Glowworm Ultracom 2 24cxi User manual

Supplied By www.heating spares.co Tel. [phone]
Ultracom2cxi
30cxi
G.C. No. 47-019-11
24cxi
G.C. No. 47-019-10
35cxi
G.C. No. 47-019-12
www.glow-worm.co.uk
Installation and Servicing
High Efficiency Condensing
Combination Boilers

Supplied By www.heating spares.co Tel. [phone]

Supplied By www.heating spares.co Tel. [phone]
- 1 -
INTRODUCTION
1 Instructions guidance.........................................................................................................................3
1.1 Product documentation...........................................................................................3
1.2 Associated documents ..........................................................................................3
1.3 Explanation of symbols...........................................................................................3
1.4 Guarantee registration............................................................................................3
2 Appliance description.........................................................................................................................3
2.1 Safety devices .......................................................................................................3
2.2 Data label ...............................................................................................................4
2.3 Gas category .........................................................................................................4
2.4 Regulation and statutory requirements ..................................................................4
2.5 Hydraulic schematic ..............................................................................................5
3 Safety instructions and regulations....................................................................................................6
3.1 Safety instructions..................................................................................................6
3.2 Regulations ............................................................................................................6
4 Recycling ...........................................................................................................................................7
4.1 Appliance................................................................................................................7
4.2 Packaging...............................................................................................................7
TECHNICAL DATA
5 Ultracom2cxi......................................................................................................................................8
INSTALLATION
6 Appliance location..............................................................................................................................9
6.1 Location..................................................................................................................9
6.2 Clearances .............................................................................................................9
6.3 Ventilation ..............................................................................................................9
7 Appliance installation ......................................................................................................................10
7.1 Scope of delivery..................................................................................................10
7.2 Recommendations before installing .....................................................................10
7.3 Dimensions...........................................................................................................12
7.4 Mounting ..............................................................................................................12
8 Hydraulic connection........................................................................................................................14
8.1 Gas and water connections..................................................................................14
8.2 Safety Discharge Valve ........................................................................................14
8.3 Connection to the condensate trap ......................................................................15
9 Evacuation of combustion gas.........................................................................................................17
9.1 Regulation ............................................................................................................17
9.2 Flue conguration description ..............................................................................19
10 Remove the front panel....................................................................................................................21
11 Electrical connections......................................................................................................................21
11.1 Access to main board ..........................................................................................21
11.2 Main board............................................................................................................21
11.3 Electrical wiring.....................................................................................................22
11.4 External accessories ............................................................................................23
11.5 Testing the electrical connections.........................................................................23
11.6 Wiring diagram .....................................................................................................24
TABLE OF CONTENTS

Supplied By www.heating spares.co Tel. [phone]
- 2 -
12 Commissioning ...............................................................................................................................25
12.1 Switching on.........................................................................................................25
12.2 Filling the CH system (Central heating)................................................................25
12.3 Filling DHW Circuit ...............................................................................................25
12.4 Filling the Condensate Trap .................................................................................25
12.5 Initial lighting.........................................................................................................26
12.6 Gas rates..............................................................................................................26
12.7 Testing heating system.........................................................................................27
12.8 Testing domestic hot water system.......................................................................27
12.9 Completion ...........................................................................................................27
13 Specic adjustment .........................................................................................................................28
13.1 Heating circuit adjustment ....................................................................................28
13.2 Appliance technical settings and parameter list ...................................................28
13.3 CO2 measurement...............................................................................................32
13.4 Re-check and restart............................................................................................32
14 User information...............................................................................................................................32
MAINTENANCE
15 Trouble-shooting..............................................................................................................................33
15.1 Fault diagnosis .....................................................................................................33
15.2 Fault memory........................................................................................................34
15.3 Fault codes...........................................................................................................34
15.4 Functional ow diagram........................................................................................36
16 Gas conversion adjustments............................................................................................................37
16.1 Settings.................................................................................................................37
16.2 Restart - re-check commissioning........................................................................38
17 Draining ...........................................................................................................................................38
17.1 Heating circuit ......................................................................................................38
17.2 Domestic Hot water circuit ...................................................................................38
18 Servicing..........................................................................................................................................39
18.1 Annual Maintenance.............................................................................................39
18.2 Casing removing...................................................................................................40
18.3 Combustion check and setting the air/gas ratio valve..........................................40
18.4 Servicing...............................................................................................................41
18.5 Silencer ................................................................................................................42
18.6 Expansion vessel..................................................................................................42
18.7 Heating lter .........................................................................................................43
18.8 Condensate trap...................................................................................................43
18.9 Combustion block.................................................................................................44
18.10 Service completion...............................................................................................45
19 Replacement of Parts ......................................................................................................................46
19.1 General.................................................................................................................46
19.2 Boiler Access........................................................................................................46
19.3 Viewing window....................................................................................................46
19.4 Hydraulic block.....................................................................................................48
19.5 Combustion block.................................................................................................50
19.6 Condensate trap...................................................................................................52
19.7 PCB......................................................................................................................53
20 Spare parts ......................................................................................................................................54
20.1 Short List of Parts.................................................................................................54
20.2 Short List of Parts.................................................................................................55
21 Manual Handling..............................................................................................................................56
22 Declaration of Conformity ................................................................................................................57
TABLE OF CONTENTS

