Ultracom2 cxi Installation and Servicing Manual Boilers - Glow-worm

Ultracom2 cxi Installation and Servicing Manual Boilers - Glow-worm
Ultracom2 cxi
Installation and Servicing
24cxi
G.C. No. 47-019-10
30cxi
G.C. No. 47-019-11
35cxi
G.C. No. 47-019-12
High Efficiency Condensing
Combination Boilers
www.glow-worm.co.uk
Table of contents
IN T R O D U C T I O N
1
Instructions guidance..........................................................................................................................3
1.1
1.2
1.3
1.4
2
Appliance description..........................................................................................................................3
2.1
2.2
2.3
2.4
2.5
3
Safety devices ........................................................................................................3
Data label................................................................................................................4
Gas category ..........................................................................................................4
Regulation and statutory requirements................................................................... 4
Hydraulic schematic ............................................................................................... 5
Safety instructions and regulations.....................................................................................................6
3.1
3.2
4
Product documentation........................................................................................... 3
Associated documents ........................................................................................... 3
Explanation of symbols........................................................................................... 3
Guarantee registration............................................................................................. 3
Safety instructions................................................................................................... 6
Regulations ............................................................................................................6
Recycling............................................................................................................................................7
4.1
4.2
Appliance.................................................................................................................7
Packaging................................................................................................................7
TE C H N I C A L D ATA
5
Ultracom2 cxi.......................................................................................................................................8
IN S TA L L AT I O N
6
Appliance location...............................................................................................................................9
6.1
6.2
6.3
7
Appliance installation .......................................................................................................................10
7.1
7.2
7.3
7.4
8
Scope of delivery...................................................................................................10
Recommendations before installing...................................................................... 10
Dimensions............................................................................................................12
Mounting . .............................................................................................................12
Hydraulic connection.........................................................................................................................14
8.1
8.2
8.3
9
Location...................................................................................................................9
Clearances..............................................................................................................9
Ventilation ...............................................................................................................9
Gas and water connections................................................................................... 14
Safety Discharge Valve......................................................................................... 14
Connection to the condensate trap....................................................................... 15
Evacuation of combustion gas..........................................................................................................17
9.1
9.2
Regulation.............................................................................................................17
Flue configuration description............................................................................... 19
10
Remove the front panel.....................................................................................................................21
11
Electrical connections.......................................................................................................................21
11.1
11.2
11.3
11.4
11.5
11.6
Access to main board ........................................................................................... 21
Main board............................................................................................................21
Electrical wiring..................................................................................................... 22
External accessories............................................................................................. 23
Testing the electrical connections.......................................................................... 23
Wiring diagram......................................................................................................24
-1-
Table of contents
12
Commissioning ................................................................................................................................25
12.1
12.2
12.3
12.4
12.5
12.6
12.7
12.8
12.9
13
Specific adjustment . ........................................................................................................................28
13.1
13.2
13.3
13.4
14
Switching on..........................................................................................................25
Filling the CH system (Central heating)................................................................. 25
Filling DHW Circuit................................................................................................ 25
Filling the Condensate Trap.................................................................................. 25
Initial lighting..........................................................................................................26
Gas rates...............................................................................................................26
Testing heating system.......................................................................................... 27
Testing domestic hot water system....................................................................... 27
Completion............................................................................................................27
Heating circuit adjustment..................................................................................... 28
Appliance technical settings and parameter list.................................................... 28
CO2 measurement................................................................................................ 32
Re-check and restart............................................................................................. 32
User information................................................................................................................................32
MA I N T E N A N C E
15
Trouble-shooting...............................................................................................................................33
15.1
15.2
15.3
15.4
16
Gas conversion adjustments.............................................................................................................37
16.1
16.2
17
General..................................................................................................................46
Boiler Access.........................................................................................................46
Viewing window.....................................................................................................46
Hydraulic block......................................................................................................48
Combustion block..................................................................................................50
Condensate trap....................................................................................................52
PCB.......................................................................................................................53
Spare parts.......................................................................................................................................54
20.1
20.2
-2-
Annual Maintenance.............................................................................................. 39
Casing removing................................................................................................... 40
Combustion check and setting the air/gas ratio valve........................................... 40
Servicing................................................................................................................41
Silencer ................................................................................................................42
Expansion vessel.................................................................................................. 42
Heating filter..........................................................................................................43
Condensate trap....................................................................................................43
Combustion block..................................................................................................44
Service completion................................................................................................ 45
Replacement of Parts.......................................................................................................................46
19.1
19.2
19.3
19.4
19.5
19.6
19.7
20
Heating circuit . ..................................................................................................... 38
Domestic Hot water circuit . .................................................................................. 38
Servicing...........................................................................................................................................39
18.1
18.2
18.3
18.4
18.5
18.6
18.7
18.8
18.9
18.10
19
Settings.................................................................................................................37
Restart - re-check commissioning......................................................................... 38
Draining ...........................................................................................................................................38
17.1
17.2
18
Fault diagnosis......................................................................................................33
Fault memory........................................................................................................34
Fault codes............................................................................................................34
Functional flow diagram........................................................................................ 36
Short List of Parts..................................................................................................54
Short List of Parts..................................................................................................55
21
Manual Handling...............................................................................................................................56
22
Declaration of Conformity.................................................................................................................57
INTRODUCTION
INTRODUCTION
1
Instructions guidance
1.1
Product documentation
The instructions are an integral part of the appliance and must
be handed to the user on completion of the installation in order
to comply with the current regulation.
• Carefully read the manual, to understand all the information
to enable safe installation, use and servicing. No liability can
be accepted in the event of damage for not complying with
the guidance in this instruction manual.
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.
1.2
Associated documents
-- 1 Instructions for use
-- 1 magnetic lighting instruction label
-- 1 flue guide
-- 1 extended guarantee leaflet
-- 1 guarantee envelope pack
-- 1 wall template
-- 1 gas conversion label
1.3
Explanation of symbols
a
DANGER: Risk of injuries.
e
DANGER: Risk of electric shock.
b
ATTENTION: Risk of damage to the appliance or
to its surroundings.
i
IMPORTANT: Important information.
1.4
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.
0020085231_02 - 05/10 - Glow-worm
The second year of guarantee, from the beginning of the 13th
month onwards after installation or manufacture, is conditional
upon the boiler having been serviced by a competent person
approved at the time by the Health and Safety Executive, in
accordance with the manufacturer’s recommendations. We
strongly recommend regular servicing of your gas appliance,
but where the condition is not met, any chargeable spare parts
or components issued within the applicable guarantee period
still benefit from a 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.
2
Appliance description
2.1
2.1.1
Safety devices
Overheating safety
The appliance is designed to recognise the potential for an
overheat lockout and will shutdown before this happens.
2.1.2
Safety discharge valve
A safety discharge valve and discharge pipe are fitted to the
boiler. This valve must not be touched.
-- The heating safety valve opens when the pressure in the
heating circuit exceeds 2.5 bars.
• Should there be any discharge from the pipe, isolate the
boiler electrical supply and call your installer or Glow-worm’s
own service organisation.
2.1.3
Frost protection
The frost protection system operates the pump to start as soon
as the temperature in the heating circuit falls below 12°C. The
pump stops as soon as the temperature of the water contained
in the heating circuit reaches 15°C.
If the temperature in the heating system falls below 7°C, the
burner ignites until it reaches 35°C.
The frost-protection system is active when the appliance is
switched on.
The system alone cannot ensure that the installation is
protected against frost. An separate frost thermostat is
necessary to control the temperature of the system.
a
2.1.4
Your domestic water circuit (hot or cold) is not
protected by the boiler.
Condensate drain blockage
During freezing conditions this may be due to the forming of
ice in the condense drain external to the house. In this case, a
safety device shuts down the appliance.
-3-
INTRODUCTION
2.2
Data label
2.3
Gas category
The data label certifies the country where the appliance is
intended to be installed.
This boiler is for use only on G20, but can be converted for use
on G31.
Data label location:
• To adapt the appliance to another type of gas, see the
chapter "Gas conversion".
2.4
2.4.1
Regulation and statutory requirements
CE Mark
This boiler meets the requirements of Statutory Instrument,
No. 3083 The Boiler (Efficiency) Regulations, and therefore is
deemed to meet the requirements of Directive 92/42/EEC on
the efficiency requirements for new hot water boilers fired with
liquid or gaseous fuels.
1
Key
1
Data label
The data label contains the following data:
Type test for purposes of Regulation 5 certified by: Notified
body 1312.
Product/production certified by: Notified body 0086.
-- The name of the manufacturer
The CE mark indicates that the appliances described in this
manual are in compliance with the following directives:
-- The country of intended destination
-- European directive n°2009-142 relative to gas appliances
-- The commercial name of the appliance and its serial number
-- European directive n°2004-108 from the European
Parliament and Council relative to electromagnetic
compatibility
-- The types of flues installations authorised
-- The appliance's gas category
-- The gas type, group and pressure, set in the factory
-- The DHW specific flow rate (D)
-- European directive n°2006-95 from the European Parliament
and Council relative to low voltage
-- European directive n°92-42 relative to the yield of boilers
-- The maximum pressure in the heating circuit (PMS)
2.4.2
-- The maximum pressure in the domestic water circuit (PMW)
Benchmark places responsibilities on both manufacturers
and installers. The purpose is to ensure that customers are
provided with the correct equipment for their needs, that it is
installed, commissioned and serviced in accordance with the
manufacturer’s instructions by a competent person approved at
the time by the Health and Safety Executive and that it meets
the requirements of the appropriate Building Regulations.
The Benchmark Checklist can be used to demonstrate
compliance with Building Regulations and should be provided to
the customer for future reference.
-- The NOx class of the appliance
-- The type and voltage of electricity supply
-- The maximum power rating
-- The electrical protection class
-- The minimum and maximum heat input (Q)
-- The minimum and maximum power output (P)
-- The CE number and logo
a
-4-
The appliance shall only be connected to the gas
type(s) indicated on the data label.
Local regulations
Installers are required to carry out installation, commissioning
and servicing work in accordance with the Benchmark Code
of Practice which is available from the Heating and Hotwater
Industry Council who manage and promote the Scheme.
• Visit www.centralheating.co.uk for more information.
0020085231_02 - 05/10 - Glow-worm
INTRODUCTION
2.5
Hydraulic schematic
14
15
13
16
12
17
11
10
18
19
9
20
21
8
22
7
23
6
24
5
25
4
26
3
27
2
1
Key
1
Gas isolating valve
2
Heating flow isolating valve
3
Heating safety valve
4
Filter on cold water inlet
5By-pass
6
DHW flow sensor
7
Domestic plate to plate heat exchanger
8
Heating filter
9
Heating return thermistor
10 Condensate trap
11 Ignition and control electrode
12Burner
13 Main heat exchanger
14 Thermal fuse
15Flue outlet
16 Silencer
17 Heating expansion vessel
0020085231_02 - 05/10 - Glow-worm
28
18Fan
19 Gas control valve
20 Ignition module
21 Heating flow thermistor
22 Air vent
23 Pump
24 Three way valve
25 Water pressure sensor
26Filling taps
27 Heating return isolating valve
28 Domestic cold water isolating valve
A Heating flow
B Pipe for heating safety valve
C Domestic hot water outlet
D Gas
E Cold water inlet
F Heating return
G Condensate drain
-5-
INTRODUCTION
3
Safety instructions and regulations
3.1
Safety instructions
If the gas pressure at the input of the appliance is outside the
range specified, the appliance must not be put into operation.
e
Incorrect installation can cause electric shock or
appliance damage.
• Never disable security devices and do not try to adjust them.
• Use only new O-rings and gaskets.
• After having completed work on gas or water carrying
components, check for their tightness.
• When work on the appliance is completed, perform an
operational test and check for safety.
3.2
3.2.1
Regulations
Statutory requirements
IMPORTANT
With regards to the “Manual Handling Operations, 1992
Regulations”, the appliance exceeds the recommended weight
for a one person lift.
The handling of the boiler may involve lifting, pushing and
pulling, the use of a sack truck may be required.
Where no British Standards exists, materials and equipment
should be fit for their purpose and of suitable quality and
workmanship.
• Be sure to consider the following handling techniques and
precautions:
-- Grip the appliance at its base
The installation of this boiler must be carried out by a competent
person approved at the time by the Health and Safety Executive
and in accordance with the rules in force in the countries of
destination.
-- Use safety clothing where appropriate, e.g. gloves, safety
footwear.
Manufacturer’s instructions must not be taken as overriding
statutory requirements.
• Ensure safe lifting techniques are used:
-- Keep back straight.
-- Avoid twisting at the waist.
-- Avoid upper body/top heavy bending.
-- Always grip using the palm of the hand.
-- Use designated hand holds.
-- Keep load as close to body as possible.
-- Always use assistance if required.
• Under no circumstances must the user interfere with or
adjust sealed parts.
• When assembling the connections, correctly position the
seals to avoid any leakage of gas or water.
• This appliance contains metal parts (components) and care
should be taken when handling and cleaning, with particular
regard to edges.
The basic safety instructions must be followed before
attempting to maintain or replace spare parts:
• Stop the appliance.
• Electrically isolate the appliance from the power supply.
• Turn off the appliance gas isolation valve.
• Hydraulically isolate the appliance using the isolation valves
if provided.
• Should you need to replace hydraulic components, drain the
appliance.
Statutory Requirements
In GB, the installation of the boiler must comply with the
requirements of the current issue of BS6798 and be carried out
by a competent person approved at the time by the Health and
Safety Executive and as described in the following regulations:
- The manufacturer’s instructions supplied.
- The Gas Safety (Installation and Use) Regulations.
- The appropriate Buildings Regulations either The Building
Regulations, The Building Regulations (Scotland), The Building
Regulations (Northern Ireland).
- The Water Supply (water fittings) Regulations 1999 and water
byelaws 2000, Scotland.
- The Health and Safety at Work Act, Control of Substances
Hazardous to Health (COSHH).
- The Current I.E.E. Wiring Regulations.
Where no specific instructions are given, reference should be
made to the relevant British Standard Code of Practice.
In IE, the installation must be carried out by a competent person
approved at the time by the Health and Safety Executive and
installed in accordance with the current edition of I.S.813
“Domestic Gas Installations”, the current Building Regulations
and reference should be made to the current ETCI rules for
Electrical Installation.
GB: the following Codes of Practice apply: BS4814, BS6798,
BS5440 Part 1 and 2, BS5546 Part 1, BS5449, BS6891,
BS6700, BS7074 Part 1 and 2, BS7593, BS7671.
IE: I.S.813, BS5546, BS 5449, BS 7074, BS 7593.
NOTE: For further information, see the current issue of the
Building Regulations, approved document L1 ( in the UK) and
the following current issues of:
1) Central heating system specification (CheSS) and
2) Controls for domestic central heating system and hot water.
