Ultracom Installation and Servicing 18sxi G.C. No. 41-019-07 30sxi G.C. No. 41-019-08 High Efficiency Condensing System Boilers www.glow-worm.co.
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.
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.
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. Sealed Components Under no circumstances must the user interfere with or adjust sealed parts.
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. Type test for purposes of Regulation 5 certified by: Notified body 0087.
Boiler Design Boiler Design This boiler is designed to provide central heating from a sealed water system with a fully indirect cylinder, pumped circulation. The pump, expansion vessel and associated safety devices are all fitted within the boiler. The integral programmer is designed for both simple operation and maximum control. Once the controls are set the boiler will operate automatically. Condensate Drain A plastic drain pipe must be fitted to allow discharge of condensate to a drain.
1 Boiler Specification 18sxi 30sxi Lift weight 36kg (80Ib) 39kg (86Ib) Total weight (installed) 41kg (90Ib) 44.5kg (98Ib) Gas connection 15mm copper 15mm copper Heating flow & return connection Ø O.D. 22mm. copper 22mm. copper Condensate connection Ø I.D. 21.5mm. plastic 21.5mm. plastic Safety valve 3 bar (43/5Ibf/in2) 3 bar (43/5Ibf/in2) Safety valve discharge 15mm. copper 15mm. copper Expansion vessel capacity 8 litres (1.76 gallons) 8 litres (1.
2 Boiler Dimensions and Hydraulic Schematic 13482 13642 Diagram 2.2 2.1 Boiler Dimensions & Hydraulic Schematic 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. Diagram 2.1 8 The data label is positioned on the front of the inner casing panel.
3 Boiler Location, Clearances and Ventilation This boiler is not suitable for outdoor installation. 13208 3.1 Location 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.
4 Flue Options and Terminal Clearances Top horizontal telescopic flue (Ø60/100) Part No. A2043600 - Section 10, page 19 Top horizontal standard flue (Ø60/100) Part No. A2043400 - Section 10, page 23 Ridge Tile Terminal Part No. A2043800 Section 10, page 29 Plume Management Kit basic set, white, concentric flue (Ø60/100) - Part No. A2044100 for use with Part No. A2043400 and Part No. A2043600 - Section 10, page 34 Twin Flue Twin Flue Adapter, concentric flue (Ø80) Part No.
4 Flue Options and Terminal Clearances 4.1 Flue Options There are various flue options to choose from as illustrated in diagram 4.1. The flue lengths and installation are described in section 10. 4.2 Flue Terminal Position In GB the minimum acceptable siting dimensions for the terminal from obstructions, other terminals and ventilation openings are shown in diagram 4.2. In IE the minimum distances for flue terminal positioning must be those detailed in I.S.813 “Domestic Gas Installations”.
5 Water System 13486 5.1 General This boiler is designed for use as part of a sealed water central heating system with fully pumped circulation. The pump, expansion vessel and associated safety devices are all fitted within the boiler. An options board accessory is available to link the internal programmer with a Honeywell S or Y plan system. 5.2 Safety Valve The safety valve is an integral part of the boiler and it cannot be adjusted.
5 Water System 13801 Diagram 5.
6 Installation Preparation 6.1 Appliance Pack 6.3 Wall Template Please check the contents of packs as shown in diagram 6.1. The packs are located in the top polystyrene packing. Take the wall template from the document pack located within the top polystyrene packing and place in the desired position on the wall, giving due consideration to the required boiler clearances, see section 3, and the flue you are fitting.
6 Installation Preparation 13853 6.4 Flue Hole Cutting External access flue installation can use a 105mm diameter core drill. Internal access only flue installation will need a 125mm diameter core drill. NOTE: The flue is designed with an internal fall of 44mm/ metre (2.5°), therefore the hole can be drilled horizontally. 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 (2.5°) towards the boiler. Diagram 6.