Supplied By www.heating spares.co Tel. [phone]
0020085231_02 - 05/10 - Glow-worm - 3 -
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 ue guide
- 1 extended guarantee leaet
- 1 guarantee envelope pack
- 1 wall template
- 1 gas conversion label
1.3 Explanation of symbols
aDANGER: Risk of injuries.
eDANGER: Risk of electric shock.
bATTENTION: Risk of damage to the appliance or
to its surroundings.
iIMPORTANT: 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.
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 benet 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 Safety devices
2.1.1 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 tted 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.
aYour domestic water circuit (hot or cold) is not
protected by the boiler.
2.1.4 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.
INTRODUCTION

Supplied By www.heating spares.co Tel. [phone]
0020085231_02 - 05/10 - Glow-worm
- 4 -
2.2 Data label
The data label certies the country where the appliance is
intended to be installed.
Data label location:
1
Key
1 Data label
The data label contains the following data:
- The name of the manufacturer
- The country of intended destination
- The commercial name of the appliance and its serial number
- The types of ues installations authorised
- The appliance's gas category
- The gas type, group and pressure, set in the factory
- The DHW specic ow rate (D)
- The maximum pressure in the heating circuit (PMS)
- The maximum pressure in the domestic water circuit (PMW)
- 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
aThe appliance shall only be connected to the gas
type(s) indicated on the data label.
2.3 Gas category
This boiler is for use only on G20, but can be converted for use
on G31.
• To adapt the appliance to another type of gas, see the
chapter "Gas conversion".
2.4 Regulation and statutory requirements
2.4.1 CE Mark
This boiler meets the requirements of Statutory Instrument,
No. 3083 The Boiler (Efciency) Regulations, and therefore is
deemed to meet the requirements of Directive 92/42/EEC on
the efciency requirements for new hot water boilers red with
liquid or gaseous fuels.
Type test for purposes of Regulation 5 certied by: Notied
body 1312.
Product/production certied by: Notied body 0086.
The CE mark indicates that the appliances described in this
manual are in compliance with the following directives:
- European directive n°2009-142 relative to gas appliances
- European directive n°2004-108 from the European
Parliament and Council relative to electromagnetic
compatibility
- 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
2.4.2 Local regulations
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.
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.
INTRODUCTION

Supplied By www.heating spares.co Tel. [phone]
0020085231_02 - 05/10 - Glow-worm - 5 -
2.5 Hydraulic schematic
14
13
12
11
10
9
8
7
6
5
4
3
2
1
15
16
17
18
19
20
23
22
21
24
25
27
28
26
Key
1 Gas isolating valve
2 Heatingowisolatingvalve
3 Heating safety valve
4 Filteroncoldwaterinlet
5 By-pass
6 DHWowsensor
7 Domestic plate to plate heat exchanger
8 Heatinglter
9 Heating return thermistor
10 Condensate trap
11 Ignition and control electrode
12 Burner
13 Main heat exchanger
14 Thermal fuse
15 Flue outlet
16 Silencer
17 Heating expansion vessel
18 Fan
19 Gas control valve
20 Ignition module
21 Heatingowthermistor
22 Air vent
23 Pump
24 Threewayvalve
25 Water pressure sensor
26 Filling taps
27 Heating return isolating valve
28 Domesticcoldwaterisolatingvalve
A Heatingow
B Pipe for heating safety valve
C Domestichotwateroutlet
D Gas
E Coldwaterinlet
F Heating return
G Condensate drain
INTRODUCTION

