 OFF) LEAD IGNITER UNIT EXPANSION VESSEL CLAMP CLAMP CLAMP EARTH LEAD CH PUMP CH PUMP SECURING SCREW (2 OFF) FLEXIBLE HOSE CONNECTION Diagram 14.8 14.13 Heating Expansion Vessel...
  • Page 47 14 Replacement of Parts Remove the two connection clips securing the flow and return pipes to the heat exchanger, see diagram 14.9. Move the pipes away from the heat exchanger. Remove the four heat exchanger securing screws and clamps, see diagram 14.8. CAUTION: There will be water in the heat exchanger.

  • Page 48: Central Heating Pump

    14 Replacement of Parts 14.15 Central Heating Pump 14.17 Domestic Pump For access, refer to section 14.1. For access, refer to section 14.1. Drain the boiler heating circuit, see section 14.1. Drain the boiler domestic water circuit, see section 14.1. Unscrew the union nut of the return pipe to the pump Remove the domestic expansion vessel and place in its connection, see diagram 14.11.
  • Page 49 14 Replacement of Parts 14.18 Safety Discharge Valve For access, refer to section 14.1. LOW WATER Refer to section 14.1 and drain the boiler heating circuit. PRESSURE The safety discharge valve is situated towards the RH side of SENSOR the boiler module, refer to diagram 14.14. Unscrew the pipework union nut from the safety discharge valve.
  • Page 50 14 Replacement of Parts 14.23 Water Pressure Sensor AUTOMATIC AIR VENT For access, refer to section 14.1. Refer to section 14.1 and drain the boiler heating circuit. RETAINING Refer to diagram 14.19. CLIP Disconnect the electrical lead and withdraw the lead plug. Remove the retaining clip to remove the low water pressure sensor.
  • Page 51 14 Replacement of Parts 14.25 Hydroblock and Bypass Tube Grip the LH and RH hydroblocks simultaneously and lift clear of the spigots on the mounting bracket. The RH hydroblock For access, refer to section 14.1. should be drawn upwards past the plastic three way valve IMPORTANT: To replace the bypass tube the LH and RH body.

  • Page 52: Filling Loop

    14 Replacement of Parts 14.26 Filling Loop For access, refer to section 14.1. Refer to section 14.1 and drain the boiler domestic water circuit. Refer to diagram 11.3. Undo the union nuts on the filling loop valve and the double check inlet valve to remove the filling loop.
  • Page 53 14 Replacement of Parts 14.31 Immersion Heater IMMERSION For access, refer to section 14.1. HEATER Refer to section 5.3 and drain the hot water storage tank. Remove the flexible condensate hose from the condensate trap and siphonic drain, see diagram 12.14. Isolate any electrical connections to the immersion heater.
  • Page 54 14 Replacement of Parts 14.33 Access to Control Box Internals For access, refer to section 14.1. RETAINING CLIPS Carefully pull the control box forwards so that it lies horizontally in its hinges. Do not allow the front of the control box to swing down and be loosely held by its electrical connections.

  • Page 55: Spare Parts

    15.1 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 56 15 Spare Parts Diagram 16.1...

  • Page 57: Declaration Of Conformity

    16 Declaration of Conformity...

  • Page 59: Service Interval Record

    SERVICE INTERVAL RECORD It is recommended that your heating system is serviced regularly and that you complete the appropriate Service Interval Record Below . Service Provider. Before completing the appropriate Service Interval Record below, please ensure you have carried out the service as described in the boiler manufacturer’s instructions.
  • Page 60 0020107236 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...

This manual is also suitable for:

Ultrapower 170sxi

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