Glowworm Ultracom2 sxi User manual

condens
Ultracom2 sxi
12sxi
G.C. No. 41-019-12
18sxi
G.C. No. 41-019-13
30sxi
G.C. No. 41-019-14
Installation
and Servicing

- 1 -

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

5 Ultracom2sxi......................................................................................................................................8

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........................................................................................................... 11
7.4 Mounting..............................................................................................................12
8 Hydraulicconnection........................................................................................................................13
8.1 Gasandwaterconnections..................................................................................13
8.2 SafetyDischargeValve........................................................................................14
8.3 Connectiontothecondensatetrap......................................................................14
9 Evacuationofcombustiongas.........................................................................................................16
9.1 Regulation............................................................................................................16
9.2 Fluecongurationdescription..............................................................................18
10 Removethefrontpanel....................................................................................................................19
11 Electricalconnections......................................................................................................................19
11.1 Accesstomainboard..........................................................................................20
11.2 Mainboard............................................................................................................20
11.3 Electricalwiring.....................................................................................................20
11.4 Externalaccessories............................................................................................22
11.5 Testingtheelectricalconnections.........................................................................22
11.6 Wiringdiagram.....................................................................................................23


- 2 -
12 Commissioning...............................................................................................................................24
12.1 Switchingon.........................................................................................................24
12.2 FillingtheCHsystem(Centralheating)................................................................24
12.3 FillingtheCondensateTrap.................................................................................24
12.4 Initiallighting.........................................................................................................24
12.5 Gasrates..............................................................................................................25
12.6 Testingheatingsystem.........................................................................................26
12.7 Testingdomestichotwatersystem.......................................................................26
12.8 Completion...........................................................................................................26
13 Specicadjustment.........................................................................................................................26
13.1 Heatingcircuitadjustment....................................................................................26
13.2 Appliancetechnicalsettingsandparameterlist...................................................27
13.3 CO2measurement...............................................................................................30
13.4 Re-checkandrestart............................................................................................30
14 Userinformation...............................................................................................................................30

15 Trouble-shooting..............................................................................................................................31
15.1 Faultdiagnosis.....................................................................................................31
15.2 Faultmemory........................................................................................................32
15.3 Faultcodes...........................................................................................................32
15.4 Functionalowdiagram........................................................................................34
16 Gasconversionadjustments............................................................................................................34
16.1 Settings.................................................................................................................35
16.2 Restart-re-checkcommissioning........................................................................35
17 Draining...........................................................................................................................................36
17.1 Heatingcircuit......................................................................................................36
18 Servicing..........................................................................................................................................36
18.1 AnnualMaintenance.............................................................................................36
18.2 Casingremoving...................................................................................................37
18.3 Combustioncheckandsettingtheair/gasratiovalve..........................................37
18.4 Servicing...............................................................................................................39
18.5 Silencer................................................................................................................39
18.6 Expansionvessel..................................................................................................39
18.7 Condensatetrap...................................................................................................40
18.8 Combustionblock.................................................................................................41
18.9 Servicecompletion...............................................................................................42
19 ReplacementofParts......................................................................................................................42
19.1 General.................................................................................................................43
19.2 BoilerAccess........................................................................................................43
19.3 Viewingwindow....................................................................................................43
19.4 Hydraulicblock.....................................................................................................44
19.5 Combustionblock.................................................................................................46
19.6 Condensatetrap...................................................................................................48
19.7 PCB......................................................................................................................49
20 Spareparts......................................................................................................................................49


0020112600_02-10/12-Glow-worm
- 3 -
INTRODUCTION

 
 
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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
 
aDANGER: Risk of injuries.
eDANGER: Risk of electric shock.
bATTENTION: Risk of damage to the appliance or
to its surroundings.
iIMPORTANT: Important information.
 
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
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.
 
 
 
Theapplianceisdesignedtorecognisethepotentialforan
overheatlockoutandwillshutdownbeforethishappens.
 
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3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.
 
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.
 
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.

0020112600_02-10/12-Glow-worm
- 4 -
INTRODUCTION
 
Thedatalabelcertiesthecountrywheretheapplianceis
intendedtobeinstalled.
Datalabellocation:
1

 
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maximumpressureintheheatingcircuit(PMS)
- 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.
 
ThisboilerisforuseonlyonG20,butcanbeconvertedforuse
onG31(except12sxi).
• Toadapttheappliancetoanothertypeofgas,seethe
chapter"Gasconversion".
 
 
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
 
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.

0020112600_02-10/12-Glow-worm
- 5 -
INTRODUCTION
 
1
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89
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
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

0020112600_02-10/12-Glow-worm
- 6 -
INTRODUCTION
 
 
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.
 
 
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).
-AnyelectricalworkmustconformtoBS7671andwhere
applicablePartPofthebuilding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.

0020112600_02-10/12-Glow-worm
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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
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).
 
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.
 
iThe recycling of the packaging must be carried
out by the qualied professional who installed the
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.
 
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.