Supplied By www.heating spares.co Tel. [phone]
0020085231_02 - 05/10 - Glow-worm
- 6 -
3 Safety instructions and regulations
3.1 Safety instructions
If the gas pressure at the input of the appliance is outside the
range specied, the appliance must not be put into operation.
eIncorrect installation can cause electric shock or
appliance damage.
• Never disable security devices and do not try to adjust them.
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.
• Be sure to consider the following handling techniques and
precautions:
- Grip the appliance at its base
- Use safety clothing where appropriate, e.g. gloves, safety
footwear.
• 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.
• Protect all the electrical components from water while
working on the appliance.
• Use only original spare parts.
• 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 Regulations
3.2.1 Statutory requirements
IMPORTANT
Where no British Standards exists, materials and equipment
should be t for their purpose and of suitable quality and
workmanship.
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.
Manufacturer’s instructions must not be taken as overriding
statutory requirements.
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 ttings) 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 specic 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 specication (CheSS) and
2) Controls for domestic central heating system and hot water.
BRECSU.
INTRODUCTION

Supplied By www.heating spares.co Tel. [phone]
0020085231_02 - 05/10 - Glow-worm - 7 -
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
uid, purge in accordance with the above standard.
Domestic Hot Water
All domestic hot water circuits, connections, ttings 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 identied 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).
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
iThe recycling of the packaging must be carried
out by the qualied professional who installed the
appliance.
4.1 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.
iBy complying with this directive, you will contribute
to the preservation of natural resources and the
protection of human health.
4.2 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.
INTRODUCTION

Supplied By www.heating spares.co Tel. [phone]
0020085231_02 - 05/10 - Glow-worm
- 8 -
TECHNICAL DATA
5 Ultracom2cxi
Boiler, type C13, C33, C43, C53
Description Unit 24 cxi 30 cxi 35 cxi
Gas category ll2H3P ll2H3P ll2H3P
SEDBUK rating % 90.3 90.3 90.4
Heating
Maximum heating input power kW 18.5 25 30.6
Minimum heating output
power at 80/60°C (P min.) kW 4.9 5.9 8.5
Maximum heating output
power at 80/60°C (P max.) kW 18.2 24.6 30
Minimum heating output
power at 50/30°C (P min.) kW 5.4 6.6 9.3
Maximum heating output
power at 50/30°C (P max.) kW 19.6 26.7 32.8
Minimum heating temperature °C 10 10 10
Maximum heating
temperature °C 80 80 80
Minimum heating ow rate l/h 400 400 400
Content of heating expansion
vessel l 8 8 8
gallons 1.76 1.76 1.76
Heating expansion vessel
preset pressure bar 0.75 0.75 0.75
psi 10.9 10.9 10.9
Maximum heating system
volume (approx) l 160 160 160
Heating safety valve preset
pressure (PMS) bar 2.5 2.5 2.5
lbf/in² 36/3 36/3 36/3
Domestic Hot Water
Minimum DHW output power
(P min.) kW 5.1 6.1 8.7
Maximum DHW output power
(P max.) kW 25.5 30.6 35.7
Maximum DHW temperature °C 60 60 60
Specic ow rate (∆T of 35 K)
EN 13203 l/min 10.4 12.5 14.6
Minimum inlet water pressure bar 0.3 0.3 0.3
psi 4.3 4.3 4.3
Maximum inlet water pressure bar 10 10 10
psi 145 145 145
Combustion
Appliance NOx class 5 5 5
Electrical
Electrical supply V/Hz 230V
50Hz 230V 50Hz 230V 50Hz
Standby mode electrical
power W 6 6 6
Operational mode electrical
power (Max) W 151 151 151
Internal fuse rating on main
PCB A 2 2 2
Index of electrical protection
(EN 60529) IPX4D IPX4D IPX4D
Description Unit 24 cxi 30 cxi 35 cxi
Gas connection Ø O.D. mm 15
(copper) 15 (copper) 15 (copper)
Heating flow and return
connection Ø O.D. mm 22 (copper) 22 (copper) 22 (copper)
Domestic Hot Water
connection Ø O.D. mm 15 (copper) 15 (copper) 15 (copper)
Condensate connection Ø I.D. mm 21.5
(plastic) 21.5 (plastic) 21.5 (plastic)
Safety valve discharge
connection Ø O.D. mm 15 (copper) 15 (copper) 15 (copper)
Lift weight kg 37 38 38
lb 82 83 84.5
Total weight (installed) kg 42 43 43
Number of CE certicate 1312 BU
5334
1312
BU
5335
1312
BV
5336
Description Unit 24 cxi 30 cxi 35 cxi
Natural Gas G 20 (15 °C, 1013.25 mbar)
Maximum DHW gas ow rate m3/h 2.70 3.24 3.77
Maximum heating gas ow
rate m3/h 1.96 2.65 3.24
Minimum gas ow 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%
Inlet pressure mbar 20 20 20
Propane Gas G 31 (15 °C, 1013.25 mbar)
Maximum DHW gas ow rate kg/h 1.98 2.38 2.77
Maximum heating gas ow
rate kg/h 1.44 1.94 2.37
Minimum gas ow 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%
CO2 at Qmin +
"tolerance case ON" %9.8 ± 0.3% 9.8 ± 0.3% 9.8 ± 0.3%
CO2 at Qmin +
"tolerance case OFF" %9.6 ± 0.2% 9.6 ± 0.2% 9.6 ± 0.2%
Inlet pressure mbar 37 37 37
TECHNICAL DATA

