Glow-worm Ultrapower 170sxi Installation And Servicing
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Glow-worm Ultrapower 170sxi Installation And Servicing

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Installation and Servicing

Ultrapower
100sxi
G.C. No. 41-019-09
170sxi
G.C. No. 41-019-10
High Efficiency
System Store
Glow-worm, Nottingham Road, Belper, Derbyshire. DE56 1JT
Supplied By www.heating spares.co Tel. 0161 620 6677
www.glow-worm.co.uk
1
0020023706-02 07.06

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  • Page 1: Installation And Servicing

    0020023706-02 07.06 Installation and Servicing Ultrapower 100sxi G.C. No. 41-019-09 170sxi G.C. No. 41-019-10 High Efficiency System Store Glow-worm, Nottingham Road, Belper, Derbyshire. DE56 1JT www.glow-worm.co.uk Supplied By www.heating spares.co Tel. 0161 620 6677...

  • 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

    These can cause irritation to skin, eyes and the respiratory worm. tract. Any alteration not approved by Glow-worm, could invalidate If you have a history of skin complaint you may be the certification, boiler warranty and may also infringe the susceptible to irritation.

  • Page 5: Gas Supply

    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 with the rules in force in...

  • Page 6: Boiler Design

    Should there be any discharge from the pipes, isolate the blockage by the use of warm cloths on the pipe, the boiler boiler electrical supply and call your installer or Glow-worm’s should then restart. own service organisation using the telephone number on the inside front cover of this booklet.

  • Page 7: Specification Table

    1 Specification Table Data All dimensions are given in millimetres (except as noted). See diagram 2.1 and the Boiler Specification Table below. The data label is positioned inside the boiler module on the base. BOILER SPECIFICATION 100sxi 170sxi Lift weight - Tank Module 39kg (86Ib) 48kg (106Ib) - Boiler Module...

  • Page 8: Boiler Dimensions & Hydraulic Schematic

    2 Boiler Dimensions & Hydraulic Schematic 106.5 FLUE 1331 (100sxi) 1260 1591 (100sxi) (170sxi) 1520 BOILER (170sxi) DISCHARGE SIPHON DISCHARGE DISCHARGE 70 80 Diagram 2.1 Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 9 2 Boiler Dimensions & Hydraulic Schematic PRIMARY HEAT EXCHANGER HEATING WATER EXPANSION VESSEL PRIMARY CIRCUIT PRIMARY CIRCUIT FLOW THERMISTOR RETURN THERMISTOR AUTOMATIC AIR VENT CONTROL HEATING PRESSURE VALVE PUMP SENSOR 3 WAY VALVE CONNECTOR BYPASS FILTER CONNECTOR AUTOMATIC PLATE TO PLATE ADJUSTABLE HEAT EXCHANGER BYPASS...

  • 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. 3.4 Room Ventilation The boiler is room sealed so a permanent air vent is not required.

  • Page 11: Flue Options And Terminal Clearances

    4 Flue Options and Terminal Clearances Flue Options Plume Management Kit Basic set, concentric flue Ø60/100 White - Part No. A2044100 Black - Part No. A2044000 for use with Part No. A2043400 and Part No. A2043600 Top horizontal telescopic flue Ø60/100 Top horizontal standard flue Ø60/100 Part No.

  • Page 12: 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 The minimum acceptable siting dimensions for the terminal from obstructions, other terminals and ventilation openings are shown in diagram 4.2.

  • Page 13: Heating System

    5 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. 5.1 Safety Valve The safety valve is an integral part of the boiler and it cannot adjusted.The pipe from the safety discharge valve must not discharge above an entrance, window or any type of...

  • Page 14: Domestic Hot Water

    5 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 5.2 6 Domestic Hot Water General Guidance on vessel sizing is also given in the current issue of BS5449 and BS7074 Part 1, for IE refer to the current edition All domestic hot water circuits, connections, fittings must be of I.S.813 “Domestic Gas Installations”.
  • Page 15 6 Domestic Hot Water SYSTEM REQUIREMENTS – Domestic Hot NOTE: The tundish is factory fitted during manufacture of the istor. The discharge pipe (D2) from the tundish should Water terminate in 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 16 6 Domestic Hot Water NOTE: The discharge will consist of scalding water and TABLE 1 steam. Asphalt, roofing felt and non-metallic rain water goods may be damaged by such discharges. Valve outlet Worked example of discharge pipe sizing G 1/2 size The example given in diagram 6.2 is for a G1/2 temperature relief valve with a discharge pipe (D2) having 4 No.