BRECSU.
• Protect all the electrical components from water while
working on the appliance.
• Use only original spare parts.
-6-
0020085231_02 - 05/10 - Glow-worm
INTRODUCTION
Gas Supply
The gas installation must be in accordance with the relevant
standards.
In GB, this is BS6891.
In IE, this is the current edition of I.S.813 “Domestic Gas
Installations”.
The supply from the governed meter must be of adequate size
to provide a steady inlet working pressure of 20mbar (8in wg) at
the boiler. On completion, test the gas installation for tightness
using the pressure drop method and suitable leak detection
fluid, purge in accordance with the above standard.
Domestic Hot Water
All domestic hot water circuits, connections, fittings must be
in accordance with the relevant standards and water supply
regulations.
GB: Guidance G17 to G24 and recommendation R17 to R24 of
the Water Regulations Guide.
IE: The current edition of I.S.813 “Domestic Gas Installations”.
Heating System
In GB, it is necessary to comply with the Water Supply (Water
Fittings) Regulations 1999 (for Scotland, the Water Byelaws
2000, Scotland). To comply with the Water regulations your
attention is drawn to: The Water Regulations guide published
by the Water Regulations Advisory Service (WRAS) gives full
details of the requirements.
In IE, the requirements given in the current edition of I.S.813
“Domestic Gas Installations” and the current Building
Regulations must be followed.
Electrical Supply
The boiler MUST be earthed. All system components shall
be of an approved type and all wiring to current I.E.E. wiring
regulations. External wiring must be correctly earthed, polarised
and in accordance with the relevant standards.
In GB, this is BS 7671.
In IE, this is the current edition of ETCI rules.
The boiler MUST be connected to a permanent 230V ac, 50Hz
supply.
Connection of the whole electrical system of the boiler, including
any heating controls, to the electrical supply MUST be through
one common isolator and must be fused 3 Amp maximum.
Isolation should be by a double pole switched fused spur box,
with a minimum gap of 3mm for both poles. The fused spur
box should be readily accessible and preferably adjacent to the
appliance. It should be identified as to its use.
Alternatively connection can be made through an unswitched
shuttered socket and 3A fused 3-pin plug both to the current
issue of BS 1363, provided they are not used in a room
containing a bath or shower.
Wiring to the boiler must be PVC 85OC insulated cable, not less
than 0.75mm2 (24/0.20mm).
0020085231_02 - 05/10 - Glow-worm
3.2.2
Other regulations
Gas Safety (Installation and Use) Regulations
In your own interests and that of safety, it is the Law that ALL
gas appliances are installed by a competent person approved at
the time by the Health and Safety Executive in accordance with
the current issue of these regulations.
Control of Substances Hazardous to Health
Under Section 6 of The Health and Safety at Work Act 1974, we
are required to provide information on substances hazardous to
health. The adhesives and sealants used in this appliance are
cured and give no known hazard in this state.
Insulation Pads:
These can cause irritation to skin, eyes and the respiratory
tract. If you have a history of skin complaint you may be
susceptible to irritation. High dust levels are usual only if the
material is broken.
Normal handling should not cause discomfort, but follow normal
good hygiene and wash your hands before eating, drinking or
going to the lavatory.
• If you do suffer irritation to the eyes or severe irritation to the
skin seek medical attention.
4
Recycling
i
4.1
The recycling of the packaging must be carried
out by the qualified professional who installed the
appliance.
Appliance
Most of the appliance is made of recyclable materials.
This symbol indicates that this appliance must not
be disposed of with household waste, that it should
be selectively collected for energy recovery, reuse
or recycling.
• Take the appliance to an appropriate collection point.
i
4.2
By complying with this directive, you will contribute
to the preservation of natural resources and the
protection of human health.
Packaging
We recommend that you recycle the packaging of the appliance
in a responsible fashion.
• Sort the waste in order to separate those elements which
can be recycled (cardboard, plastics ...) and those which
cannot be recycled.
• Eliminate the waste in accordance with existing regulations.
-7-
technical data
TECHNICAL DATA
5
Ultracom2 cxi
Boiler, type C13, C33, C43, C53
Description
Unit
24 cxi
30 cxi
35 cxi
ll2H3P
ll2H3P
ll2H3P
%
90.3
90.3
90.4
kW
18.5
25
30.6
kW
4.9
5.9
8.5
kW
18.2
24.6
30
kW
5.4
6.6
9.3
Gas category
SEDBUK rating
Heating
Maximum heating input power
Minimum heating output
power at 80/60°C (P min.)
Maximum heating output
power at 80/60°C (P max.)
Minimum heating output
power at 50/30°C (P min.)
Maximum heating output
power at 50/30°C (P max.)
Minimum heating temperature
Maximum heating
temperature
Minimum heating flow rate
Content of heating expansion
vessel
Heating expansion vessel
preset pressure
Maximum heating system
volume (approx)
Heating safety valve preset
pressure (PMS)
Domestic Hot Water
Minimum DHW output power
(P min.)
Maximum DHW output power
(P max.)
Maximum DHW temperature
Specific flow rate (∆T of 35 K)
EN 13203
Minimum inlet water pressure
Maximum inlet water pressure
kW
19.6
26.7
32.8
°C
10
10
10
°C
80
80
80
l/h
l
gallons
bar
psi
400
8
1.76
0.75
10.9
400
8
1.76
0.75
10.9
400
8
1.76
0.75
10.9
l
160
160
160
bar
lbf/in²
2.5
36/3
2.5
36/3
2.5
36/3
kW
5.1
6.1
8.7
kW
25.5
30.6
35.7
°C
60
60
60
l/min
10.4
12.5
14.6
bar
psi
bar
psi
0.3
4.3
10
145
0.3
4.3
10
145
0.3
4.3
10
145
5
5
5
Combustion
Appliance NOx class
Electrical
Electrical supply
Standby mode electrical
power
Operational mode electrical
power (Max)
Internal fuse rating on main
PCB
Index of electrical protection
(EN 60529)
-8-
Description
Unit
Gas connection Ø O.D.
mm
Heating flow and return
connection Ø O.D.
Domestic Hot Water
connection Ø O.D.
mm
mm
Condensate connection Ø I.D.
mm
Safety valve discharge
connection Ø O.D.
mm
Lift weight
Total weight (installed)
kg
lb
kg
Number of CE certificate
Description
24 cxi
30 cxi
35 cxi
15
(copper)
22
(copper)
15
(copper)
21.5
(plastic)
15
(copper)
37
82
42
1312
BU
5334
15
(copper)
22
(copper)
15
(copper)
21.5
(plastic)
15
(copper)
38
83
43
1312
BU
5335
15
(copper)
22
(copper)
15
(copper)
21.5
(plastic)
15
(copper)
38
84.5
43
1312
BV
5336
24 cxi
30 cxi
35 cxi
Unit
Natural Gas G 20 (15 °C, 1013.25 mbar)
Maximum DHW gas flow rate
m3/h
2.70
3.24
3.77
Maximum heating gas flow
rate
m3/h
1.96
2.65
3.24
Minimum gas flow rate
m3/h
0.54
0.65
0.92
CO2 at Qmax DHW +
"tolerance case ON"
%
9.2 ±
0.3%
9.2 ±
0.3%
9.2 ±
0.3%
CO2 at Qmax DHW +
"tolerance case OFF"
%
9±
0.2%
9±
0.2%
9±
0.2%
CO2 at Qmin +
"tolerance case ON"
%
8.9 ±
0.3%
8.9 ±
0.3%
8.9 ±
0.3%
CO2 at Qmin +
"tolerance case OFF"
%
8.7 ±
0.2%
8.7 ±
0.2%
8.7 ±
0.2%
20
20
Inlet pressure
mbar
20
Propane Gas G 31 (15 °C, 1013.25 mbar)
Maximum DHW gas flow rate
kg/h
1.98
2.38
2.77
Maximum heating gas flow
rate
kg/h
1.44
1.94
2.37
Minimum gas flow rate
kg/h
0.4
0.47
0.67
CO2 at Qmax DHW +
"tolerance case ON"
%
10.3 ±
0.3%
10.3 ±
0.3%
10.3 ±
0.3%
CO2 at Qmax DHW +
"tolerance case OFF"
%
10.1 ±
0.2%
10.1 ±
0.2%
10.1 ±
0.2%
V/Hz
230V
50Hz
230V
50Hz
230V
50Hz
W
6
6
6
W
151
151
151
CO2 at Qmin +
"tolerance case ON"
%
9.8 ±
0.3%
9.8 ±
0.3%
9.8 ±
0.3%
A
2
2
2
CO2 at Qmin +
"tolerance case OFF"
%
9.6 ±
0.2%
9.6 ±
0.2%
9.6 ±
0.2%
IPX4D
IPX4D
IPX4D
mbar
37
37
37
Inlet pressure
0020085231_02 - 05/10 - Glow-worm
INSTALLATION
INSTALLATION
i
6
6.1
6.1.1
All the drawings dimensions are shown in mm.
For flue installations where external access is not practicable,
consideration should be given for the space required to insert
the flue from inside the property, which may necessitate
clearance larger than those specified in diagram below.
ØA
Appliance location
+5
mi
ØA
Location
n.
Instructions
Before choosing a site for the appliance, carefully read the
safety warnings and installation manual.
• Ensure that wall to which the appliance will be mounted on is
structurally safe in order to support the weight of the appliance.
0
mi
n.
• Ensure that the space that the appliance is to be installed
within allows the appliance to be installed and the clearances
maintained. This will ensure that the connections to the
water, gas and flue can be accessed and inspected (see
chapter Clearances).
• Explain these requirements to the appliance user.
20
mi 0
n.
• The boiler must be fitted inside the property and exposed
pipe work may need to be protected from frost by fitting a
frost thermostat.
Regulations
Location
This boiler is not suitable for outdoor installation.
This boiler may be installed in any room, although particular
attention is drawn to the installation of a boiler in a room
containing a bath or shower where reference must be made to
the relevant requirements.
This boiler is suitable for installation in bathroom zones 2 and 3.
In GB this is the current I.E.E. WIRING REGULATIONS and
BUILDING REGULATIONS.
In IE reference should be made to the current edition of I.S.813
“Domestic Gas Installations” and the current ETCI rules.
0
mi
n.
*
600n.
mi
• Do not install the appliance above another appliance that
could damage it (for example, above a cooker that might
emit steam or grease) or in a room, which has a lot of dust in
the atmosphere which is corrosive.
6.1.2
15
mi 0
n.
Key
*
A removable compartment door can be placed a minimum 5
mm in front of appliance. A clearance of 600 mm is required
from a fixed surface.
The boiler and flue are suitable for installation onto and through
combustible materials provided that:
-- Minimum 5mm clearance is maintained around the
circumference of the flue (air intake).
-- The combustible surface and fixings are suitable for
supporting the load.
-- The minimum clearances from the boiler case are
maintained.
Timber Frame Buildings
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.
6.2
Clearances
• To allow periodic maintenance, ensure the distances
indicated on the diagram.
Additional clearances may be beneficial around the boiler for
installation and servicing.
0020085231_02 - 05/10 - Glow-worm
6.3
6.3.1
Ventilation
Room Ventilation
The boiler is room sealed so a permanent air vent is not required.
6.3.2
Cupboard or Compartment Ventilation
Due to the high efficiency and low casing temperature of this
boiler, cupboard or compartment ventilation is not necessary.
• Existing ventilation should be investigated for its purpose
before removing.
-9-
INSTALLATION
7
Appliance installation
7.1
4.4
4.5
4.6
4.7
Scope of delivery
The appliance is delivered in a single carton with a document
pack and fittings.
i
7.2
7.2.1
The flues package will be ordered according to the
configuration of the installation.
Extended guarantee leaflet
Guarantee envelope pack
Magnetic lighting instruction label
Gas conversion label
(x1)
(x1)
(x1)
(x1)
Recommendations before installing
Domestic hot water circuit design
Water pressure
• Please check the contents.
2.4
2.3
2.5
2.2
2.6
2.1
3
2
4
4.1
4.2
4.3
4.4
The minimum working pressure to obtain the maximum
domestic flow is 1,0 bar.
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.
‘Hard’ water areas
The temperatures within the heat exchanger are limited by the
boiler control system to minimise scale formation within the hot
water pipework. However, in areas where the water is ‘hard’ (i.e.
more than 200 mg/L of calcium carbonate), it is recommended
that the hot water setting is reduced and that a scale reducer
is fitted, refer to the manufacturer’s instructions or consult the
local water company for additional advice.
Domestic water flow rate
The domestic hot water flow has a restrictor, factory fitted,
which reduces the flow to a maximum of:
-- 24cxi ► 8 l/min,
-- 30cxi ► 10 l/min,
4.5
1
4.7
Key
1
Boiler
2
2.1
2.2
4.6
(x1)
2.6
Accessories bag
Pressure relief valve connecting pipe
Connection bag
- Heating return valve
- Cold water inlet valve
- Heating flow valve
- Domestic hot water connection
- Gas isolation valve
Hanging bracket
Filling loop extensions
Seals bag
- Flat seal ½"
- Flat seal ¾"
- Flat seal for cold water inlet ¾"
Compression fitting
(x1)
(x1)
(x1)
(x1)
(x1)
(x1)
(x1)
(x1)
(x1)
(x2)
(x1)
(x2)
(x5)
(x4)
(x1)
3
Wall template
(x1)
4
4.1
4.2
4.3
Documents bag
Installation and servicing manual
Flue book
Instructions for use
(x1)
(x1)
(x1)
(x1)
2.3
2.4
2.5
- 10 -
-- 35cxi ► 12 l/min.
0020085231_02 - 05/10 - Glow-worm
INSTALLATION
7.2.2
Heating circuit design
Bypass
The boiler is fitted with an automatic bypass which can be
adjusted to suit your system requirements.
6
5
• Ensure that under no circumstances does the flow rate drop
below the figure specified, refer to chapter "Technical data".
Filling the sealed system
7
8
9
4
i
The water pressure at the boiler must be at least
1.2bar to operate the filling loop. If the pressure
is less than 1.2bar an external filling loop must be
fitted. If this pressure is not available contact the
local water authority.
Suitable external filling systems are shown diagrammatically,
see diagram below.
3
10
2
3
4
2
5
11
1
Key
1
Drain point
2
External bypass (if required)
3
Domestic hot water out
4
Domestic cold water supply in
5Boiler
6Filling loop - to be unlocked and disconnected after use.
7
Double check valve assembly
8
Additional expansion vessel (if required)
9
Heating return circuit
10 Heating flow circuit
1
7
6
5
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.
Safety valve
The safety valve is an integral part of the boiler and it cannot
be adjusted. The pipe from the safety discharge valve must
discharge safely in accordance with standards.