Supplied By www.heating spares.co Tel. [phone]
0020085231_02 - 05/10 - Glow-worm - 9 -
INSTALLATION
iAll the drawings dimensions are shown in mm.
6 Appliance location
6.1 Location
6.1.1 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.
• 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 ue can be accessed and inspected (see
chapter Clearances).
• Explain these requirements to the appliance user.
• 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.
• The boiler must be tted inside the property and exposed
pipe work may need to be protected from frost by tting a
frost thermostat.
6.1.2 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.
Timber Frame Buildings
If the boiler is to be installed in a timber frame building it should
be tted 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 benecial around the boiler for
installation and servicing.
For ue installations where external access is not practicable,
consideration should be given for the space required to insert
the ue from inside the property, which may necessitate
clearance larger than those specied in diagram below.
ØA
ØA + 5 min.
600*
min.
0
min.
0
min.
200
min.
150
min.
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xedsurface.
The boiler and ue are suitable for installation onto and through
combustible materials provided that:
- Minimum 5mm clearance is maintained around the
circumference of the ue (air intake).
- The combustible surface and xings are suitable for
supporting the load.
- The minimum clearances from the boiler case are
maintained.
6.3 Ventilation
6.3.1 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 efciency and low casing temperature of this
boiler, cupboard or compartment ventilation is not necessary.
• Existing ventilation should be investigated for its purpose
before removing.
INSTALLATION

Supplied By www.heating spares.co Tel. [phone]
0020085231_02 - 05/10 - Glow-worm
- 10 -
7 Appliance installation
7.1 Scope of delivery
The appliance is delivered in a single carton with a document
pack and ttings.
iThe ues package will be ordered according to the
conguration of the installation.
• Please check the contents.
1 4.7
2.1
2
2.2
2.3 2.5
2.6
3
2.4
4
4.1
4.2
4.3
4.4
4.5
4.6
Key
1 Boiler (x1)
2 Accessories bag (x1)
2.1 Pressure relief valve connecting pipe (x1)
2.2 Connection bag (x1)
- Heating return valve (x1)
  -Coldwaterinletvalve (x1)
  -Heatingowvalve (x1)
  -Domestichotwaterconnection (x1)
- Gas isolation valve (x1)
2.3 Hanging bracket (x1)
2.4 Filling loop extensions (x2)
2.5 Seals bag (x1)
- Flat seal ½" (x2)
- Flat seal ¾" (x5)
  -Flatsealforcoldwaterinlet¾" (x4)
2.6  Compressiontting (x1)
3 Wall template (x1)
4 Documents bag (x1)
4.1 Installation and servicing manual (x1)
4.2 Flue book (x1)
4.3 Instructions for use (x1)
4.4  Extendedguaranteeleaet (x1)
4.5 Guarantee envelope pack (x1)
4.6 Magnetic lighting instruction label (x1)
4.7 Gas conversion label (x1)
7.2 Recommendations before installing
7.2.1 Domestichotwatercircuitdesign
Water pressure
The minimum working pressure to obtain the maximum
domestic ow 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 tted 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 tted, refer to the manufacturer’s instructions or consult the
local water company for additional advice.
Domestic water ow rate
The domestic hot water ow has a restrictor, factory tted,
which reduces the ow to a maximum of:
- 24cxi ►8 l/min,
- 30cxi ►10 l/min,
- 35cxi ►12 l/min.
INSTALLATION

