Glowworm Xtrafast 96 Operating manual

2000221595.11.01
Hepworth Heating Ltd.,
Nottingham Road, Belper, Derbyshire. DE56 1JT
General/Sales enquiries:
Tel: [phone] Fax: [phone]
One Contact Local Service
Customer Services:
Tel: [phone]
Fax: [phone]
Instructions for Use
Installation and Servicing
To beleftwiththeuser
This is a Cat II2H3+ Appliance
❑
✔
❑
✔
❑
✔
All replacement parts
All labour charges
All call-out charges
Guarantee Registration
REGISTER YOUR GLOW-WORM APPLIANCE
FOR 1ST YEAR GUARANTEE PROTECTION
CALL 0208 247 9857
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 First Year Guarantee.
In the centre pages are to be found your Guarantee Registration Card, which we recommend you complete and
return as soon as possible.
If this card is missing you can obtain a copy or record your registration by telephoning the Heatcall Customer
Service number 01773 828100.
Our Guarantee gives you peace of mind plus valuable protection against breakdown by covering the cost of:
The instructions consist of three parts, User, Installation and Servicing Instructions, which include the Guarantee Registration Card.
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.
Fanned Flue Combination Boiler
G.C. No. 47-047-25 G.C. No. 47-047-26
96 120
Hab 255a

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2000221595
Testing and Certification
This boiler is tested and certificated for safety and performance. It is therefore important that no alteration is made to the boiler,
without permission, in writing, from Hepworth Heating Ltd.
Any alteration not approved by Hepworth Heating Ltd., could invalidate the certification, boiler warranty and may also infringe the
current issue of the Statutory Requirements. The requirements are: The installation of this boiler must be carried out by a
competent person in accordance with the current rules in force in the countries of destination at the time of installation.
Manufacture's instructions supplied. Manufacture's instructions must not be taken as overriding statutory requirements.
Note: The boiler serial number is marked on the label attached to the inside of the drop down door. Refer to the
'Introduction' section for a description of the basic functions of the boiler. The 'Users' section describes how to safely operate the
boiler.
Mandatory warning for CEE countries
Warning: This appliance is designed, approved and inspected to meet the requirements of the market. The identification plate
located on the inside of the appliance certifies the origin where the product was manufactured and the country for which it is
intended.
If you see any exception to this rule, please contact your nearest Glow-worm dealer.
Thank you in advance for your assistance.
CE Mark
This boiler meets the requirements of Statutory Instrument No. 3083 The boiler (Efficiency) Regulations, and therefore is
deemed to meet the requirements of Directive 92/42/EEC on the efficiency requirements for new hot water boilers fired with
liquid or gaseous fuels.
Type test for purposes of Regulation 5 certified by: Notified body ****.
Product/production certified by: Notified body ****.
The CE mark on this appliance shows compliance with:
1. Directive 90/396/EEC on the approximation of the laws of the Member States relating to appliances burning
gaseous fuels.
2. Directive 73/23/EEC on the harmonization of the Laws of the Member States relating to the electrical equipment
designed for use within certain voltage limits.
3. Directive 89/336/EEC on the approximation of the Laws of the Member States relating to electromagnetic
compatibility.
Substances Hazardous to Health
The adhesives and sealants used in this appliance are cured and give no known hazard in this state.
INSULATION PADS/CERAMIC FIBRE, GLASSYARN, MINERAL WOOL
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.
The insulation is composed of non-combustible material.
Spare Parts
REMEMBER, When replacing a part on this appliance, use only spare parts that you can be assured conform to the safety and
performancespecificationthatwerequire. DonotusereconditionedorcopypartsthathavenotbeenclearlyauthorisedbyHepworth
Heating Ltd.
Important Information

32000221595
Introduction 4
Controls and Lighting 5
Clock-timer instructions for use 6
Draining 6
Safety Devices 6
Servicing and Maintenance 7
Technical Data 1 8
Dimensions 2 9
Heating System Design 3 9
Domestic Hot Water System Design 4 10
Boiler Schematic 5 10
Boiler Location, Flue and Ventilation 6 11
Fixing Jig Pack 7 12
Piping System Installation 8 12
Boiler Installation 9 14
Flue Installation 10 14
Electrical Connection 11 17
Commissioning 12 18
Safety Devices 13 22
Changing Gas Type 14 22
Settings 15 23
Routine Cleaning and Inspection 17 24
Fault Finding 18 27
Wiring Diagram 19 29
Replacement of Parts 20 30
Spare Parts 21 40
CONTENTS DESCRIPTION SECTION PAGE No.
SERVICING
INSTRUCTIONS
INSTALLATION
INSTRUCTIONS
INSTRUCTION
FOR USE
Contents

