Glow-worm Ultracom 12hxi Installation And Servicing Manual
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Glow-worm Ultracom 12hxi Installation And Servicing Manual

High efficiency condensing boilers
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Ultracom

Installation and Servicing

12hxi
G.C. No. 41-019-01
15hxi
G.C. No. 41-019-02
18hxi
G.C. No. 41-019-03
24hxi
G.C. No. 41-019-04
30hxi
G.C. No. 41-019-05
38hxi
G.C. No. 41-019-06
High Efficiency
Condensing Boilers
www.glow-worm.co.uk
1

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  • Page 1: Installation And Servicing

    Ultracom Installation and Servicing 12hxi G.C. No. 41-019-01 15hxi G.C. No. 41-019-02 18hxi G.C. No. 41-019-03 24hxi G.C. No. 41-019-04 30hxi G.C. No. 41-019-05 38hxi G.C. No. 41-019-06 High Efficiency Condensing Boilers 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: Warnings

    If you have a history of skin complaint you may be worm. susceptible to irritation. High dust levels are usual only if the Any alteration not approved by Glow-worm, could invalidate material is broken. the certification, boiler warranty and may also infringe the Normal handling should not cause discomfort, but follow 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

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

  • Page 7: Boiler Specification

    1 Boiler Specification BOILER SPECIFICATION 12hxi 15hxi 18hxi Lift weight 25kg (55Ib) 25kg (55Ib) 25kg (55lb) Total weight (installed) 30kg (66Ib) 30kg (66Ib) 30kg (66lb) Gas connection Rc1/2 (1/2in BSPT) Rc1/2 (1/2in BSPT) Rc1/2 (1/2in BSPT) Heating flow and return connection Ø O.D. 22mm.

  • Page 8: Boiler Dimensions & Hydraulic Schematic

    2 Boiler Dimensions & Hydraulic Schematic CONDENSATE CONNECTION Diagram 2.2 2.1 Boiler Dimensions & Hydraulic Schematic All dimensions are given in millimetres (except as noted). The general arrangment 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 Diagram 2.1 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 through combustible materials provided that:- Diagram 3.1...

  • Page 10: Flue Options And Terminal Clearances 4

    4 Flue Options and Terminal Clearances Top horizontal telescopic flue (Ø60/100) Top horizontal standard flue (Ø60/100) Part No. A2043600 - Section 9, page 20 Part No. A2043400 - Section 9, page 24 Plume Management Kit basic set, white, concentric flue (Ø60/100) - Part No.

  • Page 11: Flue Options

    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 9. 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 Systems

    5 Water Systems 1000 Diagram 5.1...

  • Page 13: Water Treatment

    5 Water Systems - General 5.1 General This boiler is designed to provide central heating from a fully pumped open vented or sealed water system and domestic hot water using a fully indirect cylinder. An options board accessory is available to link the internal programmer with a Honeywell S or Y plan system.

  • Page 14: Safety Valve

    5 Water Systems - Open Vented 5.7 Open (Vented) Water System Open (vented) system. The boiler must be supplied from an unrestricted water Recommended supply taken from a feed and expansion cistern situated at a relationship between maximum height of 27 metres (90ft) above the boiler. 450mm pump, cold feed and vent.
  • Page 15 5 Water Systems - Sealed 5.12 Sealed water Systems SUPPLY The installation must comply with the appropriate PIPE requirements of the current issue of BS4814, BS5449, BS6759, BS6798 and BS7074 Part 1 and 2. See diagram 5.3 for a suggested layout. BOILER CONTROL VALVE...

  • Page 16: Installation Preparation

    6 Installation Preparation 6.1 Appliance Pack The top polystyrene pack contains all the items illustrated in Gas Valve diagram 6.1. Remove the carton sleeve and top pack then lift the boiler and its polystyrene base support out of the lower pack. Electrical Hanging Cartridge...