  • Page 17: Installation Installation Preparation

    7 Installation Preparation FIXING JIG TANK / BOILER MODULE CONNECTION WASHERS Stored in cartridge 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 1 OFF 3/4"...

  • Page 18: Fixing Template

    7 Installation Preparation IMPORTANT With regards to the Health and Safety Manual Handling requirements, two persons shall be required to lift the appliance. It should be noted that the appliance is made up of two modules each module requiring two persons to lift. Please check the contents of packs as shown in diagram 7.1.

  • Page 19: Gas/Water & Appliance Connection

    8 Gas / Water & Appliance Connection 8.1 Systems Connection 8.2 Appliance Connection All water and gas connections are on the fixing jig with the NOTE: The appliance and may contain a small amount exception of the condense drain and safety discharge, the of water, place a water container beneath the boiler positions of these are shown on the floor template.
  • Page 20 8 Gas / Water & Appliance Connection Unpack the boiler module and remove the front panel, see BOILER MODULE diagram 8.2. Place to one side to avoid damage. FRONT PANEL The tank module front panel will need to be removed to gain access to pipe connections.
  • Page 21 8 Gas / Water & Appliance Connection 8.4 Condensate Drain Connection It is recommended that any external condensate drain pipe is insulated and also preferably of 32mm diameter, to prevent A flexible condensate hose runs from a push-fit connection freezing in adverse weather conditions. at the bottom of the heat exchanger to a drain connection The condensate is discharged periodically in ‘slugs’...
  • Page 22 8 Gas / Water & Appliance Connection INTERNAL SOIL BOILER BOILER EXTERNAL SOIL AND VENT STACK AND VENT STACK EXTERNAL MAX. 3M Ø22mm MIN. Ø22mm MIN. NO RESTRICTION NO RESTRICTION ON LENGTH ON LENGTH Internal Soil and Vent Pipe External Soil and Vent Pipe or Rainwater Pipe BOILER BOILER SINK...

  • Page 23: Electrical Preparation & Cable Routing

    This appliance must be wired in accordance with these CARTRIDGE 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 24 10 Telescopic Flue - Length, Preparation and Installation 10.1 Flue Length The flue can be installed from inside the building, when access to the outside wall face is not practicable. The maximum permissable horizontal flue length is 8 metres plus the flue terminal assembly, this can be achieved by The diagrams below describe the lengths achievable without use of the accessories, see diagram 10.3, however should the use of extensions or elbows.
  • Page 25 10 Telescopic Flue - Length, Preparation and Installation Top Outlet Horizontal Concentric Flue Packs: FLUE A2043600 Horizontal telescopic flue pack. ELBOW SECURING SCREW x 4 COLLAR SEALING SCREW x 2 TAPE (telescopic only) SCREW x 2 GASKET (fitted) SEALING COLLAR SCREW x 1 TELESCOPIC TERMINAL ASSEMBLY...
  • Page 26 10 Telescopic Flue - Length, Preparation and Installation 10.2 Horizontal Telescopic Flue Refer to diagram 10.2 for kit contents. 10.3 REAR Flue BUTT JOINT If a wall thickness is between 233mm min. to 522mm 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 27 10 Telescopic Flue - Length, Preparation and Installation AIR DUCT 13mm TERMINAL CATCH FLUE DUCT Diagram 10.7 L + 11mm Diagram 10.10 Diagram 10.8 Diagram 10.9 Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 28 10 Standard Flue - Length, Preparation and Installation 10.6 Flue Length The flue can be installed from inside the building, when access to the outside wall face is not practicable. The maximum permissable horizontal flue length is 8 metres plus the flue terminal assembly, this can be achieved by The diagrams below describe the lengths achievable without use of the accessories, see diagram 10.13, however should the use of extensions or elbows.
  • Page 29 10 Standard Flue - Length, Preparation and Installation Top Outlet Horizontal Concentric Flue Packs: FLUE A2043400 Standard horizontal flue pack. ELBOW SECURING SCREW x 4 COLLAR SCREW x 2 SCREW x 2 GASKET (fitted) SEALING COLLAR STANDARD TERMINAL ASSEMBLY SEALING Diagram 10.12 COLLAR Bend...
  • Page 30 10 Standard Flue - Length, Preparation and Installation 10.7 Standard Horizontal Flue Refer to diagram 10.12 for kit contents. 10.8 REAR Flue BUTT JOINT With the flue elbow temporarily fitted, measure the distance from the outside wall to the butt joint, see diagram 10.14.
  • Page 31 10 Standard Flue - Length, Preparation and Installation Draw the flue assembly from wall and engage the flue duct into the elbow and butt fit between the air duct and flue elbow. Ensure the correct alignment of the terminal. Fit the securing collar into position, mark through two of the pre drilled holes in the securing collar.
  • Page 32 10 Vertical Flue - Length, Preparation and Installation 10.11 Vertical flue The vertical flue system is available as an option where the boiler position does not permit the use of the top horizontal or rear flue system. The system is made up of accessories. The accessories include terminal assembly, bends 45º...