8 Gas / Water Connection 13477 8.1 Systems Connection Remove the protective caps from the boiler connections. NOTE: The appliance may contain a small amount of water, place a water container beneath the boiler connections. Assemble and secure the pre formed copper tails to their respective isolation valves making sure of their correct orientation, see diagram 8.1. Fit the isolation valves/copper tails with seals to the appliance as shown in diagram 8.
9 Safety Discharge Valve and Condensate Connections 13491 9.1 Safety Discharge Valve Take the safety discharge pipe, supplied in the pipe pack and the union nut and seal, supplied in the loose items pack and fit as shown in diagram 9.1. This must be extended, using not less than 15mm o.d. pipe, to discharge, in a visible position, outside the building, facing downwards, preferably over a drain.
13000 9 Safety Discharge Valve and Condensate Connections Diagram 9.
10 Telescopic Flue - Length, Preparation and Installation 10.1 Flue Length Multiple Boiler Chimney Flue Length The maximum permissible horizontal flue length is 10 metres plus the flue terminal assembly, this can be achieved by use of the accessories, see diagram 10.3.
10 Telescopic Flue - Length, Preparation and Installation 14826 Diagram 10.2 15418 Diagram 10.
10 Telescopic Flue - Length, Preparation and Installation Refer to diagram 10.2 for kit contents. 13223 10.2 Horizontal Telescopic Flue - A2043600 10.3 REAR Flue If a wall thickness is between 203mm min. to 413mm max. then the flue can be used without extensions. With the flue elbow temporarily fitted, measure the distance from the outside wall to the butt joint, see diagram 10.4. If the measurement ‘Y’ exceeds 525mm, then the appropriate length of extension pipe is required.
10 Telescopic Flue - Length, Preparation and Installation 12929 10.5 Flue Fitting IMPORTANT:The flue seals are sensitive to mineral oil based lubricants. Do not grease the seals. If the seals do need to be lubricated use only water. During the installation of the flue system, ensure that debris such as mortar, filings or swarf are cleared from the flue system before completion. Inspect the flue pipes before fitting and do not install damaged or dented flue components.
10 Standard Flue - Length, Preparation and Installation 10.6 Flue Length Standard Horizontal Flue 13560 The maximum permissible horizontal flue length is 10 metres plus the flue terminal assembly, this can be achieved by use of the accessories, see diagram 10.12. However should additional 87.5o or 2 x 45o elbows be used then the length MUST be reduced by 1metre. The diagram 10.10 shows the length achievable by using the kit A2043400.
10 Standard Flue - Length, Preparation and Installation 13222 Diagram 10.11 15418 Diagram 10.
10 Standard Flue - Length, Preparation and Installation 13223 10.7 Standard Horizontal Flue - A2043400 Refer to diagram 10.11 for kit contents. 10.8 REAR Flue With the flue elbow temporarily fitted, measure the distance from the outside wall to the butt joint, see diagram 10.13. If the measurement ‘Y’ exceeds 665mm, then the appropriate length of extension pipe is required. The minimum dimension is 187mm to suit a 75mm min wall thickness.
10 Standard Flue - Length, Preparation and Installation 12847 10.10 Flue Fitting IMPORTANT:The flue seals are sensitive to mineral oil based lubricants. Do not grease the seals. If the seals do need to be lubricated use only water. During the installation of the flue system, ensure that debris such as mortar, filings or swarf are cleared from the flue system before completion. Long lengths of flues must be secured to the walls or ceilings they run against.
10 Vertical Flue - Length, Preparation and Installation 10.11 Vertical flue The vertical flue system is available as an option where the boiler position does not permit the use of the top horizontal flue system. The system is made up from accessories. The accessories include terminal assembly, bends 45º and 87.5º, flue extensions, fixing bracket and appropriate weather collar, see diagram 10.19. Alternatively use 45º bends to avoid horizontal runs, see (b) in diagram10.18.