Expansion vessel
The boiler has an integral expansion vessel with a capacity of 8
litres (1.76 gallons), with a charge pressure of 0.75bar.
i
The heating system volume should be calculated to
ensure that the expansion vessel is suitable, it may
be necessary to add an additional vessel.
-- In GB, Guidance on vessel sizing is also given in the current
issue of BS5449 and BS7074 Part 1.
3
8
2
9
1
7
Key
1
Heating flow circuit
2
Heating return circuit
3Boiler
4
Double check valve assembly
5
Domestic cold water supply in
6
Temporary filling loop (remove immediately after filling)
7
Drain point
8
Back flow prevention device
9
Tundish
The system should be pressurised to 0.8bar, indicated on the
digital display with no heating demand.
-- In IE, current edition of I.S.813 “Domestic Gas Installations”.
0020085231_02 - 05/10 - Glow-worm
- 11 -
INSTALLATION
7.4
Drain points
Mounting
Drain taps must be provided at all low points of the system,
which will allow the entire system to be drained.
• Make sure that the equipment used for implementing the
installation is compatible with that of the appliance.
Drain taps shall be to the current issue of BS2879.
• Determine the assembly location. See the "Appliance
location" chapter.
Water treatment
160
Existing system- It is essential that prior to installing the new
boiler the system is thoroughly flushed.
160
Ø125*
Ø105**
New system- For optimum performance after installation, the
boiler and its associated central heating system should also be
flushed.
63***
Flushing shall be carried out in accordance with BS 7593, a
chemical cleanser can be used either Sentinel X300, X400 or
Fernox F3 are suitable.
It is recommended to flush existing systems first before fitting
the new boiler.
735
709
• Ensure all cleanser is removed from the whole system before
adding an inhibitor.
170
For long-term corrosion protection after flushing, an inhibitor
suitable for stainless steel heat exchangers can be used. Either
Sentinel X100 or Fernox F1 inhibitor can be used.
=246=
The boiler is suitable for use on systems using softened water.
7.3
Dimensions
65
58
130
65
58
*
80/125 flue ► Ø150mm
** 80/125 flue ► Ø130mm
*** 80/125 flue ► 156mm
• Take the wall template and place in the desired position
on the wall, giving due consideration to the required boiler
clearances, see chapter "Appliance location ► Clearances",
and the flue you are fitting.
740
346
418
- 12 -
344
0020085231_02 - 05/10 - Glow-worm
INSTALLATION
7.4.1
Fixing to the wall
3
7.4.2
a
130
2
90°
1
4
Boiler hanging
With regards to the Manual Handling Operations,
1992 Regulations, the following lift operation
exceeds the recommended weight for a one
person lift, refer to chapter "Manual Handling".
2
5
6
1
Key
1
Wall template
2
Standard flue length horizontal
3
2.5° 44mm/metre inclined extended flue length
4
Wall plug
5
Hanging bracket
6
Screw (not supplied)
Flue hole cutting
• Mark the position of the flue centre.
• Remove the wall template, then drilling the flue hole.
i
The flue is designed with an internal fall of 44mm/
metre (2.5o), therefore the hole can be drilled
horizontally.
• Use a 105mm diameter core drill for external access flue
installation (60/100 flue) (80/125 flue ► Ø130mm).
• Use a 125mm diameter core drill for internal access only flue
installation (60/100 flue) (80/125 flue ► Ø150mm).
i
If flue extension pipes are to be used then a core
drill size of 125mm is required. This will allow the
extension pieces to slope at 44mm/metre (2.5o)
towards the boiler.
Key
1Boiler
2
Hanging bracket
• Lifting the boiler into position, lean the top of the boiler
slightly to the wall and position just above the hanging
bracket.
• Lower the boiler slowly and engage onto the hanging bracket
• If fitting a side flue, extend the flue centre line into the corner
then 130mm along the adjacent wall.
• If fitting an extended side flue, determine the flue hole centre
by extending the dashed inclined line on the template to the
side wall. This dashed line is drawn at 44mm/metre (2.5o)
rise from the boiler. Where this line reaches the side wall, a
horizontal line should be marked. The vertical centre line of
the flue should then be marked at 130mm from the back wall.
To allow for the flue passing through the wall at this angle
a 125mm hole should be drilled irrespective of internal or
external installation.
Hanging bracket fixing
Due to the varied site conditions, fixings are not supplied and
advise that the installer should supply those which are suitable.
• Drill the holes for the fixing screws in accordance with the
wall template.
• Fix the hanging bracket on the wall.
0020085231_02 - 05/10 - Glow-worm
- 13 -
INSTALLATION
8
Hydraulic connection
8.1
8.2
Safety Discharge Valve
Gas and water connections
The whole of the gas installation, including the meter, should
be inspected, tested for tightness and purged in accordance
with the current issue of BS6891 and in IE the current edition of
I.S.813 “Domestic Gas Installations”.
i
The appliance may contain a small amount of water,
place a water container beneath the boiler connections.
• Take care to clean the pipes before assembly removing any
debris or burrs. Grease and oils may need to be removed
they are not possible to remove by cleansing and flushing.
Foreign bodies in the system may enter the appliance and
interrupt its operation.
• Do not use any solvent products, due to the risk of damaging
the circuit.
a
Do not perform any 'hot work' directly under
the appliance, this may cause damage to the
appliance base. Heat may also damage the
isolation valves.
Always pre-assemble pipes before fitting them to
the boiler.
4
3
B
2
A
• Only use original seals supplied with the appliance.
1
• Check that there are no leaks. Repair if necessary.
6
7
5
4
3
6
Key
1
Compression fitting
2
PRV pipe
3
Pipe for PRV
4
Draining outlet
A PRV outlet - to outside
B Appliance drain tap
This must be extended, using not less than 15mm o.d. pipe,
to discharge, in a visible position, outside the building, facing
downwards, preferably over a drain.
To ease future servicing it is advisable to use a compression
type fitting to extend the safety discharge valve tube.
2
1
Key
1
Heating return isolating valve + sealing washer ¾"
2
Cold water inlet isolating valve + sealing washer ¾"
3
Gas service isolating valve with pressure test point + sealing
washer ½"
4
Domestic hot water outlet isolating valve + sealing washer ¾"
5
Heating flow isolating valve + sealing washer ¾"
6
Connection Ø O.D. 22 mm
7
Connection Ø O.D. 15 mm
The pipe must have a continuous fall and be routed to a
position so that any discharge of water, possibly boiling,
or steam cannot create any danger to persons, damage to
property or external electrical components and wiring.
• Remove the protective caps from the boiler connections.
• Flush out the domestic hot water and the heating systems.
i
- 14 -
Before turning on the cold mains supply to the boiler
turn off the cold water inlet to the boiler, lock the filling
loop in the closed position and close its filling taps.
0020085231_02 - 05/10 - Glow-worm
INSTALLATION
8.3
Connection to the condensate trap
a
Condensate produced by the appliance is mildly
acidic (pH 3.5 - 5.0). Use protective gloves
b
Condensate must only be discharged in
accordance with these instructions.
i
The volume of condensates evacuated can reach
about 15 litres per day for a detached house. This
volume is negligible compared to the volume of
waste water discharged by a house, because the
condensates are diluted in this water.
• Refer to BS5546 or BS6798 for advice on disposal of boiler
condensate.
1
Key
1
Condensate pipe
• Make sure there is no protective plug fitted.
• Connect the condensate pipe (1).
i
The pipe should have a fall of a least 2.5° 44mm/
metre away from the boiler.
Condensate should, if possible be discharged into the
household internal drainage system.
• If this is not practicable, discharge can be allowed into the
external household drains or a purpose designed soak away,
refer to diagram overleaf.
It is recommended that any external condensate drain pipe is
protected and also preferably of 32mm diameter, to prevent
freezing in adverse weather conditions.
• Always ensure the pipe is installed with the correct fall
• Use 21.5mm plastic pipe to connect to the condensate
outlet - do not use metal pipes. It is permissible to use a
condensate neutraliser providing that it is checked for correct
operation.
0020085231_02 - 05/10 - Glow-worm
- 15 -
INSTALLATION
- 16 -
0020085231_02 - 05/10 - Glow-worm
INSTALLATION
9
Evacuation of combustion gas
9.1
Regulation
b
b
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
homeowner to check the flue outlet and clear
visible insects from the terminal end.
Only flue accessories supplied by Glow-worm
must be used.
Different flue outlet configurations can be carried out.
• Consult your supplier for more information about the other
possibilities and associated accessories.
44 mm/m
1
2
4
3
• Standard flue terminal kits have an in-built fall back to the
boiler to drain the condensate. These can be fitted level
between the appliance and the termination position. All other
extended flues must have a fall of at least 44mm/m
The maximum length of the flue outlet is defined according to its
type (for example C13).
• Whatever the kind of flue system chosen, observe the
minimum distances indicated in the chart below to position
the flue terminals.
• To install the flue, refer to the separate flue instruction
supplied with your appliance.
• Explain these requirements to the user of the appliance.
a
If necessary, you must install a terminal
protection kit.
b
Caution! The connection between the flue elbow
and the flue outlet must be sealed.
In GB the minimum acceptable siting dimensions for the
terminal from obstructions, other terminals and ventilation
openings are shown in diagram overleaf.
In IE the minimum distances for flue terminal positioning must
be those detailed in I.S.813 “Domestic Gas Installations”.
The terminal must be exposed to the external air, allowing free
passage of air across it at all times.
Being a condensing boiler some pluming may occur from
the flue outlet. This should be taken into consideration when
selecting the position for the terminal.
Carports or similar extensions of a roof only, or a roof and one
wall, require special consideration with respect to any openings,
doors, vents or windows under the roof. Care is required
to protect the roof if made of plastic sheeting. If the carport
comprises of a roof and two or more walls, seek advice from the
local gas supply company before installing the boiler.
0020085231_02 - 05/10 - Glow-worm
- 17 -
INSTALLATION
Position Position of the flue terminal
Horizontal flues
directly below an opening, air brick,
A
opening windows
B
above an opening, air brick, opening windows
horizontally to an opening, air brick, opening
C
windows
D
below gutter, drain/soil pipe
E
below eaves
F
below a balcony or car port
G
from vertical drain pipes and soil pipes
H
from internal/external corners
H*
to a boundary alongside the terminal
I
above adjacent ground or balcony level
J*
from surface or a boundary facing the terminal
- 18 -
mm
Position Position of the flue terminal
from opening (door/window) in car port
into dwelling
M
vertical from a terminal
N
horizontally from a terminal
Vertical flues
P
from another terminal
Q
above roof level
R
from adjacent opening window
S
from adjacent wall to flue
L
300
300
300
25
25
25
25
25
300
300
600
mm
1200
1500
300
600
300
1000
300
(*) These dimensions comply with the building regulations,
but they may need to be increased to avoid wall staining and
nuisance from pluming depending on site conditions.
0020085231_02 - 05/10 - Glow-worm
INSTALLATION
9.2
Flue configuration description
9.2.1
Horizontal concentric flue Ø 60/100 mm
or Ø 80/125 mm (C13 type installation)
a
Each time an additional 90° bend is necessary (or 2 at 45°), the
length (L) must be reduced by 1 m.
9.2.2
Vertical concentric flue Ø 60/100 mm
or Ø 80/125 mm (C33 type installation)
If necessary, you must install a terminal
protection kit.
Ø 60/100 mm
L
1
L
63
Key
1 Gasket (fitted)
Ø 80/125 mm
Type
Max length (L)
Ø 60/100
Ø 80/125
10 m
25 m
Each time an additional 90° bend is necessary (or 2 at 45°), the
length (L) must be reduced by 1 m.
L
1
Key
1 Gasket (fitted)
Type
Max length
Ø 60/100
Ø 80/125
10 m
25 m
0020085231_02 - 05/10 - Glow-worm
- 19 -
INSTALLATION
9.2.3
Multiple boiler chimney flue
Ø 60/100 mm (C43 type installation)
b
The flue connecting from the appliance to
the flue system must be supplied from the
manufacturer of the boiler.
b
C43 flue systems must not be a 'pressurised
system' but act under natural draught principles
b
C43 type flue systems must have their
own condensate drain fitted and not allow
condensate to mix into other appliances
L
Model
24cxi
30cxi
35cxi
At min thermal load (40°C/30°C)
2.4
2.9
4.1
At max thermal load (80°C/60°C)
8.3
11.3
13.8
Exhaust mass rate (g/s)
Exhaust temperature (°C)
At min thermal load (40°C/30°C)
45
37
41
At max thermal load (80°C/60°C)
65.7
63.4
71.4
4
3
A
2
1
B
5
Key
1
Pressure balancing system
2
Air-inlet pipe
3
Collector pipe
4Boiler
5
Inspection hatch
AFinal storey
B Ground floor
Type
Max length (L)
Ø 60/100
10 m
Each time an additional 90° bend is necessary (or 2 at 45°), the
length (L) must be reduced by 1 m.
- 20 -
0020085231_02 - 05/10 - Glow-worm
INSTALLATION
10 Remove the front panel
11.1
Access to main board
2
1
3
1
4
24
V
23
0
V
B
2
11.2
A
A
Key
1Front panel
2
Front panel retaining screw
• Undo the two screws (2) on the underside of the front panel
and remove the front panel (1).
11 Electrical connections
e
Key
1
24 V access cover
2
Terminal blocks for 24 V connection
3
Terminal blocks for 230 V connection
4
230 V access cover
Incorrect installation can cause electric shock or
appliance damage. The electrical connection of
the appliance must be made only by a qualified
engineer.
The appliance must be connected directly to an accessible,
fixed, switched, electrical outlet.
The external wiring must be earthed, with correct polarity and in
accordance with current standards.
1
Main board
2
3
30mm
max
Key
1
Connector
2
Electrical wires
3
Insulation
When you connect the electrical wires to a connector on the
electronic board:
• Keep a distance of a maximum of 30 mm between connector
(1) and the start of the insulation (3).
• If using single core wires are used(2) ensure that the are
wrapped together in an insulating sheath.
• Fix the cables in the cable-clamp on the eBox.
The manufacturer declines any responsibility for damages to
persons or others caused by the incorrect installation of the
appliance earthing. This includes failure to comply with current
standards.
Electrical components have been tested to meet the equivalent
requirements of the BEAB.
• Do not use cable greater than 10 mm in diameter for the
electrical connections.
All system components must be of an approved type.
• Do not interrupt the mains supply with a time switch or
programmer.
The boiler is suitable for installation in bathroom zones 2 and 3.
0020085231_02 - 05/10 - Glow-worm
- 21 -
INSTALLATION
11.3
Electrical wiring
Connection of the whole electrical system and any heating
system controls to the electrical supply must be through a
common isolator.