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2000221595
1.5
1
The XTRAFAST96and120 boilerisawallmountedmodulating
combination boiler with electronic ignition providing central
heating and instantaneous hot water. The boiler is equipped
with a 4 litre domestic hot water storage vessel that ensures
maximum hot water temperature stability during domestic
demand.
TheboilerisoftheII2H3+ categoryforusewithNaturalGas(G20)
as distributed in the United Kingdom.
Theboilerhasafanassistedbalancedfluewhichbothdischarges
the products of combustion to and draws the combustion air
from the outside of the room.
The boiler is suitable for top outlet flue connection only.
Both the central heating and domestic hot water temperature
are user adjustable from the boiler control panel.
Domestic hot water demand always has priority over heating
demand.
The boiler is designed for use as part of a sealed water central
heating system with fully pumped circulation. The pump,
expansion vessel and associated safety devices are all fitted
within the boiler.
The boiler can be installed against either an external wall or on
anadjacentinside wall,thatis,thefluesystemwillpassdirectly
to the rear or to either side to the terminal fitted on the outside
wall face.
The installation must be carried out by a competent person in
accordance with the relevant requirements of The Building
Regulations, The Water Byelaws, The Building Standards
(Scotland) Regulations and any applicable local regulations.
Theseinstructionsshouldbecarefullyfollowedfor thesafeand
economical use of your boiler.
Electrical Supply
WARNING: This boiler must be earthed.
All system components shall be of an approved type and shall
be connected in accordance with the current issue of BS7671
and any applicable local regulations.
All external wiring between the appliance and the electrical
supplyand earthingrequirements shallcomplywiththecurrent
IEE Regulations.
Connection of the boiler and system controls to the mains
supply must be through a common isolator and must be fused
3A, maximum. This method of connection must be by a fused
doublepoleisolatingswitch,withaminimumcontactseparation
Introduction
of3mmonbothpoles. Theswitchshould bereadily accessible
and preferably adjacent to the appliance. It should supply the
appliance only and be easily identifiable as so doing.
Alternatively, an unswitched shuttered socket outlet and 3A
fused 3 pin plug, both to the current issue of BS1363 may be
usedprovidedthattheyarenotusedinaroomcontainingabath
or shower.
Wiringtothe boiler mustbePVC 85oC insulatedcable, not less
than 0.75mm2(24/0.20mm).
Gas safety (Installation and use) Regulations
Inyourinterestsandthatofgas safety,itisthelawthatALL gas
appliances are installed and serviced by a qualified registered
person in accordance with the above regulations.
Gas leak or fault
Ifagasleakorfaultexistsorissuspected,turntheboileroffand
consult the local gas supply company or your installation/
service company.
Air in the heating system
Persistent air in the heating system may indicate leaks in the
systemorcorrosiontakingplace.CallyourInstallation/Servicing
company.
Overheating safety
Intheeventofaproblem,theoverheatingsafetydevicescause
safety shutdown of the boiler. If this happens, call your
Installation/Servicing company.
Boiler controls
Thecontrolpanel,locatedatthelowerfrontoftheboilercasing,
see diagram 1, allows the boiler to be started, shut down,
controlled and monitored during use.
Flue
Do not obstruct the outside terminal of the boiler.
Ancillary equipment
A range of flue accessories are available including vertical
flues, twin-pipe flues, bends etc.
For further information contact your supplier.
1 - On/Off button
2 - Summer/Winter mode selector
3 - Hot water temperature adjuster
4 - Hot water set point display
5 - Graphic display
6 - Heating temperature adjuster
7 - Heating set point display
8 - Display backlight
9 - Clock-timer
(refer to clock-timer
instructions for use).
Diagram 1
9900

52000221595
Controls and Lighting
Appuyer sur +ou -pour ajuster la température
maximale souhaitée du circuit chauffage
60°C
Visualisation de la température demandé
e
Appuyer sur +ou -pour ajuster la température
maximale de l'eau chaude sanitaire (38°C à 60°C)
Visualisation de la température demandée
50°C
Appuyer sur mode pour sélectionner la position été
1.5 bar
Appuyer sur mode pour sélectionner la position hiver
Température actuelle
dans le circuit chauffage
1.5 bar
10 °C
Apparaît lorsque le brûleur
est en fonctionnement
Apparaît lorsque le
brûleur fonctionne
mode
mode mode
mode
To stop the boiler : Press button (1)
Adjusting the hot water temperature Adjusting the heating temperature
Lighting the boiler :
Make sure that:
•The boiler is connected to the electrical supply.
•The gas service cock is open.
Then follow the instructions below :
Press the On/Off button (1)
Hab 264
1
IO
1.5 bar
mode
0
1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
A
The pressure must be between 1 and 2 bar. If not, the system must be filled by a competent person.
Setting to the SUMMER position
(Hot water only)
Setting to the WINTER position
(Heating + hot water)
B
Press the mode button to select the summer symbol Press the mode button to select the winter symbol
The flame symbol appears
when the boiler is running
The actual temperature
of the heating system
Illuminates when
the boiler lights
Hab 261
Press + or - to adjust the maximum temperature
of the hot water (38 ° C to 60 ° C) Press + or - to adjust the maximum temperature
of the heating (38 ° C to 87 ° C)
C
To obtain domestic hot water, open a hot water tap. Hot water always has priority over central heating.
Visual indication of set temperature Visual indication of set temperature