10 Vertical - Flue Length, Preparation and Installation 14849 Flue Installation IMPORTANT:The flue seals are sensitive to mineral oil based lubricants. Do not grease the seals. If the seals do need to be lubricated use only water. During the installation of the flue system, ensure that debris such as mortar, filings or swarf are cleared from the flue system before completion. Long lengths of flues must be secured to the walls or ceilings they run against.
10 Vertical - Flue Length, Preparation and Installation A ridge tile terminal is available - part no. A2043800, see diagram 10.20. 14853 Ridge Tile Terminal The installation of a ridge tile will be required. A suitable ridge tile is manufactured by: Aspect East Anglia Limited The Old Mill East Harling NORWICH NR16 2QW Website: www.aspectroofing.co.uk Contact: Chris Haythorpe General Manager - Tile Division Tel: 01953 717777 Fax: 01953 717164 Diagram 10.
Completion of Installation With the flue terminal positioned in the roof the length of the final pipe can be determined. If a telescopic length cannot be used, then a standard flue length can be cut to make the correct length. Cut the flue to the desired length measuring from the ‘O’ ring end and discard the plain end of the tube. The cuts must be square and made free of burrs to allow correct assembly.
15406 10 Twin Flue - Length, Preparation and Installation Secure long flue lengths (horizontal & vertical) to walls or ceiling at every joint or on straight flue runs at every joint and every metre flue run. Diagram 10.
10 Twin Flue - Length, Preparation and Installation 14869 10.12 Twin flue The twin flue system is available as an option when the top horizontal or vertical flue system is not appropriate. The system can provide an independent horizontal air inlet and flue outlet, horizontal air inlet and vertical flue outlet or vertical air inlet and flue outlet via a concentric terminal. The system is made up from accessories, see diagram 10.26. NOTE: The air and flue outlets do not have to be equal lengths.
10 Twin Flue - Length, Preparation and Installation 13240 Installation Details The parts available for a twin flue system installation are shown in diagram 10.26. Boiler Connection IMPORTANT: The flue seals are sensitive to mineral oil based lubricants. Do not grease the seals. If the seals do need to be lubricated use only water. Push the twin flue adaptor onto the outlet of the boiler with the air inlet to the left hand side, see diagram 10.27.
12997 10 Plume Management Kit 10.13 Plume Management Kit The Plume Management Kit: Part No. A2044100 (white) or A2044000 (black) can be used to overcome many site issues. The Plume Management Kit will fit to the Top Horizontal Telescopic, Rear Horizontal Telescopic and Standard Horizontal Flue. This enables the flue products to exhaust further away from the boiler, thereby reducing the impact of pluming.
11 Electrical Connection ● This appliance must be wired in accordance with these instructions. Any fault arising from incorrect wiring cannot be put right under the terms of the Glow-worm guarantee. 13368 WARNING: This appliance must be earthed. ● 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.
11 Electrical Connection 13488 11.2 System Controls 24V WARNING: UNDER NO CIRCUMSTANCES MUST ANY MAINS VOLTAGE BE APPLIED TO ANY OF THE TERMINALS ON THE 24V CONNECTION PLUG. Connect the mains supply and system heating controls e.g. room thermostat as diagram 11.2. External controls should be fitted in accordance with the rules in force. 11.3 Mains Voltage System Controls WARNING: UNDER NO CIRCUMSTANCES MUST ANY MAINS VOLTAGE BE APPLIED TO ANY OF THE TERMINALS ON THE 24V CONNECTION PLUG.
12 Commissioning 13476 No measurement of the combustion is necessary, having checked : ● the appliance has 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, diagram 12.1, is open.
12 Commissioning 13234 Additionally the safe nominal maximum heat input of the appliance can be achieved at an inlet pressure down to 15mbar. NOTE: 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. 13866 18 sxi 0.53 18.7 2.0 71.0 0.39 1.