  • Page 33: Flue Terminal Installation

    10 Vertical - Flue Length, Preparation and Installation NOTE: 2x45º bends can replace 1x90º bend if necessary. When using 90º bends any horizontal extension pipe should be inclined by a minimum of 44mm/metre (2.5°) towards the boiler to facilitate condense removal, see (a) in diagram 10.19.
  • Page 34 10 Vertical Flue - Length, Preparation and Installation Flue Terminal Installation (a) Pitched Roof Fit the required pitched roof weather collar over the 150mm hole in the roof. Make good the tiling or slating around the collar incorporating the flashing of the weather collar. Position the angle cap over the weather collar in the correct orientation to attain the correct angle for your roof.
  • Page 35 10 Twin Flue - Length, Preparation and Installation Diagram 10.25 Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 36 10 Twin Flue - Length, Preparation and Installation 10.12 Twin flue The twin flue system is available as an option when the top horizontal, rear 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 37: 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 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 38: Electrical Connection

    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 AIR BRICK condensate.
  • Page 39 11 Electrical Connection 11.5 Disabling the internal CH Programmer If fitting an external proprietary CH Programmer, it is necessary to disable the Internal Programmer. Press and hold the ‘mode’ button for 5 seconds. The display will change to flashing ‘0’. Use the ‘+’...

  • Page 40: Commissioning

    12 Commissioning GAS SERVICE COCK CLOSED Diagram 12.1 12.1 Filling Domestic Water Circuit QUICK FILLING Make sure that the isolation valves are securely tightened. RELEASE TAP "B" Open all domestic hot water taps. Fully open the DHW outlet and DCW inlet valves, see diagram 12.1.

  • Page 41: Initial Lighting

    12 Commissioning AUTOMATIC AIR VENT AIR VENT SCREW DOMESTIC PUMP Diagram 12.4 Diagram 12.3 5. Vent all air from the system - repeat step 4 as neccessary The appliance will then continue to fire in central heating until the system is full and all the air has been removed. mode until the user controls are satisfied or there is another demand made for hot water.

  • Page 42: Water Systems

    12 Commissioning 12.5 Gas Rate 12.7 Water Systems Should any doubt exist about the gas rate, check it using the Check that all external controls are calling for heat, the boiler gas meter test dial and stop watch at least 10 minutes after the will fire automatically.

  • Page 43: Instruct The User

    12 Commissioning 12.8 Benchmark It is necessary to complete the “Benchmark” logbook. For IE, it is necessary to complete a “Declaration of Conformity” to indicate compliance to I.S.813. An example of this is given in the current edition of I.S.813. 12.9 Instruct the User Demonstrate, then instruct the User about the lighting procedure and heating system controls operation.