Isolation should preferably be by a double pole switched fused
spur box having a minimum contact separation of 3mm on each
pole. The fused spur box should be readily accessible and
preferably adjacent to the boiler. It should be identified as to its
use.
A fused three pin plug and shuttered socket outlet may be used
instead of a fused spur box provided that it is not used in a
room containing a fixed bath or shower.
11.3.1
230V permanent supply
a
All cables connected to the appliance should be
permanently fixed to the wall.
i
This appliance will not operate without a link or
system controls fitted.
2
1
1
3
4
24
24
V
V
Key
1
Power supply cable
• Connect the appliance's power cable to the 230 V singlephase network + earth.
Key
1
230V permanent supply
2
Main board terminal block
= Mains earth
N = Mains neutral
L = Mains live
3Fuse
4
Double pole connector
• Connect mains supply as described.
• Connect the appliance in accordance with the live and
neutral connections.
- 22 -
0020085231_02 - 05/10 - Glow-worm
INSTALLATION
11.3.2
11.4
230V permanent supply + 230V system
controls
a
All cables connected to the appliance should be
permanently fixed to the wall.
i
This appliance will not operate without a link or
system controls fitted.
e
External accessories
Under no circumstances must any mains voltage
be applied to any of the terminals on the 24v
connection plug.
2
3
4
1
3
X17
24 V
BUS
RT 24V
BUS
T° ext
2
X18
1
4
24
V
5
23
0
V
6
7
Key
1
24V room thermostat connector
2
Ebus room thermostat connector or Ebus radio receiver
3
Outdoor sensor connector
4
Overheating safety connector for heating floor
Key
1
230V permanent supply
2
System controls
3Frost stat
4
Main board terminal block
FP = Frost stat 230V (switchable)
RT = Switch live (230V)
= Mains earth
N = Mains neutral
L = Mains live
5
Junction box
6Fuse
7
Double pole connector
• Fit external controls in accordance with the rules in force.
11.5
Testing the electrical connections
Carry out preliminary electrical system checks as below:
• Resistance to earth (<1 Ohm)
• Short circuit test (L-N)
• Resistance to earth (L-E)
• Polarity check
• Connect the mains supply and system heating controls e.g.
room thermostat as described.
0020085231_02 - 05/10 - Glow-worm
- 23 -
INSTALLATION
11.6
Wiring diagram
6
X31
5
X51
X40
4
X32
3
7
X90
X30
8
X2
X14
20 19 18 17 16 15 14 13 12 11
10 9 8 7 6 5 4 3 2 1
3 4
X20
X21
X18
X101
X1
X17
1
T°C
NTC
M
24 V Ebus
X2
10
N L
230 VAC
X20
20 19 18 17 16 15 14 13 12 11
10 9 8 7 6 5 4 3 2 1
Green/Yellow
10 11 12 13 14 15 16 17 18
9
Green/Yellow
1 2
Green/Yellow
Blue
Brown
X16
1 2 3 4 5 6 7 8 9
Green/Yellow
X17
2
FUS
X21
1 2 3 4 5 6 7 8 9
1 2
10 11 12 13 14 15 16 17 18
3 4
1 2 3
4 3 2 1
4 5 6
1 2 3
1 2
D
19
18
17
Key
1
Overheating safety connector for heating floor
2
Control accessories connector
3
Reserved for future use
4
Location for 24V option card
5
Location for external programmer
6
User interface
7Fuse 2A
8
Connector for 230 V option
9
Main supply 230V
10 Pump
- 24 -
5 4 3 2 1
9 8 ... 2 1
1
1
T
M
16
1
15
14
1
1
1 2
1
T
13
12
11
11 Combined spark and flame recognition electrode
12 Heating outlet temperature sensor
13 Heating return temperature sensor
14 Gas valve
15Fan
16 Thermal fuse
17 Water flow sensor
18 Three way valve
19 Water pressure sensor
0020085231_02 - 05/10 - Glow-worm
INSTALLATION
12 Commissioning
i
Key
1
Air vent
2
Pump
3
Screw for the pump shaft
At the time of commissioning, complete all relevant
sections of the Benchmark Checklist located in the
centre pages of this document.
The commissioning should be carried out by a competent
person approved at the time by the Health and Safety Executive
and in accordance with the current issue of BS6798.
12.1
Switching on
• Open the plug on the air vent located on the pump and the
automatic air vents on the installation.
If the Central Heating (C.H.) pressure falls below 0.4 bar, the
display will flash the current pressure and the boiler will not
operate. To increase the pressure, the CH circuit requires
"Topping up".
• Push the disconnector up then turn the green locking collar
to lock the disconnector in the filling position.
• Do not operate the boiler without water.
• Make sure that the system has been thoroughly flushed out with
cold water and that all cleanser if used has been removed.
• With the gas service isolation valve closed, with no demand
from any external controls and the power supply to the boiler
switched off.
• Test for gas soundness and purge air from the gas supply.
• Fully open the Lhd filling tap then gradually open the Rhd tap.
• When the operating pressure is achevied, close both taps,
unlock the disconnector and pull down to disengage.
i
• Press the on/off button to activate the appliance.
• Make sure that the domestic hot water and heating functions
on your appliance are not activated.
i
12.2
Before turning on the cold mains supply to the boiler
turn off the cold water inlet to the boiler, lock the
filling loop in the closed position and close its filling
taps. The DHW and CH circuits can then be filled,
flushed and tested independantly.
• Vent air from each radiator until the water flows normally,
then close the vents.
• Leave the pump's air vent open.
i
Filling the CH system (Central heating)
• Make sure that the installation's cold-water inlet isolating
valve is open.
When turning the 230Vac supply on to the boiler
should the water pressure be less than 0.5 bar an
automatic air vent function will be activated for a
period of 5 minutes. During this time the pressure
should be increased and air vented from the system.
Note that the burner will not fire in either CH or DHW
mode and the display will blink displaying the current
water pressure.
The following two operations will unblock the pump's
engine after a prolonged storage period and will
purge the air from the pumps circuit.
• Remove the screw from the pump shaft and introduce a flat
screwdriver. A trickle of water, under no pressure, should
normally come out of the pump.
• Open the isolating valves located on the connections: they
must be positioned in the direction of the flow.
• Rotate the pump shaft through several turns, then replace
the screw.
12.3
Filling DHW Circuit
• Open the various hot water taps to fill the DHW circuit.
1
2
3
0020085231_02 - 05/10 - Glow-worm
- 25 -
INSTALLATION
12.4
Filling the Condensate Trap
• Check the integrity of the appliance combustion circuit and
relevant seals.
• Check that all internal/external controls are calling for heat.
• Check that the gas service isolation is open.
• To adapt the appliance to another type of gas, see chapter
"LPG conversion".
12.5.2
Adjusting the temperature
3
B
C
A
2
4
2
1
1
1
Key
1Filling trap
2
Condensate trap
6
5
Key
1
Domestic hot water temperature control buttons
2
Display
3
Reset button
4
On/Off button
5
Central heating temperature control button
6
Mode selection button
• Fill the trap 3/4 full with water (1).
• Light the appliance by following the procedure below.
• Activate the Heating and Domestic Hot Water functions.
• Select the "Heating + domestic hot water" function by
pressing the “Mode” button repeatedly to scroll through your
are shown.
options until
• Run the appliance for at least 15 minutes, with a heating
temperature set to greater than or equal to 50°C (not
applicable for an installation with underfloor heating).
• Vent air from each radiator again until the water flows
normally, then close the vents.
• If you have difficulties in removing the air, launch the airremoval programs in the heating circuit (see the chapter
("Technical settings for the appliance and list of parameters").
• Make sure that the pressure indicator shows a value of 0.8
bars; otherwise, fill the appliance again.
12.5
12.5.1
i
Initial lighting
Control
The combustion for this appliance has been
checked, adjusted and preset at the factory for
operation on natural gas (G20) as defined on the
appliance data label.
No measurement of the combustion is necessary.
Should the appliance require to be converted to LPG
gas ensure you follow the gas conversion section
before lighting the boiler.
• Check that the appliance has been installed in accordance
with the instructions.
• Check the integrity of the flue system and flue seals.
- 26 -
The appliance will enter a self checking routine, then the fan
will start and the ignition sequence commence. The boiler, if
necessary, will automatically repeat the ignition sequence a
further 4 times.
If the burner fails to ignite “F28” will be displayed, initially, this
may be due to air in the gas supply line. Press the reset button.
Do not use the reset button to purge the installation - never
press reset more than 3 times.
central heating water temperature button and
• Press the
the factory setting temperature will be displayed.
• Press
or
buttons to adjust.
button and the factory
• Press the hot water temperature
setting temperature will be displayed.
• Press
or
buttons to adjust.
• Open a hot water tap, the display will indicate the domestic
hot water temperature.
• Check that hot water is available at all taps, then close.
12.6
Gas rates
The supply from the governed meter must be of adequate size
to provide a steady inlet working pressure of 20mbar (8in wg) at
the boiler.
0020085231_02 - 05/10 - Glow-worm
INSTALLATION
• On completion, test the gas installation for tightness using
the pressure drop method and suitable leak detection fluid,
purge in accordance with the above standard.
i
Due to the modulating operation of the boiler and the
need to check the gas inlet pressure and measure
the gas rate at maximum rate, it will be necessary to
force it to maximum.
• Activate the test mode "P.01" and set the value to 100 in
order to force the burner at P. max. See chapter "Specific
adjustment ► Appliance technical settings and parameter list
► Test modes".
12.6.1
Operational Gas Inlet Pressure
In communal or LPG installations where the gas rate cannot be
measured it is acceptable to measure the combustion rate as
described in the servicing section.
• On completion, press the "reset" button to reset the boiler.
12.7
Testing heating system
• Ensure that the external controls and programmer are calling
for heat.
• Fully open all radiator valves, see chapter "Appliance
installation ► Recommendations before installing ► Heating
circuit design".
• Activate the C.H. function on the appliance's control panel.
• Balance the radiators as required to give the required system
differential.
• Turn off all radiators that can be shut off by the user and
check to see if less than the maximum differential allowed of
20°C can be achieved across flow and return.
2
i
1
• Allow the system to reach maximum temperature then switch
off the boiler by isolating from the electrical supply.
Key
1
Gas service isolation valve
2
Test point
• With all other gas appliances operating, check the
operational supply pressure at the gas service isolation valve
test point.
The nominal supply pressure for Natural Gas (G20) is 20mbar.
The nominal supply pressure for LPG (G31) is 37mbar.
Additionally the safe nominal maximum heat input of the
appliance can be achieved at an inlet pressure down to 15mbar.
12.6.2
The burner pressure cannot be measured and is not
used to measure the gas rate.
Gas Rate
• Make sure that all other gas burning appliances and pilot
lights are off.
• Check the gas rate using the gas meter test dial and stop
watch, at least 10 minutes after the burner has lit, see table
below for approximate rates.
Gas rates (G20)
• Drain the entire system rapidly whilst hot, using the drain
taps at all the low points of the system. Fill and vent the
system as described previously in chapter "Commissioning
► Filling the CH system (Central heating)".
• Adjust the boiler temperature controls and any system
controls to their required settings.
12.8
• Turn the taps and appliances off, then disconnect the
pressure gauge.
i
Should the appliance require adjustment refer to the
"Specific adjustment" section overleaf.
Gas rates (G31)
Testing domestic hot water system
• Open a hot-water tap.
• Check that the temperature obtained is compliant with the
setting on the appliance.
12.9
Completion
• Ensure that the magnetic lighting instruction label is placed
on the surface of the boiler casing.
GB: It is a requirement that the “Benchmark” Installation,
Commissioning and Service Record is completed and left with
the user.
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.
(approx) after 10 mins from cold
Model
MIN
MAX
MIN
MAX
ft3 /h
kg/h
kg/h
2.70
95.35
0.40
1.98
3.24
114.42
0.47
2.38
3.77
133.14
0.68
2.77
m3 /h
ft3 /h
m3 /h
24cxi
0.54
19.07
30cxi
0.65
22.95
35cxi
0.95
33.55
0020085231_02 - 05/10 - Glow-worm
- 27 -
INSTALLATION
13 Specific adjustment
13.1
Output/pressure curve Ultracom2 30cxi
1
Heating circuit adjustment
It may be necessary to adjust the by-pass to the design of the
system. The boiler is delivered pre-set open 1/2 turn (1).
2
3
4
60
50
40
30
20
10
0
500
1000
1500
B
Key
A Available pressure between heating flow and return (kPa)
B Heating circuit flow rate (l/h)
1
Speed min, bypass closed
2
Speed max, bypass closed
3
Speed max, bypass middle position
4
Speed max, bypass opened
1
Output/pressure curve Ultracom2 35cxi
1
2
3
4
60
50
40
30
20
Key
1
Screw for by-pass
10
• Depending on the design of the system the by-pass may
need further adjustment. It is adjusted clockwise to close and
anti-clockwise to open. This should be balanced to ensure
that it operates if the pump output is adjusted.
Output/pressure curve Ultracom2 24cxi
1
2
3
4
0
50
40
1500
B
Appliance technical settings and
parameter list
The access to the boilers technical data allows you to adjust the
boiler to the exact system requirements.
30
20
10
0
1000
Key
A Available pressure between heating flow and return (kPa)
B Heating circuit flow rate (l/h)
1
Speed min, bypass closed
2
Speed max, bypass closed
3
Speed max, bypass middle position
4
Speed max, bypass opened
13.2
60
500
500
1000
1500
Key
A Available pressure between heating flow and return (kPa)
B Heating circuit flow rate (l/h)
1
Speed min, bypass closed
2
Speed max, bypass closed
3
Speed max, bypass middle position
4
Speed max, bypass opened
B
Note: the heating power decrease has no effect on the domestic
hot water power.
13.2.1
Installation settings
• Press for more than 7 seconds on the button
to
access the configuration menu. The screen displays "0".
• Press 4 times on the button
under the symbol
.
The screen displays "96". This is the installer's password.
to validate. The screen displays the
• Press on
parameter "00" and its value "XX”.
• Press on button
or
parameter to modify.
under the symbol
or
under the symbol
• Press on button
value of the parameter.
- 28 -
to access the
to modify the
0020085231_02 - 05/10 - Glow-worm
INSTALLATION
• Do likewise for each parameter that needs to be modified.
• Press for more than 3 seconds on the button
the configuration menu.
Code
Parameter
to exit
Factory
setting
Unit
Description
18
25
30
Modifiable
parameter
d.00
Maximum heating power
kW
Choose a value:
24cxi ► 5 to 18 kW
30cxi ► 6 to 25 kW
35cxi ► 8 to 30 kW
d.01
Pump over-run time - heating
min.
Choose a value between 2 and 60.
5
yes
min.
