Installation and Servicing Condensing Boilers/Ultracom hxi 12 hxi G.C.No. 41-019-01 15 hxi G.C.No. 41-019-02 18 hxi G.C.No. 41-019-03 24 hxi G.C.No. 41-019-04 30 hxi G.C.No. 41-019-05 38 hxi G.C.No.
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.
Table of contents These instructions consist of, Installation, Servicing, Fault Finding, Replacement of Parts and Spares. The instructions are an integral part of the appliance and must, to comply with the current issue of the Gas Safety (Installation and Use) Regulations, be handed to the user on completion of the installation.
INTRODUCTION WARNINGS Gas Leak or Fault Turn off the gas emergency control valve immediately. Eliminate all sources of ignition, i.e.smoking, blowlamps, hot air guns etc. Do not operate electrical lights or switches either on or off. Open all doors and windows, ventilate the area. Metal Parts This boiler contains metal parts (components) and care should be taken when handling and cleaning, with particular regard to edges.
INTRODUCTION CE Mark Gas Supply 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. Type test for purposes of Regulation 5 certified by: Notified body 0087. Product/production certified by: Notified body 0086. The CE mark on this appliance shows compliance with: 1.
INTRODUCTION Boiler Design Boiler Design Condensate Drain These boilers are designed to provide central heating from a fully pumped open vented or sealed water system and domestic hot water using a fully indirect cylinder. Once the controls are set the boiler operates automatically. A plastic drain pipe must be fitted to allow discharge of condensate to a drain. Condensate should, if possible, be discharged into the internal household draining system.
technical data 1 Boiler Specification 13497 C13, C33, C43 C13, C33, C43 C13, C33, C43 SEDBUK rating % 2005 90.5 90.5 90.4 SEDBUK rating % 2009 88.7 88.7 88.6 C13, C33, C43 C13, C33, C43 C13, C33, C43 SEDBUK rating % 2005 90.5 90.6 90.8 SEDBUK rating % 2009 88.9 88.7 89.
INSTALLATION 13751 13205 Diagram 2.2 2 Boiler Dimensions & Hydraulic Schematic Diagram 2.1 -8- All dimensions are given in millimetres (except as noted). The general arrangement of the boiler is shown in diagram 2.1. and the hydraulic and gas schematic, diagram 2.2. The data label is positioned on the front of the inner casing panel.
INSTALLATION 13204 3 Boiler Location, Clearances and Ventilation 3.1 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.
INSTALLATION 4 Evacuation of combustion Gas 4.1 Regulation 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 The maximum length of the flue outlet is defined according to its type (for example C13). H* and J* See diagram 4.2.
INSTALLATION Diagram 4.
INSTALLATION 4.2 Flue configuration description 4.2.1 Horizontal concentric flue Ø 60/100 mm or Ø 80/125 mm (C13 type installation) a If the terminal is at less than 1.80 m from the ground, you must install a terminal protection kit. Each time an additional 90° bend is necessary (or 2 at 45°), the length (L) must be reduced by 1 m. 4.2.2 Vertical concentric flue Ø 60/100 mm or Ø 80/125 mm (C33 type installation) a If the terminal is at less than 1.
INSTALLATION 4.2.3 Multiple boiler chimney flue Ø 60/100 mm (C43 type installation) The flue connecting from the appliance to the flue system must be supplied from the manufacturer of the boiler.
INSTALLATION 12342 Diagram 5.
INSTALLATION 5 Water Systems - General 5.1 General This boiler is designed to provide central heating from a fully pumped open vented or sealed water system and domestic hot water using a fully indirect vented or unvented cylinder. An options board accessory is available to activate and link the internal programmer with a Honeywell S or Y plan system. Domestic Hot Water Cylinder SINGLE FEED INDIRECT CYLINDERS ARE NOT SUITABLE.
INSTALLATION 13147 Water System - Open (Vented) Central Heating System The boiler must be supplied from an unrestricted water supply taken from a feed and expansion cistern situated at a maximum height of 27 metres (90ft) above the boiler. The cold feed must be 15mm minimum size. The vent must rise continuously and be unrestricted. It is important that the relative positions of the pump, cold feed and open vent are as shown in diagram 5.2. 5.
INSTALLATION 12999 SUPPLY PIPE BOILER CONTROL VALVE 11680 DOUBLE CHECK VALVE FLOW HEATING CIRCUIT RETURN HOSE UNION TEMPORARY CONTROL HOSE CONNECTION VALVE UNION DRAIN POINT Diagram 5.
