Glow-worm Ultracom 38cxi Installation And Servicing
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Glow-worm Ultracom 38cxi Installation And Servicing

Glow-worm Ultracom 38cxi Installation And Servicing

High efficiency condensing combination boilers
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Ultracom

Installation and Servicing

24cxi
G.C. No. 47-019-01
30cxi
G.C. No. 47-019-02
38cxi
G.C. No. 47-019-03
High Efficiency
Condensing Combination
Boilers
Supplied By www.heating spares.co Tel. 0161 620 6677
www.glow-worm.co.uk
1

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  • Page 1: Installation And Servicing

    Ultracom Installation and Servicing 24cxi G.C. No. 47-019-01 30cxi G.C. No. 47-019-02 38cxi G.C. No. 47-019-03 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

    Glow- worm. - Grip the boiler at its base Any alteration not approved by Glow-worm, could invalidate - Be physically capable the certification, boiler warranty and may also infringe the - Use safety clothing where appropriate, e.g. gloves, safety current issue of the statutory requirements.

  • Page 5: Statutory Requirements

    Statutory Requirements CE Mark NOTE: For further information, see the current issue of the Building Regulations, approved document L1 ( in the UK) and This boiler meets the requirements of Statutory Instrument, the following current issues of: No. 3083 The Boiler (Efficiency) Regulations, and therefore 1) Central heating system specification (CheSS) is deemed to meet the requirements of Directive 92/42/EEC on the efficiency requirements for new hot water boilers fired...

  • 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 BOILER SPECIFICATION 24cxi 30cxi 38cxi Lift weight 40kg (88Ib) 41kg (91Ib) 44kg (97lb) Total weight (installed) 44kg (97Ib) 45kg (99Ib) 47kg (103.5lb) Gas connection Ø O.D. 15mm. copper 15mm. copper 15mm. copper Heating flow and return connection Ø O.D. 22mm.

  • Page 8: Boiler Dimensions & Hydraulic Schematic

    2 Boiler Dimensions & Hydraulic Schematic BOILER CONDENSATE CONNECTION Diagram 2.2 2.1 Boiler Dimensions & Hydraulic Schematic outlet 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 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 Diagram 3.1...

  • Page 10: Flue Options And Terminal Clearances

    4 Flue Options and Terminal Clearances Top horizontal telescopic flue (Ø60/100) Top horizontal standard flue (Ø60/100) Part No. A2043600 - Section 10, page 20 Part No. A2043400 - Section 10, page 24 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 - Heating 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 adjusted.The pipe from the safety discharge valve must...
  • Page 13 5 Water System - Domestic Hot Water 5.9 Water Pressure The minimum working pressure to obtain the maximum domestic flow is:- 24cxi 1.0bar 30cxi 1.0bar 38cxi 2.5bar The maximum working pressure of the domestic hot water circuit is 10 bar. If the cold water supply pressure exceeds this, then a pressure-reducing valve must be fitted in the supply to the boiler.

  • 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. WALL 44mm/metre The packs are located in the top polystyrene packing. TEMPLATE inclined extended flue length Remove the carton sleeve and top pack then lift the boiler Preferred and its polystyrene base support out of the lower pack.

  • 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 PIPES AND ISOLATION VALVES ASSEMBLY ARRANGEMENT FILLING DEVICE (Refer to diagram 6.1 for parts description) DRAIN POINTS Numbers shows the sequence to be used when tightening to copper tails. O RING WIRE ISOLATION VALVE ISOLATION Step 1 Step 2 RETAINING...

  • 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 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

    10 Telescopic Flue - Length, Preparation and Installation 10.1 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 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 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 10.4.
  • Page 23 10 Telescopic Flue - Length, Preparation and Installation 10.5 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 10 Standard Flue - Length, Preparation and Installation 10.6 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 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 10.11 COLLAR Diagram 10.12...
  • Page 26 10 Standard Flue - Length, Preparation and Installation 10.7 Standard Horizontal Flue - A2043400 Refer to diagram 10.11 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 10.13. If the measurement ‘Y’...
  • Page 27 10 Standard Flue - Length, Preparation and Installation 10.10 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 10.16. The flue duct cutting length (L + 11mm.) is shown in diagram 10.16.
  • Page 28 10 Vertical Flue - Length, Preparation and Installation 10.11 Vertical flue The terminal siting should be as shown in diagram 4.2. The vertical flue system is available as an option where the Measure the distance of flue length required for the boiler position does not permit the use of the top horizontal installation.

  • Page 29: Flue Installation

    10 Vertical - Flue Length, Preparation and Installation Flue Installation Refer to diagram 10.20 and secure the flue adapter in position on top of the boiler with four screws supplied, making sure the nib fits into the locating slot in the boiler casing to ensure correct orientation.
  • Page 30 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 31 10 Twin Flue - Length, Preparation and Installation Diagram 10.24 Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 32 10 Twin Flue - Length, Preparation and Installation 10.12 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

    10 Twin Flue - Length, Preparation and Installation Installation Details The parts available for a twin flue system installation are shown in diagram 10.25. Boiler Connection Place the twin flue adaptor onto the outlet of the boiler with the air inlet to the left hand side, see diagram 10.26. 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. AIR BRICK The Plume Management Kit is supplied with installation instructions.