  • Page 44: Servicing

    4. 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. 5. On completion of servicing the “Benchmark” log book should be completed.
  • Page 45 13 Servicing BRACKET CONTROL BOX SERVICE FLEXIBLE BRACKET HOSE CONTROL BOX UNION NUT (Do not loosen) LOCK NUT DOMESTIC CONTROL BOX EXPANSION VESSEL SERVICE BRACKET Diagram 13.5 BOILER SERVICE SUPPORT MODULE CONTROL BOX BRACKET MOUNTING BRACKETS DOMESTIC EXPANSION To move the control box into its service position VESSEL carefully pull the control box forwards and upwards to release from its mounting brackets.
  • Page 46 13 Servicing SILENCER HEAT BRACKET EXCHANGER SILENCER IGNITION LEAD SECURING SCREW EARTH LEAD HEAT EXCHANGER Diagram 13.9 Diagram 13.7 13.6 Burner NOTE: If the functional checks did not indicate poor SPARK GAP combustion then it is not necessary to service the burner. GASKET The following procedure will require that you replace the burner door seal and nyloc nuts.
  • Page 47 13 Servicing 13.7 Heat Exchanger GAS SUPPLY PIPE Refer to diagram 13.11. SECURING CLIP Remove loose debris from inside the heat exchanger 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 48 13 Servicing 13.9 Condense Trap & Siphonic Drain FLUE ELBOW The condense trap and siphonic drain does not normally need removing during servicing unless the service fill level is at full, see diagram 13.15. To flush the condense trap and siphonic drain carefully pour water into the heat exchanger and check that water flows freely to drain.

  • Page 49: Fault Finding

    14 Fault Finding Electrical Testing WARNING Should there be any doubt about the voltage supply to any of Always isolate the boiler from the electrical supply before carrying out any electrical replacement work. the components, it is possible to carry out a simple electrical test.

  • Page 50: Central Heating

    14 Fault Finding CENTRAL HEATING START Is there anything displayed Is the power switched on? Switch the power on on the LCD? Check wires between main PCB and display Is the display flashing 'F'? Consult the Fault Table Initiate a CH demand. Does the boiler light? Does the display flash 'F' Successful ignition...
  • Page 51 14 Fault Finding Fault Codes Diagram 14.3 Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 52: Fault Memory

    14 Fault Finding Fault Codes (continued) Diagram 14.3a Fault Memory The Fault memory stores details of the ten most recent faults. To access this menu: a) Press and hold ‘MODE’ for 5 seconds. b) When the display shows a flashing ‘0’ press ‘MODE’ button.

  • Page 53: Diagnostic Menu

    14 Fault Finding Diagnostic Menu The Diagnostic Menu provides the ability to view and change certain parameters. See Diagram 14.4 for available parameters. To enter the diagnostic menu: a) Press and hold the ‘MODE’ button for 5 seconds. The display will change to flashing ‘0’. b) Use the ‘+’...
  • Page 54 14 Fault Finding Diagnostic Menu - Level 1 Installer Access Description Range Domestic hot water flow temperature reading Tank temperature Flow temperature setpoint Domestic hot water setpoint Tank setpoint Domestic hot water demand d.24 System water pressure in bar. d.27 Option Relay 1 Reserved for future use d.28...
  • Page 55 14 Fault Finding State list - Accessed through Diagnostic Codes - Level 1, Installer Access d.99 STATE LISTS Central heating mode (Priority 3) Possible Causes S.00 no heating required S.01 fan pre-run S.02 pump pre-run S.03 ignition S.04 burner on S.05 pump / fan overrun S.06...