  • Page 17: Boiler Fixing

    7 Boiler Fixing 7.1 Hanging Bracket Fixing Preferred If previously removed, reposition the wall template over the WALL fixing points flue hole and mark the position of the fixing holes for the TEMPLATE hanging bracket, see diagram 7.1. Mark and drill the fixing holes and secure the hanging bracket which is supplied in the polystyrene base pack.

  • Page 18: Gas/Water & Condensate Connection

    8 Gas / Water & Condensate Connection UNION CONNECTOR GAS SERVICE ISOLATION VALVE LINER GAS SERVICE SPIGOT ISOLATION VALVE (shown open) COUPLING PRESSURE CONDENSATE TEST POINT DRAIN PIPE GAS SUPPLY PIPE IN Diagram 8.1 8.1 Gas Connection Before connection check the supply of local gas. Refer to diagram 8.1, the gas supply can be connected from below or through the wall at the rear of the boiler.
  • Page 19 8 Gas / Water & Condensate Connection INTERNAL SOIL EXTERNAL SOIL AND VENT STACK AND VENT STACK BOILER BOILER EXTERNAL MAX. 3M MIN. DIA. 21mm MIN. DIA. 21mm NO RESTRICTION NO RESTRICTION ON LENGTH ON LENGTH Internal Soil and Vent Pipe External Soil and Vent Pipe or Rainwater Pipe SINK (CONSTITUTES...

  • Page 20: Flue Length Preparation And Installation

    9 Telescopic Flue - Length, Preparation and Installation 9.1 Flue Length When extension pipes are used the flue system must be designed to have a continuous fall to the boiler of at least The maximum permissable horizontal flue length is 10 metres 2.5 o 44mm/metre to allow condensate to run back into the plus the flue terminal assembly, this can be achieved by use boiler and out via the condensate drain.
  • Page 21 9 Telescopic Flue - Length, Preparation and Installation A2043600 Top Outlet Horizontal telescopic flue pack FLUE ELBOW SECURING SCREW x 4 COLLAR SEALING SCREW x 2 TAPE (telescopic only) SCREW x 2 GASKET (fitted) TRIM RING SCREW x 1 TELESCOPIC TERMINAL ASSEMBLY SEALING Diagram 9.2...
  • Page 22 9 Telescopic Flue - Length, Preparation and Installation 9.2 Horizontal Telescopic Flue - A2043600 Refer to diagram 9.2 for kit contents. 9.3 REAR Flue BUTT JOINT 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 9.4.
  • Page 23 9 Telescopic Flue - Length, Preparation and Installation 9.5 Flue Fitting With the air duct seams aligned and the flue set to the required length ‘Y’, mark the securing hole position in the air duct. Drill a 3mm diameter hole at this position, take care not to pierce the inner flue duct.
  • Page 24 9 Standard Flue - Length, Preparation and Installation 9.6 Flue Length When extension pipes are used the flue system must be designed to have a continuous fall to the boiler of at least The maximum permissable horizontal flue length is 10 metres 2.5 o 44mm/metre to allow condensate to run back into the plus the flue terminal assembly, this can be achieved by use boiler and out via the condensate drain.
  • Page 25 9 Standard Flue - Length, Preparation and Installation A2043400 Top Outlet Standard Horizontal Concentric Flue Pack FLUE ELBOW SECURING SCREW x 4 COLLAR SCREW x 2 SCREW x 2 GASKET (fitted) TRIM RING STANDARD TERMINAL ASSEMBLY SEALING COLLAR Diagram 9.11 Diagram 9.12...
  • Page 26 9 Standard Flue - Length, Preparation and Installation 9.7 Standard Horizontal Flue Refer to diagram 9.11 for kit contents. 9.8 REAR Flue BUTT JOINT With the flue elbow temporarily fitted, measure the distance from the outside wall to the butt joint, see diagram 9.13. If the measurement ‘Y’...
  • Page 27 9 Standard Flue - Length, Preparation and Installation 9.10 Flue Fitting Remove the flue elbow. Separate the flue duct from the terminal by twisting to release the terminal catch, then pull out of the retaining seal, refer to diagram 9.16. The flue duct cutting length (L + 11mm.) is shown in diagram 9.16.
  • Page 28 9 Vertical Flue - Length, Preparation and Installation 9.11 Vertical flue The terminal should be as shown in diagram 4.2. Measure the distance of flue length required for the The vertical flue system is available as an option where the installation.