0020112600_02-10/12-Glow-worm
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TECHNICALDATA

 
Boiler,typeC13,C33,C43
    
Gascategory l2H l2H l2H
SEDBUK2005rating % 90.4 90.4 90.5
SEDBUK2009rating % 89.5 89.1 89.4

Maximumheatinginputpower kW 12.3 18.5 30.6
Minimumheatingoutput
powerat80/60°C(Pmin.) kW 3.9 4.9 8.5
Maximumheatingoutput
powerat80/60°C(Pmax.) kW 12 18.2 30
Minimumheatingoutput
powerat50/30°C(Pmin.) kW 4.4 5.4 9.3
Maximumheatingoutput
powerat50/30°C(Pmax.) kW 13.2 19.6 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 3 3 3
psi 36/3 36/3 36/3

ApplianceNOxclass 5 5 5

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
    
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)
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 37.1 37.1 38.3
lb 81.8 81.8 84.5
Totalweight(installed) kg 42 43 43
NumberofCEcerticate
1312
BU
5333
1312
BU
5334
1312
BV
5336
    

Maximumheatinggasow
rate m/h 1.3 1.96 3.24
Minimumgasowrate m/h 0.43 0.54 0.92
CO2atQmax+"tolerance
caseON" %9.2± 0.3%
9.2±
0.3%
9.2±
0.3%
CO2atQmax+"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

Maximumheatinggasow
rate kg/h - 1.44 2.37
Minimumgasowrate kg/h - 0.4 0.67
CO2atQmax+"tolerance
caseON" % - 10.3± 0.3%
10.3±
0.3%
CO2atQmax+"tolerance
caseOFF" % - 10.1± 0.2%
10.1±
0.2%
CO2atQmin+
"tolerancecaseON" % - 9.8± 0.3%
9.8±
0.3%
CO2atQmin+
"tolerancecaseOFF" % - 9.6± 0.2%
9.6±
0.2%
Inletpressure mbar 37 37 37

0020112600_02-10/12-Glow-worm
- 9 -
INSTALLATION

iAll the drawings dimensions are shown in mm.
 
 
 
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.
 
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.
thisisthecurrentI.E.E.WIRINGREGULATIONSand
BUILDINGREGULATIONS.
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.
 
• 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.
600*
min.
0
min.
0
min.
200
min.
150
min.

 


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.
 
 
Theboilerisroomsealedsoapermanentairventisnotrequired.
 
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.

0020112600_02-10/12-Glow-worm
- 10 -
INSTALLATION
 
 
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.
2.4
2.3
2.2
2.1
234
4.1
4.2
4.3
4.4
4.5
4.64.7
1

  
  
   
   
   
   
   
   
   
   
   
  
  
   
   
   
   
   
   
   
 
 
1
2
3
4
5
6

 
 
 
 
 
 
General
Thisboilerisdesignedtoprovidecentralheatingfromasealed
watersystemwithafullyindirectcylinder.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”.

0020112600_02-10/12-Glow-worm
- 11 -
INSTALLATION
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.
1
2
3
3
2
17
9
8
5
6
5
4
7

 
 
 
 
 
 
 
 
 
Thesystemshouldbepressurisedto0.8bar,indicatedonthe
digitaldisplaywithnoheatingdemand.
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
-Itisessentialthatpriortoinstallingthenew
boilerthesystemisthoroughlyushed.
-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.
 
418
344
130
346
740

0020112600_02-10/12-Glow-worm
- 12 -
INSTALLATION
 
• 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
156
160 160
Ø105*
Ø125*
Ø130**
Ø150**
=246=
170
65 65
58
58
 
 
• 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.
 
130
90°
6
5
4
1
2
3

 
 
 
 
 
 
Flue hole cutting
• Markthepositionoftheuecentre.
• Removethewalltemplate,thendrill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.

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- 13 -
INSTALLATION
 
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

 
 
• 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
 
 
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-solder 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
4

 
 

 
 
 
• UseonlytheoriginalgasserviceisolationvalvetypeGER/1
DN15,CE-0085CL0082
• Useonlytheolivewhichisdeliveredwiththegasisolation
valve
• Useonlyoriginalsealingwashers
• Removetheprotectivecapsfromtheboilerconnections.
• Flushoutthedomestichotwaterandtheheatingsystems.

0020112600_02-10/12-Glow-worm
- 14 -
INSTALLATION
 
B
A
3
2
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.
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.
 
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

 
• 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
• Connecttheboilercondensatedrain(1)toacondensate
dischargepipewhichshouldbeminimumof19mm
internaldiameterandbemadeofanacidresistantmaterial
(e.g.plasticoverowpipe).Donotusemetalpipes.Itis
permissibletouseacondensateneutraliserprovidingthatit
ischeckedforcorrectoperation.

0020112600_02-10/12-Glow-worm
- 15 -
INSTALLATION

0020112600_02-10/12-Glow-worm
- 16 -
INSTALLATION
 
 
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
4 3
• 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.
theminimumacceptablesitingdimensionsforthe
terminalfromobstructions,otherterminalsandventilation
openingsareshownindiagramoverleaf.
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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.

0020112600_02-10/12-Glow-worm
- 17 -
INSTALLATION
  

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
I aboveadjacentgroundorbalconylevel 300
  
J* fromsurfaceoraboundaryfacingtheterminal 600
Lfromopening(door/window)incarport
intodwelling 1200
M verticalfromaterminal 1500
N horizontallyfromaterminal 300

P fromanotherterminal 600
Q aboverooflevel 300
R fromadjacentopeningwindow 1000
S from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.

0020112600_02-10/12-Glow-worm
- 18 -
INSTALLATION
 
 

aIf necessary, you must install a terminal
protection kit.
Ø 60/100 mm
L
63
1


Ø 80/125 mm
L
1


 



Ø60/100 10m
Ø80/125 20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
 



Ø60/100 10m
Ø80/125 20m 25m
Eachtimeanadditional90°bendisnecessary(or2at45°),the
length(L)mustbereducedby1m.
 

bThe ue connecting from the appliance to
the ue system must be supplied from the
manufacturer of the boiler.
bC43 ue systems must not be a 'pressurised
system' but act under natural draught principles
bC43 type ue systems must have their
own condensate drain tted and not allow
condensate to mix into other appliances