12 Commissioning 13538 12.8 Instruct the User ● Demonstrate, then instruct the User about the lighting procedure and heating system controls operation. ● Advise the user on the use and maintenance of any scale reducer and pass on any relevant instructional documents. ● Advise that to ensure the continued efficient and safe operation of the boiler it is recommended that it is checked and serviced at regular intervals.
12 Commissioning - Nat. Gas (G20) to LPG (G31) Conversion 12.9 LPG CONVERSION - all models As an option, a chargeable boiler only commissioning service can be provided by Glow-worm Service by calling telephone No. 01773 828100. NOTE: Steps 12.1 and 12.3 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.
13 Servicing IMPORTANT NOTES: 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. 2. It is the Law that any servicing is carried out by a competent person approved at the time by the Health and Safety Executive. 3.
13 Servicing 1. Maximum Rate Check and Adjustment COMPLETION NOTE: To verify the maximum gas rate CO2 setting the appliance must be checked at the maximum rate first. Press the “reset” button on the controls fascia, release and immediately press and hold in the “+” button. After approximately 5 seconds “Hi” will be displayed.
13 Servicing 13.2 Spark Electrode 13.3 Burner Disconnect the spark electrode plug and earth lead, see diagram 13.5. Remove the two securing screws and withdraw the spark electrode carefully from the combustion chamber, see diagram 13.4. NOTE: Inspect the tips for damage. Clean away any debris and check the spark gap is 3.5 to 4.5 mm. Check the electrode gasket for signs of damage and replace if necessary. ● The following procedure will require that you replace the burner door seal and nyloc nuts.
13 Servicing 13527 Diagram 13.7 10063 13.4 Combustion Chamber and Heat Exchanger Remove loose debris from inside the heat exchanger using a soft brush and vacuum cleaner. Carefully flush by spraying water into the heat exchanger, any remaining debris should pass through the condensate trap (Ensure the water is kept away from electrical components). 13.
14 Fault Finding 13535 14.1 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 11.4 for access and diagram 14.4.
14 Fault Finding 13167 FAN b GAS CONTROL VALVE y w r HEATING RETURN THERMISTOR gy IGNITION ELECTRODE w IGNITER UNIT HEATING FLOW THERMISTOR bk r b bk WATER PRESSURE SENSOR r b g/y w or p PUMP bk g/y CHASSIS EARTH b br g/y bk KEY br b g/y gy bk y r w or p BROWN BLUE GREEN/YELLOW GREY BLACK YELLOW RED WHITE ORANGE PURPLE g/y b b g/y bk b br br bk w r r MAIN CONTROL BOARD APPLIANCE INTERFACE BOARD Diagram 14.
14 Fault Finding 13012 CENTRAL HEATING Diagram 14.
14 Fault Finding 13860 Fault Codes If -9OC is displayed, check that the thermistor wires are unconnected, faulty or trapped. Diagram 14.
14 Fault Finding 13447 Fault Codes (continued) Diagram 14.6 Diagnostic Menu The Diagnostic Menu provides the ability to view and change certain parameters. See Diagram 14.7 for available parameters. To enter the diagnostic menu: a) Press and hold the ‘MODE’ button for 5 seconds. The display will change to flashing ‘0’. c) Press ‘MODE’ to confirm, see diagnostic display 1. If necessary the values can be changed by: a) Pressing the ‘MODE’ button.
14 Fault Finding 13454 Diagnostic Menu - Level 1 Installer Access (see State Lists table) Indicates read and write function - all other diagnostics are read only Diagram 14.
14 Fault Finding 13011 State list - Accessed through Diagnostic Codes - Level 1, Installer Access d.99 STATE LISTS Central heating mode (Priority 3) S.00 S.01 S.02 S.03 S.04 S.05 S.06 S.07 S.08 Possible Causes no heating required fan pre-run pump pre-run ignition burner on pump / fan overrun fan overrun pump overrun Anti cycling period Domestic hot water mode (Priority 2) S.10 S.11 S.13 S.14 S.15 S.16 S.