INSTALLATION Gas Valve 6.1 Appliance Pack The top polystyrene pack contains all the items illustrated in diagram 6.1. Remove the carton sleeve and top pack then lift the boiler and its polystyrene base support out of the lower pack. 15705 6 Installation Preparation Hanging Bracket Electrical Cartridge 6.2 Site Requirements The boiler mounting wall should be suitable for the weight of the appliance and be true and flat.
INSTALLATION 7.1 Hanging Bracket Fixing 13503 7 Boiler Fixing Reposition the wall template over the flue hole and mark the position of the fixing holes for the hanging bracket, see diagram 7.1. Mark and drill the fixing holes and secure the hanging bracket which is supplied in the polystyrene base pack. NOTE: Due to the varied site conditions we do not supply fixings and advise that the installer should supply those which are suitable. 7.
INSTALLATION 13504 Diagram 8.1 8.1 Gas Connection 13505 Gas/Water & Condensate Connection Before connection check the supply of local gas. Refer to diagram 8.1, the gas supply can be connected from below or through the wall at the rear of the boiler. 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”. 8.
13000 INSTALLATION Diagram 8.
INSTALLATION ELECTRICAL CARTRIDGE WARNING: This appliance must be earthed. ● This appliance must be wired in accordance with these instructions. Any fault arising from incorrect wiring cannot be put right under the terms of the Glow-worm guarantee. ● All system components must be of an approved type. Electrical components have been tested to meet the equivalent requirements of the BEAB. ● Do not interrupt the mains supply with a time switch or programmer.
INSTALLATION 9.4 Electrical Cartridge Securing 13301 ELECTRICAL CARTRIDGE Close the cartridge and secure with the previously removed screw. Push the electrical cartridge into the interface housing on completion of the wiring, see diagram 9.3. Secure with the two cartridge retaining screws provided in the cartridge body. 9.5 Electrical Connections - Testing Carry out preliminary electrical system checks as below: 1. Test insulation resistance to earth of mains cables. 2.
INSTALLATION 13473 Extt MODE PROG TOGGLE BUTTON MODE and PROG LCD DISPLAY RESET BUTTON NOT CH TEMPERATURE USED ADJUSTMENT SYMBOLS DISPLA YED ON THE LCD AND DESCRIPTIONS Central Heating Function Min burner display Appliance OFF Temperature Max burner display Ext Glow-worm control (Optional) System pressure - not applicable Diagram 10.2 10.
INSTALLATION 10.7 Heating System kW 38 37 36 35 34 33 32 31 30 29 28 27 26 25 m3/hr 4.06 3.9 3.8 3.7 3.6 3.5 3.4 3.3 3.2 3.1 3.0 2.9 2.8 2.6 ft3/hr kW m3/hr ft3/hr 143 138.5 135 131 127 124 120 117 113 109.5 106 102.4 98.9 91.8 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 2.5 2.4 2.3 2.2 2.1 2.0 1.9 1.8 1.7 1.6 1.5 1.4 1.3 1.2 1.12 88.3 84.8 81.2 77.7 74.2 70.6 67.1 63.6 60.0 56.5 53.0 49.5 45.9 42.4 38.9 13540 Check that all external controls are calling for heat.
INSTALLATION 10.10 LPG CONVERSION - all models As an option, a chargeable boiler performance and function service can be provided by Glow-worm Service by calling telephone No. 01773 828100. NOTE: Steps 10.1 and 10.3 will need to be completed before the appliance can be converted. 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.
MAINTENANCE 1. 2. 3. 4. 5. 6. IMPORTANT NOTES: 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.
MAINTENANCE 1. Maximum Rate Check and Adjustment GAS RATE CHECK Check the gas rates as described in the commissioning section. 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.
MAINTENANCE 11.1 Servicing 11.2 Spark Electrode IMPORTANT: 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. In any case, a full service including the replacement of the burner door seal must be carried out at least once every 5 years. Disconnect the spark electrode plug and earth lead, see diagram 11.5.
MAINTENANCE SEAL COMBUSTION CHAMBER NYLOC SECURING NUTS (5 OFF) 13864 SECTION THROUGH BURNER DOOR SHOWING POSITION OF SEAL BURNER FAN GAS VALVE GAS PIPE BRACKET AND SEAL 13272 Gently remove the fan, gas valve and burner assembly from the combustion chamber. Clean the burner with a soft brush taking great care not to damage the front insulation. DO NOT use wire or sharp instruments to clean the holes of the burner. Inspect the burner for any signs of damage.
