Glow-worm 24cx Installation And Servicing Manual
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Glow-worm 24cx Installation And Servicing Manual

High efficiency condensing combination boilers
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Ultracom

Installation and Servicing

24cx
G.C. No. 47-019-06
30cx
G.C. No. 47-019-07
High Efficiency
Condensing Combination
Boilers
Supplied By www.heating spares.co Tel. 0161 620 6677
www.glow-worm.co.uk

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  • Page 1: Installation And Servicing

    Ultracom Installation and Servicing 24cx G.C. No. 47-019-06 30cx G.C. No. 47-019-07 High Efficiency Condensing Combination Boilers www.glow-worm.co.uk Supplied By www.heating spares.co Tel. 0161 620 6677...

  • 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: Warnings

    If you have a history of skin complaint you may be susceptible to irritation. High dust levels are usual only if the material is Any alteration not approved by Glow-worm, could invalidate broken. the certification, boiler warranty and may also infringe the current issue of the statutory requirements.

  • Page 5: Statutory Requirements

    Statutory Requirements IMPORTANT Gas Supply Where no British Standards exists, materials and equipment The gas installation must be in accordance with the relevant should be fit for their purpose and of suitable quality and standards. workmanship. In GB, this is BS6891. The installation of this boiler must be carried out by a In IE, this is the current edition of I.S.813 “Domestic Gas competent person in accordance the rules in force in the...

  • Page 6: Boiler Design

    This valve must not be touched. Should there be any discharge from the pipe, isolate the boiler electrical supply and call your installer or Glow-worm’s own service organisation using the telephone number on the inside front cover of this booklet.

  • Page 7: Boiler Specification

    1 Boiler Specification Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 8: Boiler Dimensions & Hydraulic Schematic

    2 Boiler Dimensions & Hydraulic Schematic Diagram 2.2 2.1 Boiler Dimensions & Hydraulic Schematic All dimensions are given in millimetres (except as noted). The general arrangement of the boiler is shown in diagram 2.1. and the hydraulic and gas schematic, diagram 2.2. The data label is positioned on the front of the inner casing panel.

  • Page 9: Boiler Location, Clearances And 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. 3.4 Combustible Material The boiler and flue are suitable for installation onto and...

  • Page 10: Flue Options And Terminal Clearances

    4 Flue Options and Terminal Clearances Ridge Tile Terminal Part No. A2043800 - Section 10, page 30 Top horizontal standard flue (Ø60/100) Top horizontal telescopic flue (Ø60/100) Part No. A2043400 - Section 10, page 24 Part No. A2043600 - Section 10, page 20 Plume Management Kit basic set, white, concentric flue (Ø60/100) - Part No.

  • Page 11: Flue Terminal Position

    4 Flue Options and Terminal Clearances 4.1 Flue Options There are various flue options to choose from as illustrated in diagram 4.1. The flue lengths and installation are described in section 10. 4.2 Flue Terminal Position In GB the minimum acceptable siting dimensions for the terminal from obstructions, other terminals and ventilation openings are shown in diagram 4.2.

  • Page 12: Water System 5

    5 Water System 5.1 General This boiler is designed for use as part of a sealed water central heating system with fully pumped circulation. The pump, expansion vessel and associated safety devices are all fitted within the boiler. 5.2 Safety Valve The safety valve is an integral part of the boiler and it cannot be adjusted.

  • Page 13: Water Pressure

    5.11 Domestic Water Flow Rate The domestic hot water flow has a restrictor, factory fitted, which reduces the flow to a maximum of, 8.0 l/min for 24cx and 12.0 l/min for 30cx. Diagram 5.2 Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 14: Installation Preparation

    6 Installation Preparation Base Coverplate Hanging Bracket Gas and Water Electrical Cartridge Isolating Valves 0020036801 Retaining Screws stored in cartridge Pipe Pack 0020029671 Loose Items Pack A - Central Heating x 2 A - Wire Retaining Clip B - Domestic Hot Water Outlet B - Union Nut and Sealing Washer C - Gas C - Tap and Securing Screw...

  • Page 15: Site Requirements

    6 Installation Preparation 6.1 Appliance Pack Please check the contents of packs as shown in diagram 6.1. The packs are located in the top polystyrene packing. Remove the carton sleeve and top pack then lift the boiler and its polystyrene base support out of the lower pack. 6.2 Site Requirements The boiler mounting wall should be suitable for the weight of the appliance and be true and flat.