  • Page 29: Flue Terminal Installation

    9 Vertical - Flue Length, Preparation and Installation Flue Terminal Installation Refer to diagram 9.20 and secure the flue adapter in position on top of the boiler with the screws supplied, making sure the nib fits into the locating slot in the boiler casing to ensure correct orientation.
  • Page 30 9 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 31 9 Twin Flue - Length, Preparation and Installation Diagram 9.24...

  • Page 32: Terminal Position

    9 Twin Flue - Length, Preparation and Installation 9.12 Twin flue The twin flue system is available as an option when the top horizontal or vertical flue system is not appropriate. The system can provide an independent horizontal air inlet and flue outlet, horizontal air inlet and vertical flue outlet or vertical air inlet and flue outlet via a concentric terminal.

  • Page 33: Installation Details

    9 Twin Flue - Length, Preparation and Installation Installation Details The parts available for a twin flue system installation are shown in diagram 9.25. Boiler Connection Push the twin flue adaptor onto the outlet of the boiler with the air inlet to the left hand side. Secure the adaptor to the top panel with the screws provided.
  • Page 34 For each 90 bend or 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 AIR BRICK instructions.

  • Page 35: Electrical Connection

    Slacken the cable strain relief and route the pump electrical supply cable and connect as shown in diagrams 10.1 and 10.2. 10.3 System Controls If you are fitting the Glow-worm Options Board Kit, please refer to the instructions supplied with the kit for the system wiring.
  • Page 36 10 Electrical Connection ELECTRICAL CARTRIDGE NOTE: This appliance FIXING will not operate without SCREWS a link or system controls fitted. PUMP 230Vac SYSTEM CONTROLS - Zone valve - Programmer - Room thermostat - Cylinder thermostat Diagram 10.3 NOTE: ALL CABLES CONNECTED TO THE APPLIANCE SHOULD BE PERMANENTLY...

  • Page 37: Commissioning

    SECURING SCREW until the system is full and all the air has been vented. 11.4 Initial Lighting NOTE: If you have fitted a Glow-worm Options Board Kit, UNION please refer to the instructions supplied with the kit for completion of commissioning.
  • Page 38 11 Commissioning 11.6 Gas Rate The gas valve is factory set for natural gas (G20) and should GAS RATES (G31) GAS RATES (G20) need no adjustment. approx. after 10 mins from cold approx. after 10 mins from cold Should any doubt exist about the gas rate, check it using the gas meter test dial and stop watch, at least 10 minutes after Model kg/hr...
  • Page 39 During the conversion to Propane use of a suitable flue gas analyser is necessary. GAS VALVE As an option a chargeable boiler only commissioning service can be provided by Glow-worm Service by calling telephone No. 01773 828100. ELECTRICAL Tools required to make the conversion are a 2mm Allen key PLUG and an electricians screwdriver.

  • Page 40: 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 41: Spark Electrode

    12 Servicing 12.3 Servicing SEALING GAS PIPE BRACKET Note: GROMMET SECURING SCREW If the Combustion & Gas rate checks did not require adjustment then it will not be necessary to service the Combustion Chamber, Heat Exchanger or Burner. Complete this section, 12.4 and then proceed to 12.9.
  • Page 42 12 Servicing COMBUSTION SECTION THROUGH CHAMBER BURNER DOOR SHOWING NYLOC SECURING POSITION OF SEAL NUTS (5 OFF) SEAL BURNER GAS VALVE GAS PIPE BRACKET AND SEAL Diagram 12.7 12.5 Burner 12.6. Combustion Chamber and Heat Exchanger. NOTE: If the functional checks did not indicate poor combustion then it is not necessary to service this NOTE: If the functional checks did not indicate poor component.
  • Page 43 12 Servicing 12.7 Combustion Check G31 BURNER % CO With the appliance operational connect the CO combustion CHECK SETTING MODEL analyser to the test point, see diagram 12.10. (case on) (case off) 9.2 to 10.2 10.1 IMPORTANT: Remember to replace the cap on 12hxi completion of the test.