  • Page 56: Replacement Of Parts

    15 Replacement of Parts 15.3 Silencer assembly 15.1 General Replacement of parts must be carried out by a competent For access, refer to section 15.1. person. To aid access to the silencer and securing screw, loosen the Before replacing any parts the boiler and immersion heater locknut at the top of the domestic expansion vessel, see should be isolated from the mains electric supply and the gas diagram 15.1 and slide the vessel forward out of its bracket...
  • Page 57 15 Replacement of Parts 15.4 Ignition Lead SPARK GAP For access, refer to section 15.1. Refer to diagram 13.9. GASKET Pull the spark plug style connector off the spark electrode and the ignition lead connected to the igniter unit, see diagram 15.2. ELECTRODE 15.5 Igniter Unit For access, refer to section 15.1.
  • Page 58 15 Replacement of Parts 15.9 Burner REAR For access, refer to section 15.1. INSULATION WASHER Refer to section 13.6 for removal of the fan, gas valve and burner assembly. SECURING Remove the four screws that secure the burner, see diagram SCREW 13.12.
  • Page 59 15 Replacement of Parts 15.13 Primary Expansion Vessel SECURING For access, refer to section 15.1. SCREW (2 OFF) Drain the boiler primary circuit, refer to section 15.1. Remove the retaining clip from the flexible hose at the central heating pump, see diagram 15.7. Remove the flexible hose from the pump, ensure the ‘O’...
  • Page 60 15 Replacement of Parts 15.14 Heat Exchanger Remove the two connection clips securing the flow and return pipes to the heat exchanger, see diagram 15.9. Refer to Manual Handling Operations, 1992. Move the pipes away from the heat exchanger. For access, refer to section 15.1. Remove the four heat exchanger securing screws and Drain the boiler primary circuit, see section 15.1.

  • Page 61: Central Heating Pump

    15 Replacement of Parts 15.15 Central Heating Pump 15.17 Domestic Pump For access, refer to section 15.1. For access, refer to section 15.1. Drain the boiler primary circuit, see section 15.1. Drain the boiler hot water circuit, see section 15.1. Unscrew the union nut of the return pipe to the pump Remove the domestic expansion vessel and place in its connection, see diagram 15.10.
  • Page 62 15 Replacement of Parts 15.18 Safety Discharge Valve For access, refer to section 15.1. LOW WATER Refer to section 15.1 and drain the boiler primary circuit. PRESSURE The safety discharge valve is situated towards the RH side of SENSOR the boiler module, refer to diagram 15.13. Unscrew the pipework union nut from the safety discharge valve.
  • Page 63 15 Replacement of Parts AUTOMATIC PRIMARY AIR VENT RETURN THERMISTOR RETAINING CLIP Diagram 15.17 Diagram 15.16 15.21 Primary Return Thermistor LOW WATER ELECTRICAL For access, refer to section 15.1. PRESSURE LEADS SENSOR Refer to diagram 15.16. Remove the electrical connections from the thermistor. Remove the thermistor and noting its position on the return pipe.
  • Page 64 15 Replacement of Parts 15.24 Plate-to-Plate Heat Exchanger For access, refer to section 15.1. PLATE TO PLATE SECURING Refer to section 15.1 to drain the boiler primary circuit. HEAT EXCHANGER SCREWS (4) Refer to section 15.1 and drain the boiler hot water circuit. Refer to diagram 15.19.
  • Page 65 15 Replacement of Parts 15.25 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 15.1. should be drawn upwards past the plastic three way valve IMPORTANT: To replace the bypass tube the LH and body.
  • Page 66 15 Replacement of Parts 15.26 Filling Loop BYPASS AUTOMATIC For access, refer to section 15.1. SCREW BYPASS VALVE Refer to section 15.1 and drain the boiler hot water circuit. Refer to diagram 12.2. RETAINING CLIP Undo the union nuts on the filling loop valve and the double check inlet valve to remove the filling loop.
  • Page 67 15 Replacement of Parts 15.31 Immersion Heater IMMERSION For access, refer to section 15.1. HEATER Refer to section 6.3 and drain the hot water storage tank. Remove the flexible condensate hose from the condensate trap and siphonic drain, see diagram 13.15. The trap may also be removed if required, refer to section 15.32.
  • Page 68 15 Replacement of Parts 15.33 Access to Switches and User Interface RETAINING For access, refer to section 15.1. CLIPS Release the front of the control box by carefully pushing on the retaining clips to release, see diagram 15.26. Carefully rotate the control box front forward on its hinges to gain access to electrical connections, main PCB and user interface.

  • Page 69: 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 70 16 Spare Parts Diagram 16.1 Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 71 Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 72 Because of our constant endeavour for improvement, details may vary slightly from those shown in these instructions. Supplied By www.heating spares.co Tel. 0161 620 6677...

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