To prevent the burner frequently switching on and off,
the reactivation of the burner is electronically blocked for a period
that is determined each time the burner stops. The burner blocking
time can be adapted to the usage conditions for the heating
installation and depends on the temperature that is set for heating:
- at 80°C, the period is fixed (2 minutes)
- at 10°C, the period is adjustable: choose a value between 2 and
60 minutes.
20
yes
Display the temperature of the DHW outlet.
-
no
d.02
Blocking time for burner in heating
mode (anti-cycle time)
d.03
Temperature of the DHW outlet
°C
d.04
Temperature of water in the tank
°C
yes
The following menu is displayed if a domestic hot water tank is connected to the appliance.
d.18
Pump function
d.19
Speed of the pump
d.20
Maximum temperature setting for
domestic hot water
Display tank water temperature.
-
no
-
Mode:
0 = With the burner
1 = Continuous with ambient temperature
2 = Continuous
1
yes
-
Functioning mode:
0 = Automatic: maximum speed when the burner is switched on
1 = Minimum speed
2 = Automatic: automatic speed when the burner is switched on
3 = Maximum speed
2
yes
The recommended maximum temperature setting for domestic hot
water is 60°C. Choose a value suitable for your needs.
60
yes
°C
The following 2 menus are displayed if an option card (not supplied) is installed on the appliance.
d.27
Function relay 1
-
Reserved for future use
1
yes
d.28
Function relay 2
-
Reserved for future use
2
yes
d.34
Speed of fan
Fan speed is displayed between 0 and 99.
Multiply the displayed value by 100.
-
no
rpm
d.36
Domestic hot water flow
l/min.
Display domestic hot water flow.
-
no
d.40
Heating flow temperature
°C
Display the heating flow temperature.
-
no
d.41
Heating return temperature
°C
Display the heating return temperature.
-
no
1.2
yes
The following 2 menus are displayed if an outdoor sensor (not supplied) is installed on the appliance.
d.43
Heating curve
K
See the instructions for the external sensor connected to the
appliance.
d.47
Exterior temperature
°C
Display the temperature measured by the external sensor.
-
no
d.67
Time remaining before the end of the
anti-cycle in heating mode.
min.
Display the time remaining before the end of the anti-cycle.
-
no
d.71
Maximum temperature setting for
heating outlet
75
yes
d.90
Detection of eBUS controller
-
no
0020085231_02 - 05/10 - Glow-worm
°C
-
Select a value between 50°C and 80°C.
0 = Not detected
1 = Detected
- 29 -
INSTALLATION
13.2.2
After Sales Service settings
• Press for more than 7 seconds on the button
to
access the configuration menu. The screen displays "0".
• Press on button
or
under the symbol
After Sales Service password.
and enter the
to validate. The screen displays the
• Press on
parameter "00" and its value "XX”.
• Press on button
or
parameter to modify.
under the symbol
or
under the symbol
• Press on button
value of the parameter.
to access the
to modify the
• Repeat the process for each parameter modified.
• Press for more than 3 seconds on the button
the configuration menu.
to exit
Factory
setting
Modifiable
parameter
230V room thermostat :
0 = open (no heating),
1 = closed (heating mode).
-
no
External eBus set value.
-
no
0 = off
1 = on
-
no
°C
0 = open (no heating),
1 = closed (heating mode)
-
no
°C
Temperature regulation on flow (radiator) or return
(under-floor heating) temperature sensor.
0
yes
-
0 = warmstart function disabled
1 = warmstart activated
-
no
DHW demand active (tapping)
-
0 = off
1 = on
-
no
d.23
Central heating mode
-
0 = CH not available (summer mode)
1 = CH available (winter mode)
-
no
d.25
Warm start
-
Loading enabled or disabled by Appliance Interface
or Ebus or external controls.
-
no
d.33
Speed setpoint of fan
Fan speed is displayed between 0 and 99.
Multiply the displayed value by 100.
-
no
d.44
Digitalized ionisation voltage
V
Display the digitalized ionisation voltage
-
no
-
no
Code
Parameter
d.08
Current state of the 230V room thermostat
d.09
Flow temperature set point from external eBus control
d.10
Heating pump status
d.16
Current state of the 24V room thermostat
d.17
Flow or Return temperature monitoring
d.21
Warmstart status
d.22
Unit
°C
-
rpm
Description
d.68
Unsuccessfull ignitions at first attempt
-
Display the number of unsuccessfull ignitions at first
attempt.
d.69
Unsuccessfull ignitions at second attempt
-
Display the number of unsuccessfull ignitions at
second attempt.
-
no
d.80
Operating hours in heating mode
h
Display the number of operating hours in heating
mode. Multiply the displayed value by 100.
-
no
d.81
Operating hours in domestic hot water mode
h
Display the number of operating hours in domestic
hot water mode. Multiply the displayed value by 100.
-
no
d.82
Number of burner starts in heating mode
-
Display the number of burner starts in heating
mode. Multiply the displayed value by 100.
-
no
d.83
Number of burner starts in DHW mode
-
Display the number of burner starts in DHW mode.
Multiply the displayed value by 100.
-
no
-
Select the product code of the appliance:
24cxi = 15
30cxi = 22
35cxi = 17
-
All parameters stored in EEPROM (main board +
appliance interface) are reset to factory settings if
this function is activated.
0 = deactivated
1 = activated
d.93
d.96
- 30 -
Device Specific Number
Factory reset
15
22
17
0
yes
yes
0020085231_02 - 05/10 - Glow-worm
INSTALLATION
13.2.3
Status of the appliance
• Press button
under the symbol
for more than 3
seconds to learn the current state of functioning of the
appliance.
The screen displays the state of the appliance "S.XX".
• Press button
menu.
Status
S.00
S.01
S.02
S.03
S.04
S.05
S.06
S.07
S.08
Status
S.10
S.11
S.13
S.14
S.15
S.16
S.17
Status
S.20
S.21
S.23
S.24
S.25
S.26
S.27
S.28
Status
S.30
S.31
S.32
S.34
S.39
S.40
S.41
S.53
S.54
S.96
S.98
for more than 3 seconds to exit this
Heating Mode
No request for heating
Pre-run fan
Pre-run pump
Ignition
Burner lit
Post run pump/fan
Post run fan
Post run pump
Time delay anti short-cycles after heating
Domestic hot water mode
Request for domestic hot water
Pre-run fan
Ignition
Burner lit
Post run pump/fan
Post run fan
Post run pump
Domestic hot water heating
Pre-run pump
Pre-run fan
Ignition
Burner lit
Post run pump/fan
Post run fan
Post run pump
The boiler blocks tank reheating after a reheating cycle.
Specific messages
Default status, no request for heating or domestic water. If
an EBUS controller is connected to the boiler, check that
a wiring link is present on terminals 3 and 4 of the boiler's
main board.
"Hot water only" mode
Control cycle: the speed of the fan in the functioning phase
is outside tolerance.
"Frost protection" mode
Underfloor heating contact open.
Heating mode activated
Water pressure too high
Waiting cycle: temperature differential between heating flow
and return is too high. If ∆T > 30, forcing to Pmin.
Waiting cycle: lack of water in the installation/temperature
rise between heating flow and return is too high.
Test temperature sensor for heating return.
Test temperature sensors for heating flow and return, or the
appliance has a fault.
0020085231_02 - 05/10 - Glow-worm
13.2.4
Test modes
By activating these various test modes, you can enable special
functions on the appliance.
• Press the on/off button to switch off the appliance.
pressed for more than 5
• While keeping the button
seconds, press the on/off button.
The screen displays the first test mode "P01" and "Off".
• Press button
or
under the symbol
mode that you wish to launch.
to choose the test
• Test mode "P.01" :
to display the burner forcing setting. The
-- Press button
screen displays "P.01" and "0".
or
under the symbol
to modify the
-- Press on button
value of the setting from "0" (0%) to "100" (100%).
for 1 second to exit the submenu or
-- Press on button
for more than 7 seconds to access the configuration menu.
• Test mode "P.02" to "P.07" :
to launch the test mode. The screen displays
-- Press
"P.0X" and "On".
-- The test mode will be automatically stop after 15 minutes.
• When you have finished, press the reset button
On/Off button to exit the test modes.
or the
Code
Parameter
Description
P.01
Forcing the
adjustablepower burner
when heating
The appliance functions at a power
adjustable from "0" (0% = Pmin.) to "100"
(100% = Pmax.) by using buttons
or
under the symbol
after successful
ignition.
P.02
Forcing the
burner to
heating ignition
power
The appliance functions at ignition power
after successful ignition.
P.03
Forcing the
burner to
Heating Pmax.
The appliance functions at its maximum
power after successful ignition.
P.05
Filling the
appliance
The 3 way valve is in the central position,
the pump and the burner stop so that the
appliance can be filled.
P.06
Venting the
installation
The function is activated for a period of 5
minutes on the heating circuit.
Make sure that the air vent is open.
P.07
Venting the
appliance
The function is activated for a period of 5
minutes on the short circuit.
Make sure that the air vent is open.
- 31 -
INSTALLATION
13.3
CO2 measurement
The combustion for this appliance has been pre-set at the
factory for operation on Natural Gas G20 as defined on the
appliance data label.
No adjustment of the combustion is necessary.
If you wish to check the combustion then follow the instructions
in the Servicing section.
14 User information
At the end of the installation, the installer must:
-- explain the operation of the appliance and its safety devices
to the user, if necessary provide a demonstration and answer
any questions;
-- hand over to the user all the required documentation,
-- fill in the documents where necessary;
13.4
Re-check and restart
• Once the appliance is installed, check the operation of the
appliance.
• Start the appliance to ensure that any adjustments operate
correctly and check that the appliance operates safely.
• Check the gas-tightness and water-tightness of the appliance
and eliminate any leaks.
• Check that the flue joints are tested for tightness and fitted in
accordance with the instructions.
• Check the entire control and safety system, its settings and
its operation.
-- advise the user of the precautions necessary to prevent
damage to the system, appliance and the building;
-- remind the user to service the appliance annually.
• Draw attention, if applicable, to the current issue of the
Gas Safety (Installation and Use) Regulations, Section 35,
which imposes a duty of care on all persons who let out any
property containing a gas appliance in the UK.
The user shall not interfere with or adjust sealed components.
It is the Law that any servicing is carried out by a competent
person approved at the time by the Health and Safety
Executive.
• Advise the user that, like all condensing boilers this
appliance will produce a plume of condensation from the flue
terminal in cool weather. This is due to the high efficiency
and low flue gas temperature of the boiler.
• Advise the user that the permanent mains electrical supply
should not be switched off, as the built in frost protection and
pump exercise program will not operate.
• Advise the User if the mains electricity and gas are to be
turned off for any long periods during severe weather, it is
recommended that the whole system, including the boiler,
should be drained to avoid the risk of freezing.
i
Sealed system: The system must be refilled and
to the correct pressure as indicated in these
instructions
• Leave these instructions and the ‘Benchmark’ Installation,
Commissioning and Service Record with the user.
- 32 -
0020085231_02 - 05/10 - Glow-worm
MAINTENANCE
MAINTENANCE
15.1.1
To ensure the continued efficient and safe operation of the
boiler it is recommended that it is checked and serviced at
regular intervals. The frequency of servicing will depend upon
the particular installation and usage, but in general once a year
should be enough.
It is the Law that any servicing is carried out by a competent
person approved at the time by the Health and Safety
Executive.
Check the electrical installation
3
2
1
V
• Before commencing with a service or replacement of parts
isolate the boiler from the electrical supply and turn off the
gas supply at the gas isolation valve.
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.
• 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 chapter
"Trouble-shooting ► Fault diagnosis ► Check the electrical
installation".
• After servicing, complete the relevant Service Interval
Record section of the Benchmark Checklist located in the
centre pages of this document.
15 Trouble-shooting
15.1
Fault diagnosis
The following checks should be performed before proceeding
onto specific diagnostics:
• Make sure that the electricity supply has not been interrupted
and that the appliance is connected correctly (See chapter
"Trouble-shooting ► Fault diagnosis ► Check the electrical
installation")
• Check the appliance’s gas supply (See chapter "Troubleshooting ► Fault diagnosis ► Check the gas supply").
24
V
Key
1
Main board
2
Neutral
3
Live
4
Multimeter
• Remove the front casing panel
• 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
main board.
• Check the electrical installation and appliance, carry out tests
for earth continuity, polarity, short circuit and resistance to
earth, using a suitable multimeter.
• Bare metal points such as screws or rivets will act as suitable
earth check points on the appliance.
15.1.2
Check the gas supply
• Ensure that the isolating valves are open.
• Ensure that the pressure indicator displays a value of 0.8 bar
(if the pressure falls below 0.4 bar, the air vent function will
run automatically for a period of 5 minutes until you see 0.5
bar on the pressure indicator). If not, fill the appliance.
2
• Check that all external controls are connected correctly.
and the message "rE SEt" are displayed
• If the symbol
on the screen, display the fault code memory (see chapter "
Trouble-shooting ►Fault memory").
• Press the reset button
to restart the appliance.
• Check the functional flow diagram.
1
Key
1
Gas service isolation valve
2
Test point
• Check that there is a gas supply to the boiler and the gas
service isolation valve is turned on.
• Check pressure at the gas service isolation valve.
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MAINTENANCE
15.2
Fault memory
• This menu allows you to display the 10 most recent failure
codes registered by the appliance.
• In order to display the fault code memory, simultaneously
and
under the symbol
for more
press the buttons
than 7 seconds.
• The screen will display the first fault "01" (record) and "F.XX"
(fault code).
• To display the other faults registered by the appliance, press
the button
or
under the symbol
.
for more than 3 seconds to exit this
• Press button
menu.
Record
Fault code
01
XX
Description
Consult the “Fault codes” chapter.
02
XX
Consult the “Fault codes” chapter.
03
XX
Consult the “Fault codes” chapter.
04
XX
Consult the “Fault codes” chapter.
05
XX
Consult the “Fault codes” chapter.
06
XX
Consult the “Fault codes” chapter.
07
XX
Consult the “Fault codes” chapter.
08
XX
Consult the “Fault codes” chapter.
09
XX
Consult the “Fault codes” chapter.
10
XX
Consult the “Fault codes” chapter.
• To erase the fault memory registered by the appliance,
consult the “Installation adjustments” chapter and use code
“d.94”.
15.3
i
Fault codes
The faults described in this chapter should be
carried out by a qualified engineer and if needed by
the After Sales Service.
Fault
Description
codes
Cause
Solution
F00
Flow heating temperature sensor fault
Sensor open circuit
F01
Return heating temperature sensor fault
Return heating temperature sensor
disconnected
F10
Flow heating temperature sensor fault
Sensor short-circuit
F11
Return heating temperature sensor fault
Return heating temperature sensor
shorted.
Overheating fault
Overheating safety device activated
(97°C)
• Check the operation of the pump.