Supplied By www.heating spares.co Tel. [phone]
0020085231_02 - 05/10 - Glow-worm - 11 -
7.2.2 Heating circuit design
5
4
3
2
1
6
8
7
9
10
11
Key
1 Drain point
2 External bypass (if required)
3 Domestichotwaterout
4 Domesticcoldwatersupplyin
5 Boiler
6 Filling 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owcircuit
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 tted
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.
iThe 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.
- In IE, current edition of I.S.813 “Domestic Gas Installations”.
Bypass
The boiler is tted with an automatic bypass which can be
adjusted to suit your system requirements.
• Ensure that under no circumstances does the ow rate drop
below the gure specied, refer to chapter "Technical data".
Filling the sealed system
iThe water pressure at the boiler must be at least
1.2bar to operate the lling loop. If the pressure
is less than 1.2bar an external lling loop must be
tted. If this pressure is not available contact the
local water authority.
Suitable external lling systems are shown diagrammatically,
see diagram below.
3
2
1
3
2
1
4
8
9
7
5
7 6
5
Key
1 Heatingowcircuit
2 Heating return circuit
3 Boiler
4 Double check valve assembly
5 Domesticcoldwatersupplyin
6 Temporaryllingloop(removeimmediatelyafterlling)
7 Drain point
8 Backowpreventiondevice
9 Tundish
The system should be pressurised to 0.8bar, indicated on the
digital display with no heating demand.
INSTALLATION

Supplied By www.heating spares.co Tel. [phone]
0020085231_02 - 05/10 - Glow-worm
- 12 -
Drain points
Drain taps must be provided at all low points of the system,
which will allow the entire system to be drained.
Drain taps shall be to the current issue of BS2879.
Water treatment
Existing system- It is essential that prior to installing the new
boiler the system is thoroughly ushed.
Newsystem- For optimum performance after installation, the
boiler and its associated central heating system should also be
ushed.
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 ush existing systems rst before tting
the new boiler.
• Ensure all cleanser is removed from the whole system before
adding an inhibitor.
For long-term corrosion protection after ushing, an inhibitor
suitable for stainless steel heat exchangers can be used. Either
Sentinel X100 or Fernox F1 inhibitor can be used.
The boiler is suitable for use on systems using softened water.
7.3 Dimensions
418
344
130
346
740
7.4 Mounting
• Make sure that the equipment used for implementing the
installation is compatible with that of the appliance.
• Determine the assembly location. See the "Appliance
location" chapter.
735 709
63***
160 160
=246=
170
Ø105**
Ø125*
65 65
58
58
* 80/125ue►Ø150mm
** 80/125ue►Ø130mm
*** 80/125ue►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 ue you are tting.
INSTALLATION

Supplied By www.heating spares.co Tel. [phone]
0020085231_02 - 05/10 - Glow-worm - 13 -
7.4.1 Fixingtothewall
130
90°
4
5
6
2
1
3
Key
1 Wall template
2 Standarduelengthhorizontal
3 2.5°44mm/metreinclinedextendeduelength
4 Wall plug
5 Hanging bracket
6 Screw(notsupplied)
Flue hole cutting
• Mark the position of the ue centre.
• Remove the wall template, then drilling the ue hole.
iThe ue 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 ue
installation (60/100 ue) (80/125 ue ► Ø130mm).
• Use a 125mm diameter core drill for internal access only ue
installation (60/100 ue) (80/125 ue ► Ø150mm).
iIf ue 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.
• If tting a side ue, extend the ue centre line into the corner
then 130mm along the adjacent wall.
• If tting an extended side ue, determine the ue 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 ue should then be marked at 130mm from the back wall.
To allow for the ue passing through the wall at this angle
a 125mm hole should be drilled irrespective of internal or
external installation.
Hanging bracket xing
Due to the varied site conditions, xings are not supplied and
advise that the installer should supply those which are suitable.
• Drill the holes for the xing screws in accordance with the
wall template.
• Fix the hanging bracket on the wall.
7.4.2 Boiler hanging
aWith 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
1
Key
1 Boiler
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
INSTALLATION