MAINTENANCE 13738 Fault Finding CHASSIS FRONT 12.1 Preliminary fault finding The following checks should be performed before proceeding onto specific diagnostics: • Check the external electrical supply to the boiler is on and a supply of 230V is present at the ‘L’ and ‘N’ terminals on the installer interface, refer to section 10.4 for access and diagram 12.4.
MAINTENANCE 13456 Diagram 12.
MAINTENANCE 13012 CENTRAL HEATING Diagram 12.
MAINTENANCE 13508 Fault Codes Diagram 12.
MAINTENANCE 13447 Fault Codes (continued) Diagram 12.6 Diagnostic Menu 0020107233_00 - 06/11 - Glow-worm 13451 If necessary the values can be changed by: a) Pressing the ‘MODE’ button. b) The diagnostic value flashes, see diagnostic display 2. c) Use the ‘+’ and ‘-’ buttons to cycle through available values. d) The change is saved by pressing ‘MODE’ once more. (NOTE: Only certain parameters can be adjusted) To exit the diagnostic menu press and hold the ‘MODE’ button for 5 seconds.
MAINTENANCE Description 13567 Diagnostic Menu - Level 1 Installer Access Range Tank temperature -99 will be displayed. Reserved for future use. Flow temperature setpoint intelligent control Status central heating pump Status additional heating pump (option) d.27 Option Relay 1 Reserved for future use d.28 Option Relay 2 Reserved for future use > 80 no flame < 40 good flame Minutes External intelligent control connected d.91 Internal Programmer type 0:24 hour (default) d.
MAINTENANCE 13568 State list - Accessed through Diagnostic Codes - Level 1, Installer Access d.99 STATE LISTS Diagram 12.
MAINTENANCE 13 Replacement of Parts 13.1 General 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”. 13274 IMPORTANT: The replacement parts described in sections 13.5 to 13.9 and section 13.12, will require the removal of the burner module assembly and the replacement of the burner door seal and self locking nuts.
MAINTENANCE 13238 13.6 Fan For access, refer to section 13.1. Refer to section 11.3 for removal of the fan, gas valve and burner assembly. Remove the gas valve as described in the relevant parts of section 13.5. Remove the venturi plate secured with three screws, see diagram 13.2, and remove the two screws securing the fan to the gas manifold. Check the gasket and replace if necessary.
MAINTENANCE Diagram 13.6 13544 For access, refer to section 13.1. Refer to diagram 13.6. Remove the igniter unit as described in section 13.3 to improve accessibility. Remove the securing clip from the heat exchanger adapter, then disconnect the adapter and flexible hose. Lift the siphon adapter and hose out of the condensate trap and siphonic drain, do not disconnect the hose. Disconnect the drain connection. Slacken to disengage but do not remove the two securing screws.
MAINTENANCE 13281 13.13 Flue Hood For access, refer to section 13.1. Remove heat exchanger as described in section 13.12. Remove the two securing screws and pull the flue hood down and away from the flue hood bracket and flue elbow, see diagram 13.9. 13.14 Heating Flow Thermistor For access, refer to section 13.1. Refer to diagram 13.10. Remove the electrical connections from the thermistor. Remove the retaining clip from the flow pipe.
MAINTENANCE For access, refer to section 13.1. Remove control box retaining screw, see diagram 13.11. Hinge down the control box. Release the control box cover by carefully pressing the four retaining latches, see diagram 13.11. 13.17 Main PCB IMPORTANT: When replacing the board refer to instructions supplied with the replacement. For access, refer to section 13.16. Remove the electrical connections to the PCB.
MAINTENANCE 14 Spare Parts When ordering spare parts, contact Glow-worm’s own service organisation using the telephone number on the inside front cover of this booklet. Please quote the name of the appliance and serial number, to be found on the data label. If ordering from British Gas also quote the G.C. number of the part. Key No. Part No. Description GC Part No.
MAINTENANCE 15 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.
MAINTENANCE 0020107233_00 - 06/11 - Glow-worm - 45 -
SERVICE INTERVAL RECORD It is recommended that your heating system is serviced regularly and that you complete the appropriate Service Interval Record Below . Service Provider. Before completing the appropriate Service Interval Record below, please ensure you have carried out the service as described in the boiler manufacturer’s instructions. Always use the manufacturer ‘s specified spare part when replacing all controls.
0020107233_00 - 06/11 Subject to engineering changes 0020107233 GLOW-WORM Nottingham Road, Belper, Derbyshire. DE56 1JT www.glow-worm.co.uk Because of our constant endeavour for improvement, details may vary slightly from those shown in these instructions.