• Check the wiring harness.
• Check that the flow and return heating isolation
valves are open.
F22
Water pressure of the installation (<0.3 bar)
Return water valve closed
Pump disconnected
Leak in the installation
• Fill the installation.
• Purge the installation.
• Check the pump connections.
• Check the flow and return heating sensor
connections.
• Check that there are no leaks.
F23
Maximum temperature difference reached
between return and flow heating
Water circulation fault
• Check the flow and return heating sensor
connection.
• Check the pump speed.
F24
Water circulation fault
Malfunction of the pump (excessively
rapid temperature increase)
• Check that the flow and return heating isolation
valves are open.
F20
- 34 -
• Check the sensor’s connections.
• Check the wiring harness.
• Check the sensor.
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MAINTENANCE
Fault
Description
codes
Cause
Solution
F26
Fault in gas valve motor.
Disconnected or defective cables
• Check the gas valve connections.
• Check the operation of the gas valve.
• Check the operation of the condensate pump (option).
F27
Flame detection fault.
Abnormal flame detection
• Check the flame detection electrode.
• Check the main board.
• Check the igniter unit.
F28
Ignition fault
F29
Loss of flame during operation
No return gas / Insufficient gas flow
Gas valve incorrectly adjusted
Defective firing electrode and flame
control / Defective igniter unit
• Check the return gas circuit (gas valve open).
• Check the observe the flame picture and check
the CO2 setting.
• Check the igniter unit connections.
• Check the state of the electrode (corrosion).
F32
Incorrect air pressure
Incorrect fan speed.
• Check the entire flue system.
• Check the fan’s electrical connections.
F49
EBUS voltage fault
Fault in EBUS line
Short circuit in EBUS connector
• Check that the eBus controls are fitted and wired
correctly.
F61
Gas valve command fault
F62
Gas valve closure fault
F63
Fault in the main board memory
F64
Fault in the main board
Rapid fluctuation of return or flow
heating sensor.
• Check the main boards connections.
• Check the main board.
• Check the appliance DSN number is correct.
• Reset the appliance.
F65
Excessive main board temperature
F67
Flame signal fault in the main board
F68
No return gas / Insufficient gas flow
Gas valve incorrectly adjusted
Defective firing electrode and flame
control / Defective igniter unit
• Check the return gas circuit (gas valve open).
• Check the observe the flame picture and check
the CO2 setting.
• Check the igniter unit connections.
• Check the state of the electrode (corrosion).
Fluctuation of flame signal
F70
User interface incompatible with the main
board
Incorrect product code
• Check that the appliance DSN code on the screen
matches the product code of the nameplate (in the
event of a fault and the appliance DSN does not
appear, consult menu.d.93 reserved for the code).
• Check the boards reference.
F71
Flow heating temperature sensor fault
Flow heating temperature sensor
unclipped or defective (no
temperature variation)
• Check the sensor connections.
• Make sure that the sensor is clipped to the tube.
F72
Permanent temperature difference between
flow and return heating sensors
Mismatch between the flow and return
heating temperatures (permanent
difference)
• Check temperature sensors connections.
• Replace faulty sensors.
F73
Heating circuit pressure sensor fault
The sensor is shorted or disconnected.
F74
Heating circuit pressure sensor fault
Fault in pressure sensor
• Check the sensor’s connections.
• Check the sensor.
F76
Thermal fuse fault
Thermal fuse disconnected
Defective thermal fuse
• Check the fuses connections.
• Replace the heat exchanger.
F77
Fault in gas valve motor.
Defective gas valve.
Defective condensate pump (option)
• Check the gas valve connections.
• Check the operation of the gas valve.
• Check the operation of the condensate pump (option).
F83
No water in the installation : the temperature
does not increase when the burner is lit
Return water valve closed
Pump disconnected
Leak in the installation
• Fill the installation.
• Purge the installation.
• Check the pump connections.
• Check the flow and return heating sensor
connections.
• Check that there are no leaks.
F84
Permanent temperature difference between
flow and return heating sensors
Inverted or disconnected flow and
return heating temperature sensors
Defective temperature sensors
• Check temperature sensors connections.
• Replace faulty sensors.
F85
Flow and return heating sensors fault
Flow and return heating temperature
sensor connected to same tube
• Check temperature sensors connections.
F86
Underfloor heating contact fault
Floor heating contact open
Sensor disconnected or defective
• Check the sensor connections.
• Check that the sensor is connected to the main
board and the shunt is removed.
Err
User interface fault
Defective user interface
• Check connection from user interface PCB to main
PCB.
• Replace user interface.
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MAINTENANCE
15.4
Functional flow diagram
15.4.1
Central Heating
15.4.2
Domestic Hot Water
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MAINTENANCE
16 Gas conversion adjustments
2
3
In order to operate with a gas other than that provided from the
factory, it is necessary to some adjustments to the gas valve.
This conversion should only be carried out by a competent
person approved at the time by the Health and Safety
Executive.
• During the conversion to Propane, use of a suitable flue gas
analyser is necessary.
The person carrying out a combustion measurement should
have been assessed as competent in the use of a flue gas
analyser and the interpretation of the results.
1
The flue gas analyser used should be one meeting the
requirements of BS7927 or BS-EN50379-3 and be calibrated in
accordance with the analyser manufacturers’ requirements.
24
Competence can be demonstrated by satisfactory completion of
the CPA1 ACS assessment, which covers the use of electronic
portable combustion gas analysers in accordance with BS
7967, parts 1 to 4.
16.1
i
2B
Settings
Steps "Switching on" to "Re-pressurising System"
will need to be completed before the appliance can
be converted (See chapter "Commissioning").
Tools required to make the conversion are a 2mm Allen key and
an electricians screwdriver.
Having checked :
-- the appliance and system have been installed in accordance with the instructions.
-- the integrity of the flue system and flue seals....
-- the integrity of the appliance combustion circuit and relevant
seals....
-- that all internal/external controls are calling for heat.
-- the gas service isolation valve is opened.
2A
Key
1
Throttle
2
Combustion analyser sample
2A Flue elbow
2B Vertical flue adaptor
3
Cap
point
• Remove the front panel first.
• Remove the cap (3) and connect a CO2 analyser to effect
the measurement (2).
16.1.1
Adjusting the gas valve
• Press the on/off button to turn the appliance off.
• Turn the screw in the direction and the number of times
indicated in the following table.
Gas adjustment
Model
G20 ► G31
24cxi
2 turns
30cxi
3 turns
35cxi
24cxi
16.1.2
G31 ► G20
2.5 turns
2 turns
30cxi
3 turns
35cxi
2.5 turns
Adjusting the maximum power setting
• Activate the test mode "P.01" and set the value to 100 in
order to force the burner at P. max. See chapter "Specific
adjustment ► Appliance technical settings and parameter list
► Test modes".
• Wait approximately 5 minutes to read a stabilized CO2 value.
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MAINTENANCE
• Compare the value measured with the values indicated in the
table below.
Gas adjustment
17.1
G20
G31
CO2 case ON
9 ± 0.2 %
10.1 ± 0.2 %
CO2 case OFF
9.2 ± 0.3 %
10.3 ± 0.3 %
i
16.1.3
17 Draining
Heating circuit
Safe combustion can only be verified by measuring
CO/CO2 ratio. This must not exceed the value
shown in the table under the section "Maximum Rate
and Adjustment".
Restarting
• Replace the cap
• Replace the appliance front panel.
2
Note: following the replacement of the front panel, the CO2
value will change: you can check that the value "case on" is
correct by the values in the previous table.
B
A
1
Key
1
Length of hose (not supplied)
2
Drain valve
1
2
Key
1
Serial number stickers
2
Data label location
• Firmly attach the gas replacement label to the appliance in
the corresponding location (1) on the electrical box.
16.2
Restart - re-check commissioning
• Before putting the appliance into operation, follow the
instructions within the chapter Specific adjustment.
- 38 -
• Drain down the heating circuit of the boiler only, by closing
the heating flow and return isolating valves. See chapter
"Hydraulic connection ► Gas and water connections"
• Attach a length of hose (1) to the drain point and open the
drain valve (2).
• After draining, close the drain valve (2) and remove the hose.
17.2
Domestic Hot water circuit
• Drain the Domestic Hot Water circuit by closing the coldwater isolation valve on the wall mounting jig.
• Open one or more hot water taps to drain the hot water
circuit.
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MAINTENANCE
18 Servicing
• To ensure the continued efficient and safe operation of the
boiler it is recommended that it is checked and serviced as
necessary at regular intervals.
The frequency of servicing will depend upon the particular
installation conditions and usage.
If this appliance is installed in a rented property there is a duty
of care imposed on the owner of the property by the current
issue of the Gas Safety (Installation and Use) Regulations,
Section 35.
• Servicing/maintenance should be carried out by a
competent person approved at the time by the Health and
Safety Executive in accordance with the rules in force in the
countries of destination.
• Check that the pressure sensor is working properly. The
pressure must be displayed on the screen.
• Check the pressure of the expansion vessel.
18.1.2
Other checks
• Check the CO2 rate in the fuel and compare with the values
indicated in the chapter "CO2 Measurement".
• Check that there are no leaks in the joints and the safety
valves.
• Check that there are no gas leaks.
• Verify that the flue system is sound and complete.
• Check the appliance’s electrical safety.
• To obtain service, please call your installer or Glow-worm’s
own service organisation.
18.1.3
PLEASE NOTE: During routine servicing, and after any
maintenance, we recommend that the following must be
checked:
-- The heating filter
-- The integrity of the flue system and the flue seals,
-- The integrity of the boiler combustion circuit and the relevant
seals,
-- The operational (working) gas inlet pressure at maximum
rate,
-- The gas rate,
Cleaning of the components
• Clean the following components:
-- The condensate trap
-- The heat exchanger.
-- The burner
-- The fan
18.1.4
Corrosion and anti-sludge protection
• See the "Safety instructions" chapter for a list of operations
to be performed prior to the maintenance of the application.
In order to avoid corrosion, the addition of a corrosion inhibiter
to the heating circuit water is recommended. The inhibiter will
stop electrolytic reaction and bacterial growth between the
different metals used in the installation.
• Once the maintenance operations have been completed,
consult the ¨Start Up¨ chapter to restart the appliance.
It will also avoid the formation of gas which could be produced
following the chemical reactions.
18.1
It is especially important to treat the water in underfloor heating
systems, as low temperatures favour bacterial growth. This can
lead to the formation of sludge, which in turn may block some or
all of the circuits.
-- The combustion performance.
18.1.1
Annual Maintenance
Verification of components
• Check that the flow sensor is working properly.
See chapter "Specific adjustment ► Appliance technical
settings and parameter list ► Installation settings" and use
code “d.36”.
• Check that the fan is working properly.
See chapter "Specific adjustment ► Appliance technical
settings and parameter list ► Installation settings" and use
code “d.34”.
In order to add the correct dosage of these products, you must
know the volume of water contained in the installation. It is
recommended that you note down the volume for future needs.
The inhibitors must be compatible with the materials employed
in the installation.
• Check that the temperature sensors are working properly.
See chapter "Specific adjustment ► Appliance technical
settings and parameter list ► Installation settings" and use
code “d.3, d.4, d.40, d.41”.
• Check the ionisation quality.
• Check that the thermal fuse protects the appliance against
dry fire. Disconnect the thermal fuse and check if "F76" fault
code is displayed on the screen.
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MAINTENANCE
18.2
18.2.1
Casing removing
18.3
Front panel
Combustion check and setting the air/gas
ratio valve
18.3.1
1
i
Competency to carry out the check of
combustion performance
BS 6798: 2009 Specification for installation and
maintenance of gas-fired boilers of rated input not
exceeding 70kW net advises that:
-- The person carrying out a combustion measurement must be
assessed as competent in the use of a flue gas analyser and
the interpretation of the results.
-- The flue gas analyser used should be one meeting
the requirements of BS7927 or BS-EN50379-3 and be
calibrated in accordance with the analyser manufacturers’
requirements.
-- Competence can be demonstrated by satisfactory completion
of the CPA1 ACS assessment, which covers the use of
electronic portable combustion gas analysers in accordance
with BS 7967, parts 1 to 4.
24
V
23
0
V
• Ensure that the gas analyser is set to the correct fuel setting.
B
2
A
A
Key
1Front panel
2
Front panel retaining screw
i
18.3.2
• Undo the two screws (2) on the underside of the front panel
and remove the front panel (1).
18.2.2
• Select the “
+ ”, constant central heating with DHW
function by pressing the “
” button repeatedly, refer to
commissioning section. The boiler should fire automatically.
Control box
Safe combustion can only be verified by measuring
CO/CO2 ratio. This must not exceed the value
shown in the table opposite.
Preliminaries
Prior to, during servicing and after any maintenance or changed
parts, the following must be checked.
• The integrity of the flue system and flue seals.
• The integrity of the appliance combustion circuit and relevant
seals.
• Electrical, gas and water connections.
1
• System pressure.
• The combustion performance, refer to the following
procedure.
24
V
23
0
V
Key
1
Control box
• Position the control box (1) into the service position.
• The operational gas inlet pressure and gas rates, refer to
the commissioning section paragraph 12.5. Correct any falt
before continuing.
Combustion check and setting the air/gas ratio
• Remove the front casing panel, see diagram above and
hinge down the control box. Taking care not to touch any
internal components, proceed as follows:
• Connect the CO2 combustion analyser to the relevant test
point, see diagram opposite.
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MAINTENANCE
2
3
If the combustion reading is not within the acceptable values
and the integrity of the complete flue system and combustion
circuit seals have been verified and the inlet gas pressure (and
gas rate) have been verified, then, it will necessary to adjust the
combustion rate of the appliance.
i
Adjustment is made by turning the throttle an ⅛
of a turn, waiting 1 minute to allow the appliance
to stabilise before checking or making further
adjustments.
• Remove the sticker covering the “throttle” adjustment screw,
if fitted.
1
• Rotate the “throttle” (1) (anti-clockwise to increase), to the
required CO2, refer to previous diagram and the “Setting”
column in the table.
24
• When you have finished, press the On/Off button to exit the
test modes.
• Remove the analyser probe and replace the cap on the
sampling point, replace the controls fascia, and the front
casing panel.
2B
i
2A
18.3.4
Key
1
Throttle
2
Combustion analyser sample point
2A Flue elbow
2B Vertical flue adaptor
3
Cap
18.3.3
i
Remember to replace the sample point cap on
completion of the test.
Gas rate check
• Check the gas rates as described in the commissioning
section.
18.3.5
Maximum rate check and adjustment
To verify the maximum gas rate CO2 setting the
appliance must be checked at the maximum rate.
• Activate the test mode "P.01" and set the value to 100 in
order to force the burner at P. max. See chapter "Specific
adjustment ► Appliance technical settings and parameter list
► Test modes".