Supplied By www.heating spares.co Tel. [phone]
0020085231_02 - 05/10 - Glow-worm
- 14 -
8 Hydraulic connection
8.1 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”.
iThe 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 ushing.
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.
aDo 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 tting them to
the boiler.
• Only use original seals supplied with the appliance.
• Check that there are no leaks. Repair if necessary.
1
2
3
4
5
6
7
6
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owisolatingvalve+sealingwasher¾"
6 ConnectionØO.D.22mm
7 ConnectionØO.D.15mm
• Remove the protective caps from the boiler connections.
• Flush out the domestic hot water and the heating systems.
iBefore turning on the cold mains supply to the boiler
turn off the cold water inlet to the boiler, lock the lling
loop in the closed position and close its lling taps.
8.2 Safety Discharge Valve
B
A
3
4
2
1
Key
1 Compressiontting
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 tting to extend the safety discharge valve tube.
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.
INSTALLATION

Supplied By www.heating spares.co Tel. [phone]
0020085231_02 - 05/10 - Glow-worm - 15 -
8.3 Connection to the condensate trap
aCondensate produced by the appliance is mildly
acidic (pH 3.5 - 5.0). Use protective gloves
bCondensate must only be discharged in
accordance with these instructions.
iThe 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 tted.
• Connect the condensate pipe (1).
iThe 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.
INSTALLATION

Supplied By www.heating spares.co Tel. [phone]
0020085231_02 - 05/10 - Glow-worm
- 16 -
INSTALLATION

Supplied By www.heating spares.co Tel. [phone]
0020085231_02 - 05/10 - Glow-worm - 17 -
9 Evacuation of combustion gas
9.1 Regulation
bOnly ue accessories supplied by Glow-worm
must be used.
Different ue outlet congurations can be carried out.
• Consult your supplier for more information about the other
possibilities and associated accessories.
44 mm/m 1 2
34
• Standard ue terminal kits have an in-built fall back to the
boiler to drain the condensate. These can be tted level
between the appliance and the termination position. All other
extended ues must have a fall of at least 44mm/m
The maximum length of the ue outlet is dened according to its
type (for example C13).
• Whatever the kind of ue system chosen, observe the
minimum distances indicated in the chart below to position
the ue terminals.
• To install the ue, refer to the separate ue instruction
supplied with your appliance.
• Explain these requirements to the user of the appliance.
aIf necessary, you must install a terminal
protection kit.
bCaution! The connection between the ue elbow
and the ue 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 ue 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 ue 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.
bIf the ue terminal is positioned near a light
source insects may enter the ue system.
Where safe and practical to do so advise the
homeowner to check the ue outlet and clear
visible insects from the terminal end.
INSTALLATION

Supplied By www.heating spares.co Tel. [phone]
0020085231_02 - 05/10 - Glow-worm
- 18 -
Position Positionoftheueterminal mm
Horizontalues
Adirectly below an opening, air brick,
opening windows 300
B above an opening, air brick, opening windows 300
Chorizontally to an opening, air brick, opening
windows 300
D below gutter, drain/soil pipe 25
E below eaves 25
F below a balcony or car port 25
G from vertical drain pipes and soil pipes 25
H from internal/external corners 25
H* to a boundary alongside the terminal 300
Iabove adjacent ground or balcony level 300
J* from surface or a boundary facing the terminal 600
Position Positionoftheueterminal mm
Lfrom opening (door/window) in car port
into dwelling 1200
M vertical from a terminal 1500
N horizontally from a terminal 300
Verticalues
P from another terminal 600
Q above roof level 300
Rfrom adjacent opening window 1000
Sfrom adjacent wall to ue 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.
INSTALLATION