  • Page 35: 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 36 If fitting a proprietary programmer as part of the system controls the internal central heating programmer will need to be disabled as described in section 11.4. If fitting the Glow-worm Climapro programmer, the internal programmer will automatically be disabled. SECURING SCREW (2 OFF) 11.3 Mains Voltage System Controls...

  • Page 37: Commissioning

    Central Heating Function secure by tightening the knurled nut marked ‘A’, refer water temperature is less than 50 Domestic Hot Water Function Glow-worm control (Optional) diagram 12.2. Central Heating Min burner display 2. Open the Central Heating Flow and Return isolation Timed Mode valves marked ‘B’...

  • Page 38: Initial Lighting

    12 Commissioning 12.4 Domestic Water Circuit 12.6 Gas Inlet Pressure Open all hot water taps in turn then close when water flows. Check the supply pressure at the gas service isolation valve Check for water tightness of the complete domestic water test point, see diagram 12.2.

  • Page 39: Instruct The User

    12 Commissioning 12.8 Heating System Ensure that the external controls and programmer are calling for heat. Fully open all radiator valves, flow control valve, if fitted, see diagram 5.1. Press the “MODE” button to change to the CH. Balance the radiators as required and if fitted adjust valve to give the required system differential.
  • Page 40 As an option a chargeable boiler only commissioning service THROTTLE can be provided by Glow-worm Service by calling telephone No. 01773 828100. Tools required to make the conversion are a 2mm Allen key and an electricians screwdriver.

  • Page 41: 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 42: Spark Electrode

    13 Servicing 13.3 Servicing Note: 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, 13.4 and then proceed to 13.9. All routine servicing requirements can be achieved by the removal of the front and inner panels, see diagram 13.1.
  • Page 43 13 Servicing Diagram 13.7 Disconnect the electrical plug from the fan. FRONT SECURING BURNER Disconnect the spark electrode plug and earth lead, refer to INSULATION SCREW (4) diagram 13.6. Remove the five combustion chamber/burner door securing nuts, see diagram 13.7, these should be discarded and replaced with the new nylocs nuts supplied in the burner door seal kit.

  • Page 44: Service Completion

    13 Servicing 13.7 Combustion Check FLUE ELBOW With the appliance operational connect the CO combustion analyser to the test point, see diagram 13.9. IMPORTANT: Remember to replace the cap on completion of the test. Check the burner %CO , at maximum rate(open a hot water tap fully to generate a demand).

  • Page 45: Fault Finding

    14 Fault Finding 14.1 Preliminary fault finding RETAINING SECURING The following checks should be performed before proceeding SLOTS SCREW 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 46 14 Fault Finding w or 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 47 14 Fault Finding CENTRAL HEATING Diagram 14.5 Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 48 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 49 14 Fault Finding Fault Codes (continued) Diagram 14.6 continued. Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 50 14 Fault Finding 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 ‘+’ or ‘-’ buttons to scroll to 96 (This is the installer level access password). c) Press ‘MODE’...
  • Page 51 14 Fault Finding Diagnostic Menu - Level 1 Installer Access Description Range DHW Flow temperature reading Flow temperature setpoint DHW setpoint in 0C, 4 to 62 intelligent control Status central heating pump Status additional heating pump d.22 Domestic hot water demand 1 = on, 0 = off d.24 System water pressure...
  • Page 52 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 53: Replacement Of Parts

    15 Replacement of Parts 15.1 General IGNITER BRACKET IGNITER UNIT IMPORTANT: The replacement of parts described in sections SECURING SCREW 15.5 to 15.9 and section 15.12 will require the removal of the IGNITER burner module assembly and the replacement of seal and self SPADE SECURING locking nuts.
  • Page 54 15 Replacement of Parts 15.5 Gas Valve For access, refer to section 15.1. Refer to section 13.5 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 55: Expansion Vessel

    15 Replacement of Parts 15.10 Viewing Window For access, refer to section 15.1. GLASS FIBRE WASHER 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 56 15 Replacement of Parts 15.12 Heat Exchanger Refer to Manual Handling section on page 65. For access, refer to section 15.1. HEAT Refer to section 13.5 for removal of the fan, gas valve and EXCHANGER burner assembly. Drain the boiler heating circuit as described in the appropriate section of 15.1.
  • Page 57 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 58 15 Replacement of Parts 15.17 Pump (head only) CAP HEAD For access, refer to section 15.1. SCREW (4) 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.

  • Page 59: Maintenance

    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 60 15 Replacement of Parts 15.22 Flow Sensor BYPASS For access, refer to section 15.1. TUBE FLOW REAR Drain the boiler hot water circuit as described in the SENSOR SECURING appropriate section of 15.1. CLIP 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 61 15 Replacement of Parts Disconnect the CH flow, return and DHW inlet pipes at the SECURING PLATE TO PLATE bulkhead connectors, then the retaining clips, remove the SCREWS (4) HEAT EXCHANGER pipes and “o” ring seals. Remove the low water pressure sensor as described in section 15.21.
  • Page 62 15 Replacement of Parts 15.27 Access User Interface and Main PCB RETAINING SECURING For access, refer to section 15.1. SLOTS SCREW 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.

  • Page 63: 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 64: Spare Parts 16

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

  • Page 65: 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 brack- Regulations, the following lift operation exceeds the recommended et securely onto wall before lifting appliance into position.
  • Page 66 Ultracom 24cxi, 30cxi & 38cxi Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 67 Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 68 0020020820-02 12.06 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 Supplied By www.heating spares.co Tel. 0161 620 6677...

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