Completion
If it is not possible to achieve the required results for either the
combustion or gas rates, it will be necessary to complete a full
service of the appliance and then repeat the combustion check
procedure.
If after servicing and adjustment of the appliance the
combustion values are still unacceptable and after further
remedial work has been carried out, the appliance must be
disconnected until the CO/CO2 ratio is acceptable.
• Wait approximately 5 minutes to read a stabilised CO2 value.
• Advice can be sought from the Glow-worm Technical
Helpline.
• Check that the value is within the range specified in table in
the “check” column.
18.4
G20 Burner % CO2
Model
Check (case on)
Setting (case off)
CO/CO2 ratio
24cxi
9.2 ± 0.3%
9 ± 0.2%
0.004
30cxi
9.2 ± 0.3%
9 ± 0.2%
0.004
35cxi
9.2 ± 0.3%
9 ± 0.2%
0.004
G31 Burner % CO2
Model
Check (case on)
Setting (case off)
CO/CO2 ratio
24cxi
10.3 ± 0.3%
10.1 ± 0.2%
0.004
30cxi
10.3 ± 0.3%
10.1 ± 0.2%
0.004
35cxi
10.3 ± 0.3%
10.1 ± 0.2%
0.004
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i
Servicing
If the Combustion CO2, CO/CO2 ratio & Gas rate
checks did not require adjustment then it will not be
necessary to complete a full service.
All routine servicing requirements can be achieved by the
removal of the front panel.
• Position the control box into the service position.
• Before commencing with a service or replacement of parts,
isolate the boiler from the electrical and gas supplies.
18.4.1
Service interval record
• Refer to benchmark book stapled in the centre pages of this
manual.
- 41 -
MAINTENANCE
18.5
Silencer
Key
1Fixed silencer
2
Silencer retaining clip
3
Removable silencer
24cxi / 30cxi
3
2
• Unclip and remove the silencer (3).
• Clean the interior of the silencer with a dry cloth if necessary,
taking care not to damage the internal foam.
• Repeat the operation in reverse order to replace the silencer.
B
18.6
1
C
Expansion vessel
2
A
1
Key
1
Silencer retaining screw
2Fixed silencer
3
Removable silencer
• Remove the silencer retaining screws (1) and remove the
silencer (3).
• Clean the interior of the silencer with a dry cloth if necessary,
taking care not to damage the internal foam.
• Repeat the operation in reverse order to replace the silencer.
35cxi
Key
1
Expansion vessel
2
Expansion vessel pressure inlet
• Check the expansion vessel's supply pressure (see «
Technical Data » chapter) by means of the pressure inlet
located on the expansion vessel. Adjust the pressure if
necessary.
3
• Following the installation of a new expansion vessel, fill and
purge the appliance or installation, if necessary.
2
A
1
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MAINTENANCE
18.7
Heating filter
18.8
a
D
3
E
Condensate trap
Warning: condensate is mildly acidic. Use
protective gloves.
5
1
4
5
C
B
1
3
A
B
2
1
4
1
A
2
Key
1
Plate-to-plate heat exchanger retaining arm
2
Plate-to-plate heat exchanger retaining screw
3
Gasket
4
Heating filter
5
Plate-to-plate heat exchanger
The heating filter improves the degassing of the heating circuit.
• Close the flow and return heating stop valves and drain the
boiler.
• Remove the retaining screw (2) and arm (1).
• Remove the plate-to-plate heat exchanger (5).
• Remove the gasket (3).
• Remove the heating filter (4).
• Clean and replace.
2
Key
1
The condensate trap
2
Discharge of condensates
3
Siphon
4
Condensate trap retaining clips
5
Hose
• Place a container under the condensate trap (1).
• Remove the siphon (3) from he recoverer and clean.
• Disconnect the condensation discharge (2).
• Disconnect the heat exchanger hose (5).
• Remove the condensate trap (1) using the clips (4).
• Clean the hose, the trap and the siphon, remove any
accumulated dirt.
• Reassemble the components, taking care to position the
gaskets correctly.
• Start the siphon (3) and fill with water.
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MAINTENANCE
18.9
Combustion block
9
8
7
6
5
10
4
11
3
12
2
13
1
14
15
16
17
Legend
1
Gas valve connection
2
Grounding cable
3
Spark electrode inlet
4
Spark electrode retaining screw.
5
Spark electrode gasket
6
Spark electrode
7Burner retaining nut
8
Burner retaining screw
9
Thermal fuse connection
- 44 -
10 Coil
11 Heat exchanger
12Burner gasket
13Burner
14 Gas valve
15Fan
16Fan connection
17 Gas pipe
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MAINTENANCE
18.9.1
Spark electrode
18.9.5
Re-assembling the burner group
• Disconnect the electrode inlet (3) and the grounding cable (2).
• Place the burner group on the heat exchanger (11).
• Remove the 2 spark electrode retaining screws (4).
• Progressively tighten the 4 nuts (7) in an alternate order.
• Carefully remove the electrode from the combustion
chamber.
• Reassemble the silencer.
• Check that the extremes of the electrode (6) are not
damaged.
• Clean away any accumulation of dirt and check that the
distance between the two electrodes is between 3.5 and 4.5
mm.
• Connect the gas tube (17) with a new gasket to the burner
group.
• Connect the spark electrode connector (6) to the igniter unit.
• Connect the connector to the gas valve (1) and the fan (15).
• Open the appliance gas input.
• Check that the gasket (5) is not damaged. Replace if
necessary.
• Check the watertightness of the gas connection.
18.9.2
18.10 Service completion
b
Dismantling the burner
Warning: The gasket (12) must be replaced each
time the burner is dismantled.
• Disconnect the spark electrode connector (6) from the igniter
unit.
• Re-check the combustion, see chapter "Combustion check".
On completion of the service, the "Benchmark" Service Record
sould be completed.
• Remove the gas pipe (17).
• Remove the connectors from the gas valve (1) and the fan
(15).
• Remove the retaining screw of the silencer.
• Loosen the 4 nuts (7).
• Remove the burner group from the heat exchanger (11).
• The studs (8) fixed to the heat exchanger must not
be damaged. Should it be damaged, replace the heat
exchanger.
• The burner gate insulation should not be damaged Replace
if damaged.
18.9.3
Cleaning the heat exchanger
• Clean the coil (19) in the heat exchanger (11) with water.
18.9.4
Burner control
• The burner (13) does not require maintenance and should
not be cleaned.
• Check that its surface is not damage. Replace the burner if
necessary.
• Following the verification or replacement of the burner,
assemble the burner group as described in the following
chapter.
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MAINTENANCE
19 Replacement of Parts
19.3
Viewing window
• Do not use reconditioned or copy parts, only use original
parts supplied by Glow-worm.
2
• If a part is required, contact the Glow-worm service
organisation.
1
• Please quote the name of the appliance, this information will
be on the name badge on the front of the appliance.
3
• If in doubt seek advice from the local gas company or Glowworm’s own service organisation.
a
4
Replacement of parts must be carried out by a
competent person approved at the time by the
Health and Safety Executive.
PLEASE NOTE: During change of part of the combustion
circuit, we recommend that the following is the following must
be checked:
-- The integrity of the flue system and the flue seals,
-- The integrity of the boiler combustion circuit and the relevant
seals,
5
1
24
V
23
0
V
-- The gas rate,
Key
1
Fibre washer
2
Steel washer
3
Glass
4
Steel washer
5
Circlip
-- The combustion performance.
• Remove the circlip (5).
-- The operational (working) gas inlet pressure at maximum
rate,
19.1
b
General
The replacement of parts described in sections
"Combustion block" will require the removal
of the burner module assembly and the
replacement of seal and self locking nuts.
• Remove the steel washer (4).
• Remove fibre washer (1).
• Remove the glass (3).
Replacement parts that have associated components that need
replacing on removal, i.e. ‘O’ ring, seals, gasket, etc., will be
supplied and should be fitted.
• Before replacing any parts of the boiler, isolate from the
mains electric supply and turn off the gas at the gas service
isolation valve on the boiler.
Unless stated otherwise parts are replaced in the reverse order
to removal.
• After replacing any parts, always test for gas soundness and
if necessary carry out functional test of the controls.
19.2
Boiler Access
For replacement of parts, the front casing panel of the boiler will
need to be removed.
• To remove undo the two screws on the underside of the front
casing and lift off.
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0020085231_02 - 05/10 - Glow-worm
MAINTENANCE
19.3.1
Expansion vessel
A
4
D
3
E
2
2
1
C
B
1
Key
1
Connector
2
Expansion vessel
3
Upper support bracket
4
Retaining screw
5
Gasket
Drain the boiler heating circuit as described in the appropriate
chapter "Draining".
• Remove the two screws (4).
• Undo the connector (1) at the base of the vessel.
• Remove upper support bracket (3).
• Remove the expansion vessel (2).
• Fit a new gasket between the expansion vessel and
connector.
• Refill, vent and pressurise the boiler.
0020085231_02 - 05/10 - Glow-worm
- 47 -
MAINTENANCE
19.4
Hydraulic block
12
13
11
10
14
9
15
8
16
17
18
7
19
6
20
5
21
29
4
3
22
2
28
23
1
27
24
26
25
Key
1
Three-way valve electrical plug
2
Three-way valve retaining screws
3
Three-way valve
4
Flow sensor electrical plug
5
Flow sensor
6
Safety Discharge Valve retaining clip
7
Safety Discharge Valve discharge pipe
8
Safety Discharge Valve
9
Plate-to-plate heat exchanger retaining
arm
- 48 -
10
11
12
13
14
15
16
17
18
Plate-to-plate heat exchanger retaining
screws
Heating flow pipe retaining clip
Heating flow pipe
Heating return pipe
Plate-to-plate heat exchanger
Low water pressure sensor connector
Low water pressure sensor
Low water pressure sensor retaining
clip
Heating return pipe retaining clip
19 Expansion vessel pipe
20 Automatic air vent
21 Pump housing
22 Pump housing retaining clip
23Bypass retaining clip
24 Bypass screw
25 Pump head earth lead
26 Pump head connector
27 Pump head retaining screws
28 Pump head
29 Automatic air vent retaining clip
0020085231_02 - 05/10 - Glow-worm
MAINTENANCE
19.4.1
Pump (head only)
19.4.5
Flow sensor
• Drain the boiler heating circuit as described in the
appropriate chapter "Draining".
• Drain the boiler hot water circuit as described in the
appropriate chapter "Draining".
• Disconnect the electrical plug (26) from the main board.
• Remove the side securing clip and the electrical connection (4).
• Disconnect the electrical plug (25) from the pump head.
• Disengage the flow sensor (5).
• Remove the four cap head screws (27).
• After replacing the flow sensor, open the cold-water isolation
valve and slowly open a hot water tap to remove air.
• Carefully remove the pump head (28) together with cable.
Do not strain cable.
• Reconnect wiring to new pump head and fit cover.
• Fit the new pump head by repeating the operations in
reverse.
19.4.2
Safety discharge valve
• Drain the boiler heating circuit as described in the
appropriate chapter "Draining".
• Undo the safety discharge valve union and remove from the
pipework (7).
19.4.6
Bypass
• Drain the boiler heating circuit as described in the
appropriate chapter "Draining".
• Remove the retaining clip (23) to remove the bypass screw (24).
• After replacing the bypass, refill, vent and pressurise the
boiler.
19.4.7
Three way valve
• Drain the boiler heating circuit as described in the
appropriate chapter "Draining".
• Remove the securing clip (6) and withdraw the safety
discharge valve (8).
• Disconnect the electrical plug (1).
• Fit new ‘O’ ring. Refill, vent and pressurise the boiler.
• Remove the two retaining screws (2).
19.4.3
Automatic air vent
• Drain the boiler heating circuit as described in the
appropriate chapter "Draining".
• Remove the retaining clip (29).
• Remove the automatic air vent (20).
• Fit the new automatic air vent and ‘O’ ring ensuring the vent
cap is left loose.
• Refill, vent and pressurise the boiler.
19.4.4
Low water pressure sensor
• Drain the boiler heating circuit as described in the
appropriate chapter "Draining".
• Disconnect the electrical lead (15).
• Remove the retaining clip (17), remove the low water
pressure sensor (16).
• Remove the three way valve (3).
• Fit new three way valve assembly.
• Refill, vent and pressurise the boiler.
19.4.8
Plate-to-plate heat exchanger
• Drain the boiler heating and domestic hot water circuits as
described in the appropriate chapter "Draining".
• Remove the two securing screws (10).
• Open the two retaining brackets (9).
• Remove the plate-to-plate heat exchanger (14) by lifting it up.
• When replacing the plate-to-plate heat exchanger, ensure
that the four rubber sealing washers are fitted into the
hydroblock.
NOTE: The plate-to-plate heat exchanger only fits one way.
• Refill, vent and pressurise the boiler.
• Fit the new low water pressure sensor.
• Refill vent and pressurise the boiler.
0020085231_02 - 05/10 - Glow-worm
- 49 -
MAINTENANCE
19.5
Combustion block
19
20
21
18
17
16
15
14
13
12
22
11
23
10
24
9
25
8
26
27
29
28
30
7
6
31
38
32
5
4
3
37
33
36
2
1
34
35
- 50 -
0020085231_02 - 05/10 - Glow-worm
MAINTENANCE
Legend
1
Igniter unit retaining bracket
2
Igniter unit
3
Igniter unit retaining screw
4
Igniter unit electrical connector
5
Electrode / igniter unit connection cable
6
Earth cable
7
Spark electrode cap
8
Spark electrode retaining screw
9
Spark electrode gasket
10 Spark electrode
11 Combustion burner door assembly
12 Combustion burner door assembly - nut
13 Combustion burner door assembly - gasket
14Burner gasket
15Burner
16 Burner retaining screw
17 Heat exchanger retaining screw
18 Heat exchanger retaining bracket
19 Burner gate retaining screw
20 Thermal fuse connection
21 Heat exchanger
22 Heat exchanger retaining bracket
23 Heat exchanger retaining screw
24 Heating return pipe
25 Heating return pipe retaining clip
26 Return heating temperature sensor
27 Heating flow pipe
28 Flow heating temperature sensor
29 Heating flow pipe retaining clip
30 Gas valve retaining screw
31 Gas valve
32 Gas valve gasket
33Fan
34Fan electrical connection
35Fan/burner gasket
36 Gas pipe
37 Gas valve electrical connection
38 Fan retaining screw
19.5.1
Spark electrode
• Disconnect the electrode cap (7) and the earthing cable (6).
19.5.3
b
Removing the combustion/burner door
assembly
Warning: The gasket (13) must be replaced each
time the combustion/burner door assembly is
removed.
• Disconnect the spark electrode cap (7) from the igniter unit.