  • Page 44: Fault Finding

    13 Fault Finding 13.1 Preliminary fault finding CHASSIS FRONT The following checks should be performed before proceeding onto specific diagnostics: • Check the external electrical supply to the boiler is on and SECURING a supply of 230V is present at the ‘L’ and ‘N’ terminals on SCREW the installer interface, refer to section 10.3 for access and REAR...
  • Page 45 13 Fault Finding BROWN BLUE GREEN/YELLOW GREY BLACK YELLOW WHITE Diagram 13.4...
  • Page 46 13 Fault Finding CENTRAL HEATING Diagram 13.5...
  • Page 47 13 Fault Finding Fault Codes Diagram 13.6...
  • Page 48 13 Fault Finding Fault Codes (continued) Diagram 13.6...

  • Page 49: Diagnostic Menu

    13 Fault Finding Diagnostic Menu The Diagnostic Menu provides the ability to view and Diagnostic change certain parameters. value See Diagram 13.7 for available parameters. To enter the diagnostic menu: Diagnostic a) Press and hold the ‘MODE’ button for 5 seconds. number The display will change to flashing ‘0’.
  • Page 50 13 Fault Finding Diagnostic Menu - Level 1 Installer Access Description Range Tank temperature -99 will be displayed. Reserved for future use. Flow temperature setpoint intelligent control Status central heating pump Status additional heating pump (option) d.27 Option Relay 1 Reserved for future use d.28 Option Relay 2...
  • Page 51 13 Fault Finding State list - Accessed through Diagnostic Codes - Level 1, Installer Access d.99 STATE LISTS Central heating mode (Priority 3) 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 CENTRAL HEATING S.05 pump / fan overrun...

  • Page 52: Replacement Of Parts

    14 Replacement of Parts 14.1 General IGNITER BRACKET IGNITER UNIT IMPORTANT: The replacement parts described in sections SECURING SCREW 14.5 to 14.9 and section 14.12, will require the removal of the burner module assembly and the replacement of the burner IGNITER door seal and self locking nuts.
  • Page 53 14 Replacement of Parts 14.6 Fan For access, refer to section 14.1. MANIFOLD Refer to section 12.5 for removal of the fan, gas valve and burner assembly. Remove the gas valve as described in the relevant parts of section 14.5. Remove the venturi plate secured with three screws, see diagram 14.2, and remove the two screws securing the fan to the gas manifold.

  • Page 54: Heat Exchanger

    14 Replacement of Parts 14.11 Condensate Trap and Siphonic Drain For access, refer to section 14.1. HEAT Refer to diagram 14.6. EXCHANGER Remove the igniter unit as described in section 14.3 to improve accessibility. Remove the securing clip from the heat exchanger adapter, then disconnect the adapter and flexible hose.
  • Page 55 14 Replacement of Parts 14.13 Flue Hood For access, refer to section 14.1. Remove heat exchanger as described in section 14.12. Remove the two securing screws and pull the flue hood down and away from the flue hood bracket and flue elbow, see diagram 14.9.
  • Page 56 14 Replacement of Parts 14.16 Access User Interface and Main PCB RETAINING For access, refer to section 14.1. CHASSIS FRONT SCREW Remove control box retaining screw, see diagram 14.11. Hinge down the control box. Release the control box cover by carefully pressing the four retaining latches, see diagram 14.11.

  • Page 57: 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 58: Manual Handling

    16 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 brack- Regulations, the following lift operation exceeds the recommended et securely onto wall before lifting appliance into position.
  • Page 60 0020020819-02 02.07 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...

This manual is also suitable for:

Ultracom 24hxiUltracom 30hxiUltracom38hxiUltracom 15hxiUltracom 18hxiUltracom 38hxi

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