  • Page 16: Boiler Fixing

    7 Boiler Fixing 7.2 Boiler Hanging 7.1 Hanging Bracket Fixing The Wall Hanging Bracket is supplied in the main boiler IMPORTANT: With regards to the Manual Handling packaging at the rear of the boiler. Operations, 1992 Regulations, the following lift operation Reposition the wall template over the flue hole and mark exceeds the recommended weight for a one man lift, refer to the position of the fixing holes for the hanging bracket, see...
  • Page 17 8 Gas / Water Connections Diagram 8.1 Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 18: Safety Discharge Valve And Condensate Connections

    9 Safety Discharge Valve & Condensate Connections 9.1 Safety Discharge Valve Take the safety discharge pipe, supplied in the pipe pack and the union nut and seal, supplied in the loose items pack and fit as shown in diagram 9.1. This must be extended, using not less than 15mm o.d.
  • Page 19 9 Safety Discharge Valve & Condensate Connections Diagram 9.3 Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 20: Flue Length Preparation And Installation

    The appliance maximum flue length must be included when calculating the overall design of the flue system. NOTE: The horizontal flue terminal must be removed, see diagram 10.2. MODEL 24cx 30cx Exhaust mass rate (g/s) At Min Thermal 2.30 2.36 Load (40C°/30°C)
  • Page 21 10 Telescopic Flue - Length, Preparation and Installation Diagram 10.2 Diagram 10.3 Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 22 10 Telescopic Flue - Length, Preparation and Installation 10.2 Horizontal Telescopic Flue - A2043600 Refer to diagram 10.2 for kit contents. 10.3 REAR Flue If a wall thickness is between 203mm min. to 413mm max. then the flue can be used without extensions. With the flue elbow temporarily fitted, measure the distance from the outside wall to the butt joint, see diagram 10.4.
  • Page 23 10 Telescopic Flue - Length, Preparation and Installation 10.5 Flue Fitting IMPORTANT: The flue seals are sensitive to mineral oil based lubricants. Do not grease the seals. If the seals do need to be lubricated use only water. During the installation of the flue system, ensure that debris such as mortar, filings or swarf are cleared from the flue system before completion.
  • Page 24 The appliance maximum flue length must be included when calculating the overall design of the flue system. NOTE: The horizontal flue terminal must be removed, see diagram 10.11. MODEL 24cx 30cx Exhaust mass rate (g/s) At Min Thermal 2.30 2.36 Load (40C°/30°C)
  • Page 25 10 Standard Flue - Length, Preparation and Installation Diagram 10.11 Diagram 10.12 Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 26 10 Standard Flue - Length, Preparation and Installation 10.7 Standard Horizontal Flue Refer to diagram 10.11 for kit contents. 10.8 REAR Flue With the flue elbow temporarily fitted, measure the distance from the outside wall to the butt joint, see diagram 10.13. If the measurement ‘Y’...
  • Page 27 10 Standard Flue - Length, Preparation and Installation 10.10 Flue Fitting IMPORTANT: The flue seals are sensitive to mineral oil based lubricants. Do not grease the seals. If the seals do need to be lubricated use only water. During the installation of the flue system, ensure that debris such as mortar, filings or swarf are cleared from the flue system before completion.
  • Page 28 10 Vertical Flue - Length, Preparation and Installation 10.11 Vertical flue Alternatively use 45º bends to avoid horizontal runs, see (b) in diagram 10.18. The vertical flue system is available as an option where the boiler position does not permit the use of the top horizontal The terminal siting should be as shown in diagram 4.2.

  • Page 29: Flue Installation

    10 Vertical - Flue Length, Preparation and Installation Flue Installation IMPORTANT: The flue seals are sensitive to mineral oil based lubricants. Do not grease the seals. If the seals do need to be lubricated use only water. During the installation of the flue system, ensure that debris such as mortar, filings or swarf are cleared from the flue system before completion.
  • Page 30 10 Vertical Flue - Length, Preparation and Installation Ridge Tile Terminal A ridge tile terminal is available - part no. A2043800, see diagram 10.20. The installation of a ridge tile will be required. A suitable ridge tile is manufactured by: - Aspect East Anglia Limited The Old Mill East Harling...
  • Page 31 10 Vertical Flue - Length, Preparation and Installation Completion of Installation With the flue terminal positioned in the roof the length of the final pipe can be determined. If a telescopic length cannot be used, then a standard flue length can be cut to make the correct length.
  • Page 32 10 Twin Flue - Length, Preparation and Installation Secure long flue lengths (horizontal & vertical) to walls or ceiling at every joint or on straight flue runs at every joint and every metre flue run. Diagram 10.25 Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 33: Terminal Position

    Ventilation" section. In addition the horizontal air inlet must not be closer than 300 mm from a flue outlet on the same wall or 1200mm from an opposing flue outlet. MODEL 24cx 30cx Exhaust mass rate (g/s) At Min Thermal 2.30 2.36...