• Disconnect the gas supply pipe (36) at the gas valve.
• Remove the electrical connectors from the gas valve (37)
and the fan (34).
• Remove the retaining screw of the silencer.
• Loosen the 4 nuts (12).
• Remove the combustion/burner door assembly from the heat
exchanger (11).
• The studs (19) must not be damaged. If damaged you will
need to replace the heat exchanger.
• The combustion/burner door assembly insulation should be
inspected and replaced if damaged.
19.5.4
Burner
• Remove the 3 burner retaining screws (16).
• Remove the burner (15) and the gasket (14).
• Fit the new burner and the new gasket.
19.5.5
b
Heat exchanger
There will be water in the heat exchanger.
Carefully ease heat exchanger out.
• Remove the 2 spark electrode retaining screws (8).
• Drain the boiler heating and hot water circuits as described in
the appropriate chapter "Draining".
• Carefully remove the electrode (10) from the combustion
chamber.
• Remove the flue connection.
• Remove the gasket (9).
• Check that the distance between the 2 electrodes is between
3.5 and 4.5 mm.
• Install the electrode and a new gasket.
19.5.2
Igniter unit
• Remove the ignition lead (2).
• Remove electrical connections (4).
• Loosen the screws (3) located on the igniter unit (2).
• Remove the igniter unit (2).
• Undo the two screws located on the top of each side panel.
• Remove the thermal fuse connector (20).
• Remove the 2 heating pipe retaining clips (25) and (29).
• Release the heating pipes (24) and (27) from the heat
exchanger.
• Release the condensate trap pipe from the heat exchanger.
• Remove the combustion/burner door assembly (11)
refering to chapter "Removing the combustion/burner door
assembly".
• Unscrew the 4 retaining screws (17) and (23) and remove
the 2 retaining plates (18) and (22) from the heat exchanger.
• Pull the heat exchanger towards you to extract it from its 2
side rails.
0020085231_02 - 05/10 - Glow-worm
- 51 -
MAINTENANCE
19.5.6
Re-assembling the burner group
• Place the burner assembly on the heat exchanger (21).
• Progressively tighten the 4 nuts (12) in an alternate order.
• Reassemble the silencer.
• Connect the gas pipe (36) with a new gasket to the burner
group.
• Connect the spark electrode connector (5) to the igniter unit.
• Connect the connector to the gas valve (37) and the fan (34).
• After assembly test for gas tightness and purge in
accordance with the current issue of BS6891or in IE, the
current edition of I.S.813 “Domestic Gas Installations”.
19.6
a
Condensate trap
Warning: condensate is mildly acidic. Wear
protective gloves.
5
1
• Open the appliance’s gas input.
• Check the tightness of the gas connection.
19.5.7
Heating Flow Thermistor
• Remove the electrical connections from the thermistor (28).
• Remove the retaining clip from the flow pipe (27).
i
19.5.8
When reconnecting, the polarity of the wiring to
thermistors is not important.
Heating Return Thermistor
4
3
• Remove the electrical connections from the thermistor (26).
• Remove the retaining clip from the return pipe (24).
i
19.5.9
When reconnecting, the polarity of the wiring to
thermistors is not important.
2
1
Gas valve
• Remove the burner door (11) refering to chapter "Dismantling
the burner door".
• Remove the two gas valve retaining screws (30).
• Remove the gas valve (31) and the gasket (32).
Key
1
Condensate trap
2
Condensate outlet pipe
3
Condensate reservoir
4
Condensate reservoir retaining clips
5
Hose
• Fit the new gas valve and the new gasket by repeating the
operations in reverse.
• Place a container under the condensate trap (1).
• After assembly test for gas tightness and purge in
accordance with the current issue of BS6891or in IE, the
current edition of I.S.813 “Domestic Gas Installations”.
• Disconnect the condensation discharge (2).
• Check the combustion CO2.
19.5.10
Fan
• Remove the burner door (11) refering to chapter "Dismantling
the burner door".
• Remove the gas valve (31) (see previous paragraph).
• Remove the condensate (3) from the reservoir.
• Disconnect the heat exchanger hose (5).
The condense trap will contain water, lift taking care not to spill
the water.
• Remove the condensate trap (1) using the clips (4).
• IMPORTANT: Partially fill the condensate trap with water
before replacing. Start the siphon (3) and fill with water.
• Loosen the 3 screws (38) located on the burner door (11).
• Remove the fan (33) and the gasket (35).
• Fit the new gasket (35).
• Screw the new fan to the burner door (11).
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0020085231_02 - 05/10 - Glow-worm
MAINTENANCE
19.7
i
19.8.1
PCB
19.8.3
When replacing the board refer to instructions
supplied with the spare part.
User interface PCB
5
Main PCB
4
B
B
C
C
B
4
B
3
3
1
1
2
A
1
Key
1
Control panel
2
Rear panel
3
Retainings clips
4
Main PCB
• Remove the 24V and 230V connections.
• Remove the rear panel (2).
• Ease back the two PCB retaining clips (3) and withdraw the
PCB from the retaining lugs.
• Remove the electrical connections to the PCB (appliance
interface cable).
• When refitting the rear panel, ensure the leads are not
trapped.
19.8.2
A
2
Key
1
User interface
2
Retaining slots
3
User interface PCB
4
Retainings clips
5
Control Panel
• Remove the user interface (1) easing back the two retaining
slots (2).
• Ease back the two PCB retaining clips (4) and withdraw the
PCB from the retaining lugs.
• Remove the electrical connections to the PCB.
• When refitting the user interface, ensure the leads are not
trapped.
19.8.4
e
Mains supply cable
The main supply cable must be replaced by a
qualified and competent electrician.
• If the main supply cable is damaged, replace it refering to the
chapter "Electrical connection".
2A Fuse Rating
• For access, refer to chapter "Main PCB".
• The fuse is located at top right hand side of the PCB, see
chapter "Electrical connection ►Wiring diagram".
0020085231_02 - 05/10 - Glow-worm
- 53 -
MAINTENANCE
20 Spare parts
In order to guarantee the safe and prolonged life of the product,
manufacturers genuine spare parts must be used.
i
This appliance displays a CE Mark of conformity.
Only use the manufacturer’s genuine, new spare
parts.
• Ensure that spare parts are correctly mounted in the right
position and direction. After fitting any spare part or servicing,
the appliance must be tested for its safe operation.
20.1
Short List of Parts
• When ordering spare parts, contact Glow-worm’s own
service organisation.
• 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. number of the part.
Key
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Part No.
Description
0020097277
A000035144
2000801935
0020097279
0020097278
0020038071
0020038441
0020097299
0020059452
0020097179
0020097181
0020097214
0020097216
0020097220
0020097207
0020075428
0020097329
0020075429
0020097400
A000024135
801635
Fan
Spark igniter
Thermistor (flow and return)
Gas valve 24cxi
Gas valve 30cxi
Gas valve 35cxi
Electrode assembly
User interface PCB
Plate to plate heat exchanger 24cxi
Plate to plate heat exchanger 30cxi
Plate to plate heat exchanger 35cxi
3 way valve assembly
Pump (head assembly) 24cxi / 30cxi
Pump (head assembly) 35cxi
Water flow sensor
Flow restrictor 24cxi
Flow restrictor 30cxi
Flow restrictor 35cxi
Main PCB
Low water pressure sensor
Burner Door Seal Kit
- 54 -
GC Part No.
0020085231_02 - 05/10 - Glow-worm
MAINTENANCE
20.2
Short List of Parts
7
6
8
5
9
4
10
11
12
3
13
2
1
14
0020085231_02 - 05/10 - Glow-worm
- 55 -
Manual Handling
IMPORTANT. With regards to the Manual Handling Operations, 1992
Regulations, the following lift operation exceeds the recommended
weight for a one man lift.
General recommendations when handling
Clear the route before attempting the lift.
Ensure safe lifting techniques are used – keep back straight – bend
using legs. Keep load as close to body as possible. Do not twist –
reposition feet instead. If 2 persons performing lift, ensure co-ordinated
movements during lift. Avoid upper body/top heavy bending - do not
lean forward/sideways. Recommend wear suitable cut resistant gloves
with good grip to protect against sharp edges and ensure good grip.
Always use assistance if required.
Removal of carton from delivery van
Recommend 2 person lift or 1 person with use of sack truck. If 1 person
is performing lift, straddle the load, tilt and place carton into position on
truck. Recommend secure appliance onto truck with suitable straps.
Ensure safe lifting techniques are used – keep back straight – bend
using legs. Keep load as close to body as possible. If 2 persons
performing lift, ensure co-ordinated movements during lift. Always use
assistance if required.
Carriage of carton from point of delivery to point of installation –
ground floor.
Recommend 2 person lift or 1 person with use of sack truck. If 1 person
is performing lift, straddle the load, tilt and place carton into position on
truck. Recommend secure appliance onto truck with suitable straps.
Ensure safe lifting techniques are used – keep back straight – bend
using legs. Keep load as close to body as possible. If 2 persons performing lift, ensure co-ordinated movements during lift. Clear the route
before attempting the lift. If removing boiler from truck straddle the load
and tilt forwards to facilitate secure grip. Ensure safe lifting techniques
are used – keep back straight – bend using legs. Do not twist – reposition feet instead. Take care to avoid trip hazards, slippery or wet
surfaces and when climbing steps and stairs. Always use assistance if
required.
Carriage of carton from point of delivery to point of installation –
first or higher floor, cellar.
Recommend 2-person lift or 1 person with use of sack truck. If 1 person
is performing lift, straddle the load, tilt and place carton into position on
truck. Recommend secure appliance onto truck with suitable straps.
Ensure safe lifting techniques are used – keep back straight – bend using legs. Keep load as close to body as possible. If 2 persons performing lift, ensure co-ordinated movements during lift. Avoid upper body/top
heavy bending - do not lean forward/sideways. Clear the route before
attempting the lift. If removing boiler from truck straddle the load and
tilt forwards to facilitate secure grip. Ensure safe lifting techniques are
used – keep back straight – bend using legs. Do not twist – reposition
feet instead. Take care to avoid trip hazards, slippery or wet surfaces
and when climbing steps and stairs. Always use assistance if required.
Carriage of carton from point of delivery to point of installation –
roofspace.
Recommend 2-person lift. Ensure co-ordinated movements during
lift. Avoid upper body/top heavy bending - do not lean forward/sideways. Clear the route before attempting the lift. Take care to avoid trip
hazards, slippery or wet surfaces and when climbing steps and stairs.
When transferring appliance into roofspace, recommend 1 person to be
in roofspace to receive the appliance and other person to be below to
pass up and support appliance. Ensure safe lifting techniques are used
– keep back straight – bend using legs. Keep load as close to body as
possible. Always use assistance if required. It is assumed safe access,
flooring and adequate lighting are provided in the roof space. It is
recommended a risk assessment of the roof space area be carried out
before moving the appliance into the area to take into account access,
stability of flooring, lighting and other factors, and appropriate measures
taken.
Unpacking of appliance from carton.
Recommend 2 persons unpack appliance from carton. Always keep
working area clear. Cut the carton straps, lift carton up and slide over
polystyrene end packs. Remove top polystyrene pack with fittings.
Positioning of Appliance for Final Installation – no obstructions.
Recommend 2 persons lift appliance to position into place. Fit bracket
securely onto wall before lifting appliance into position. Obtain firm
grip on front and sides of appliance, lift upwards, ensure stable balance achieved and lift upwards to position in place on bracket. Ensure
safe lifting techniques are used – keep back straight – bend using
legs - when lifting load from floor level. Do not twist – reposition feet
instead. Keep boiler as close as possible to body throughout lift to
minimise strain on back. Ensure co-ordinated movements to ensure
equal spread of weight of load. Always use assistance if required.
Recommend wear suitable cut resistant gloves with good grip to protect
against sharp edges and ensure good grip when handling appliance.
Positioning of Appliance for Final Installation – above worktop,
foreseeable obstructions etc.
Recommend 2 persons lift appliance to position into place. Fit bracket
securely onto wall before lifting appliance into position. Obtain firm grip
on front and sides of appliance, lift upwards, onto worktop if practicable.
Ensure stable balance achieved and lift upwards to position in place on
bracket. If 2 persons positioning onto bracket obtain firm grip at front and
sides/base of boiler. Ensure co-ordinated movements during 2 person
lifts to ensure equal spread of weight of load. Ensure safe lifting techniques are used – keep back straight – bend using legs - when lifting
load from floor level. Do not twist – reposition feet instead. Keep boiler
as close as possible to body throughout lift to minimise strain on back.
Avoid upper body/top heavy bending - do not lean forward/sideways. Always use assistance if required. Recommend wear suitable cut resistant
gloves with good grip to protect against sharp edges and ensure good
grip when handling appliance.
Positioning of Appliance for Final Installation – within compartment
etc. restricting installation.
Recommend 2 persons lift appliance to position into place, space permitting. Fit bracket securely onto wall before lifting appliance into position. Obtain firm grip on front and sides of appliance, lift upwards, onto
worktop if practicable. Ensure stable balance achieved and lift upwards
to drop into place onto bracket. If 2 persons positioning onto bracket
obtain firm grip at front and sides/base of boiler. Ensure co-ordinated
movements during 2 person lifts to ensure equal spread of weight of
load. If 1 person positioning onto bracket recommend obtain firm grip
supporting base of boiler. Ensure safe lifting techniques are used – keep
back straight – bend using legs - when lifting load from floor level. Do
not twist – reposition feet instead. Keep boiler as close as possible to
body throughout lift to minimise strain on back. Always use assistance
if required. Recommend wear suitable cut resistant gloves with good
grip to protect against sharp edges and ensure good grip when handling
appliance.
Positioning of Appliance for Final Installation – in roof space restricting installation.
Recommend 2 persons lift appliance to position into place, space permitting. Fit bracket securely onto wall before lifting appliance into position.
Obtain firm grip on front and sides of appliance, lift upwards, ensure stable balance achieved and lift upwards to drop into place onto bracket. If 2
persons positioning onto bracket obtain firm grip at front and sides/base
of boiler. Ensure co-ordinated movements during 2 person lifts to ensure
equal spread of weight of load. If 1 person positioning onto bracket recommend obtain firm grip supporting base of boiler. Ensure safe lifting
techniques are used - keep back straight – bend using legs - when lifting
load from floor level. Do not twist – reposition feet instead. Keep boiler as
close as possible to body throughout lift to minimise strain on back. Always use assistance if required. Recommend wear suitable cut resistant
gloves with good grip to protect against sharp edges and ensure good
grip when handling appliance. It is recommended a risk assessment of
the roof space area be carried out before moving the appliance into the
area to take into account access, stability of flooring, lighting and other
factors, and appropriate measures taken.
Declaration of Conformity
0020085231_02 - 05/10
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
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