15 Replacement of Parts IMPORTANT: The replacement parts described in sections 15.5 to 15.9 and section 15.12, will require the removal of the burner module assembly and the replacement of the burner door seal and self locking nuts. 13274 15.1 General 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.
15 Replacement of Parts 13276 15.5 Gas Valve For access, refer to section 15.1. Refer to section 13.3 for removal of the fan, gas valve and burner assembly. Before removing the gas valve note its orientation in relationship to the fan. Remove the three securing screws, which also secures the plastic swirl plate to the venturi on the fan, see diagram 15.2. Withdraw the gas valve. After assembly test for gas tightness and purge in accordance with the current issue of BS6891or in IE, the current edition of I.
15 Replacement of Parts 15.10 Viewing Window 15.13 Flue Hood For access, refer to section 15.1. For access, refer to section 15.1. Refer to diagram 15.5. Remove heat exchanger as per section 15.12. Remove circlip. Remove the two securing screws and pull the flue hood down and away from the flue hood bracket and flue elbow, see diagram 15.9. Remove steel washer. Remove glass. Remove fibre washer. 13279 Replace in reverse order. 15.11 Expansion Vessel For access, refer to section 15.1.
15 Replacement of Parts Remove the securing clip from the heat exchanger adapter, then disconnect the adapter and flexible hose. 15.14 Heating Flow Thermistor For access, refer to section 15.1. Lift the siphon adapter and hose out of the condensate trap and siphonic drain, do not disconnect the hose. Refer to diagram 15.10. Remove the electrical connections from the thermistor. Disconnect the drain connection. Remove the retaining clip from the flow pipe.
15 Replacement of Parts For access, refer to section 15.1. Drain the boiler heating circuit as described in the appropriate paragraph of 15.1. 13530 15.17 Pump (head only) CAP HEAD SCREW (4) Refer to diagram 15.12. Remove the four cap head screws. Carefully remove the pump head together with cable. Do not strain cable. CABLE COVER Support the pump head, unscrew cable cover at the side of pump head and take off. Disconnect wiring from pump head. Reconnect wiring to new pump head and fit cover.
15 Replacement of Parts For access, refer to section 15.1. Drain the boiler heating circuit as described in the appropriate section of 15.1. MAINTENANCE COVER RETAINING AUTOMATIC CLIP AIR VENT 13854 15.20 Low Water Pressure Sensor Refer to diagram 15.15. Disconnect the electrical leads. Remove the retaining clip, remove the low water pressure sensor. CABLE COVER Fit new ‘O’ ring. Fit the new low water pressure sensor. Refill vent and pressurise the boiler. 15.
15 Replacement of Parts Remove the 3 screws which retain the automatic bypass housing, refer to section 15.21. 15.22 Hydroblock and Bypass Tube For access, refer to section 15.1. IMPORTANT: To replace the bypass tube the LH and RH hydroblocks will need to be removed. The following procedure must also be used for the replacement of either the LH or RH hydroblock. Drain the boiler heating circuit as described in the appropriate section of 15.1.
15 Replacement of Parts 13535 15.23 Access User Interface and Main PCB For access, refer to section 15.1. Remove control box retaining screw, see diagram 15.18. Hinge down the control box. Release the control box cover by carefully pressing the four retaining clips, see diagram 15.18. 15.24 Main PCB IMPORTANT: When replacing the board refer to instructions supplied with the replacement. For access, refer to section 15.23. Remove the electrical connections to the PCB.
16 Spare Parts 16.1 Spare Parts When ordering spare parts, contact Glow-worm’s own service organisation using the telephone number on the inside front cover of this booklet. Please quote the name of the appliance and serial number, to be found on the data label. If ordering from British Gas also quote the G.C. number of the part. 60 Key No. Part No.
16 Spare Parts 13861 1 12 13 2 11 10 3 9 4 5 8 7 6 Diagram 15.
17 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.
0020020821-04 09.09 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 www.high-efficiency.