  • Page 34: Installation Details

    10 Twin Flue - Length, Preparation and Installation Installation Details The parts available for a twin flue system installation are shown in diagram 10.26. Boiler Connection IMPORTANT: The flue seals are sensitive to mineral oil based lubricants. Do not grease the seals. If the seals do need to be lubricated use only water.
  • Page 35 2 x 45 bends the maximum length of the Plume Management Kit must be reduced by 1m. For more information contact Glow-worm, refer to page 2. The Plume Management Kit is supplied with installation instructions. Refer to BS5546 or BS6798 for advice on disposal of boiler condensate.

  • Page 36: Electrical Connection

    ● This appliance must be wired in accordance with these instructions. 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. Electrical components have been tested to meet the equivalent requirements of the BEAB.
  • Page 37 11 Electrical Connection 11.2 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 11.2. External controls should be fitted in accordance with the rules in force.

  • Page 38: Commissioning

    Health and Safety The domestic hot water flow has a factory fitted restrictor, Executive and in accordance with the current issue of which reduces the flow to a maximum of, 8.0 l/min for 24cx, BS6798. 12.0 l/min for 30cx.

  • Page 39: Initial Lighting

    12 Commissioning Commissioning should only be carried out by a competent The nominal supply pressure should be 20mbar (8in wg) person approved at the time by the Health and Safety when the appliance is operating at the maximum heat input. Executive.

  • Page 40: Instruct The User

    12 Commissioning 12.8 Instruct the User 12.6 Heating System Check that all remote controls are calling for heat. The boiler ● Demonstrate, then instruct the User about the lighting will fire automatically. Fully open all radiator valves, flow procedure and heating system controls operation. control valve ‘A’, if fitted, see diagram 5.1.
  • Page 41 Natural Gas (G20) to LPG (G31) Conversion 12.9 LPG CONVERSION - all models G31 BURNER % CO As an option, a chargeable boiler only commissioning service can be provided by Glow-worm Service by calling telephone Throttle CHECK No. 01773 828100.

  • Page 42: 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 14.

  • Page 43: Combustion Ratio

    CO/CO2 ratio is acceptable. If the combustion reading is not within the acceptable values Advice can be sought from the Glow-worm Technical Helpline. AND the integrity of the complete flue system and combustion circuit seals have been verified and the inlet gas pressure 13.1 Servicing...

  • Page 44: Spark Electrode

    13 Servicing 13.3 Burner 13.2 Spark Electrode NOTE: Disconnect the spark electrode plug and earth lead. Remove ● The following procedure will require that you replace the the two securing screws and withdraw the spark electrode burner door seal and nyloc nuts. carefully from the combustion chamber, see diagram 13.4.

  • Page 45: Inner Casing Panel Seal Check

    13 Servicing Diagram 13.7 13.4. Combustion Chamber and Heat Exchanger Remove loose debris from inside the combustion chamber using a soft brush and vacuum cleaner. Carefully flush by spraying water into the heat exchanger, any remaining debris should pass through the condensate trap (Ensure the water is kept away from electrical components).

  • Page 46: Fault Finding

    14 Fault Finding 14.1 Preliminary fault finding The following checks should be performed before proceeding 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 on the installer interface, refer to section 11.5 for access and diagram 14.4.
  • Page 47 14 Fault Finding bk g REFER TO SECTION 11 ELECTRICAL CONNECTION BROWN BLUE GREEN/YELLOW GREY GREEN BLACK YELLOW WHITE ORANGE PURPLE PINK Diagram 14.4 Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 48 14 Fault Finding CENTRAL HEATING Diagram 14.5 Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 49 14 Fault Finding Fault Codes If -9 C is displayed, check that the DHW thermistor wires are unconnected and are not faulty or trapped. Diagram 14.6 Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 50 14 Fault Finding Fault Codes (continued) Diagram 14.6 continued. Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 51: Diagnostic Menu

    14 Fault Finding Diagnostic Menu The Diagnostic Menu provides the ability to view and change certain parameters. See Diagram 14.8 for available parameters. To enter the diagnostic menu: a) Press and hold the ‘MODE’ and ‘+’ button for 5 seconds. The display will change to ‘0’. b) Use the ‘+’...
  • Page 52 14 Fault Finding Diagnostic Menu - Level 1 Installer Access (see State Lists table) Indicates read and write function - all other diagnostics are read only Diagram 14.8 Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 53 14 Fault Finding State list - Accessed through Diagnostic Codes - Level 1, Installer Access d.99 STATE LISTS Central heating mode Description S.00 no heating required S.01 fan pre-run S.02 pump pre-run S.03 ignition NORMAL OPERATING S.04 burner on STATE FOR CH MODE S.05 pump / fan overrun S.06...

  • Page 54: Replacement Of Parts

    15 Replacement of Parts 15.1 General IMPORTANT: The replacement of parts described in sections 15.5 to 15.9 and section 15.12 will require the removal of the burner module assembly and the replacement of the burner door seal and self locking nuts. Replacement parts that have associated components that need replacing on removal, i.e.

  • Page 55: Gas Valve

    15 Replacement of Parts 15.5 Gas Valve For access, refer to section 15.1. Refer to section 13.3 for removal of the fan, gas valve and burner assembly. Before removing the gas valve note its orientation in relationship to the fan. Remove the three securing screws, which also secures the plastic swirl plate to the venturi on the fan, see diagram 15.2.

  • Page 56: Expansion Vessel

    15 Replacement of Parts 15.10 Viewing Window GLASS FIBRE WASHER For access, refer to section 15.1. Refer to diagram 15.5. Remove circlip. Remove steel washer. Remove glass. Remove fibre washer. 15.11 Expansion Vessel For access, refer to section 15.1. Drain the boiler heating circuit as described in the appropriate section of 15.1.

  • Page 57: Heat Exchanger

    15 Replacement of Parts 15.12 Heat Exchanger Refer to Manual Handling section on page 65. For access, refer to section 15.1. Refer to section 13.3 for removal of the fan, gas valve and burner assembly. Drain the boiler heating circuit as described in the appropriate section of 15.1.
  • Page 58 15 Replacement of Parts 15.14 Heating Flow Thermistor For access, refer to section 15.1. Refer to diagram 15.10. Remove the electrical connections from the thermistor. Remove the retaining clip from the flow pipe. NOTE: When reconnecting, the polarity of the wiring to thermistors is not important.
  • Page 59 15 Replacement of Parts 15.17 Pump (head only) For access, refer to section 15.1. Drain the boiler heating circuit as described in the appropriate section of 15.1. Refer to diagram 15.12. Remove the four cap head screws. Carefully remove the pump head together with cable. Do not strain cable.

  • Page 60: Automatic Air Vent

    15 Replacement of Parts 15.19 Domestic Hot Water Thermistor For access, refer to section 15.1. Refer to diagram 15.14. Disconnect the domestic hot water thermistor electrical connections Remove hot water thermistor and retaining clip. Remove domestic hot water thermistor from clip. NOTE: When reconnecting electrical connections, polarity is not important.

  • Page 61: Flow Sensor

    15 Replacement of Parts 15.22 Flow Sensor For access, refer to section 15.1. Drain the boiler hot water circuit as described in the appropriate section of 15.1. Refer to diagram 15.17. Remove the front securing clip. Disconnect the domestic cold water pipe at the bulkhead connection and remove the pipe.
  • Page 62 15 Replacement of Parts Disconnect the CH flow, return and DHW inlet pipes at the bulkhead connectors, then the retaining clips, remove the pipes and “o” ring seals. Remove the low water pressure sensor as described in section 15.21. Remove the flow sensor as described in section 15.22. Remove the 3 way valve as described in section 15.24.

  • Page 63: Main Pcb

    15 Replacement of Parts 15.27 Appliance Interface and Main PCB For access, refer to section 15.1. Remove control box retaining screw, see diagram 15.21. Hinge down the control box. Release the control box cover by carefully pressing the four retaining latches, see diagram 15.21. 15.28 Main PCB IMPORTANT: When replacing the board refer to instructions supplied with the replacement.

  • Page 64: Spare Parts

    16.1 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 65: Spare Parts 16

    16 Spare Parts Diagram 16.1 Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 66: Manual Handling

    17 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.
  • Page 67 Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 68 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 Supplied By www.heating spares.co Tel. 0161 620 6677...

This manual is also suitable for:

Ultracom 24cxUltracom 30cx30cx

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