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2000221595
Clock-timer instructions for use
The boiler must be conected to the electrical supply and
switched on.
Setting the time
Rotate the clock actuater mechanism clockwise, by hand, until
the current time is indicated by the arrow, see diagram 2.
Note: The time is set in 24 hour format, for example, 1300 for
1pm.
Setting the programme "On" and "Off" times
• Select the "On" times by pushing the white tappets to the
outside, see diagram 2.
•Selectthe'Off'timesbypushingthewhitetappetstotheinside,
see diagram 2.
The clock shown in diagram 2 is set as follows:
ON - 07.00am to 09.00am (7-9)
OFF - 09.00am to 4.00pm (9-16)
ON - 4.00pm to 10.00pm (16-22)
OFF - 10.00pm to 07.00am (22-7)
Reg 049
Diagram 2 Diagram 3
To override or advance the
clock
The clock has a manual On/
Off switch, see diagram 3,
which operates as follows :
Reg 050
Upper position
HeatingOn/Offasset by the
tappets.
Middle position
Heating Off continuously
Lower position
Heating On continuously
Draining
Safety Devices
Protection against freezing
Iftheboileristobeoutofuseforanylongperiodsduringsevere
weather conditions, it is recommended that the whole system,
including the boiler, be drained to avoid the risk of freezing.
If in doubt, consult your servicing company.
Draining and filling
Caution:Theboilerisinstalledaspartofasealedsystemwhich
must only be drained and filled by a competent person.
Air flow rate safety device
Ifanobstruction,evenpartial,oftheflueoccurs,foranyreason,
thebuiltinsafetysystemoftheboilerwillturntheboilerOFFand
the fan will continue to run. The boiler will be ready to operate
when the fault has been cleared.
Overheat safety
In case of boiler overheating, the overheat thermostat will turn
the boiler off. The thermostat, located on the heat exchanger
flowpipe,willneedtobemanuallyreset. To havethisdonecall
a qualified service engineer or Heatcall (Glow-worm’s own
service organisation) using the telephone number behind the
controls cover door or on the front cover of this booklet.
In case of power supply failure
The boiler no longer operates. As soon as power supply is
restored, the boiler will be automatically restarted.
Frost protection
The XTRAFAST has a built in frost protection device that
protects the boiler from freezing. If the boiler is to be left and
thereisariskoffrost,ensurethatthegasandelectricalsupplies
areleftconnected.Thefrostprotectiondevicewilllighttheboiler
whenthetemperatureoftheboilerwaterfallsbelow6°C.When
the temperature reaches 16°C, the boiler stops.
Note : This device works irrespective of any room thermostat
setting and will protect the complete heating system.
Heating safety valve
CAUTION:Aheatingsafetyvalvewithadischargepipeisfitted
to this boiler.
The valve MUST NOT BE TOUCHED except by a qualified
registeredperson.Ifthevalvedischargesatanytime,switchthe
boiler off and isolate it from the electrical supply. Contact your
installation/service company.
Pressure relief valve
CAUTION: A domestic hot water pressure relief valve, with a
discharge pipe is fitted to this boiler.
The valve MUST NOT BE TOUCHED except by a qualified
registeredperson.Ifthevalvedischargesatanytime,switchthe
boiler off and isolate it from the electrical supply. Contact a
qualifiedserviceengineerorHeatcall(Glow-worm’sownservice
organisation) using the telephone number behind the controls
cover door or on the front cover of this booklet.

72000221595
To ensure the continued efficient and safe operation of the
appliance it is recommended that it is checked and serviced as
necessary at regular intervals. The frequency of servicing will
depend upon the particular installation conditions and usage,
but in general once a year should be enough.
If this appliance is installed in a rented property there is a duty
of care imposed on the owner of the property by the current
issue of the Gas Safety (Installation and Use) Regulations,
Section 35.
Servicing/maintenance should be carried out by a competent
person in accordance with the rules in force in the countries of
destination.
To obtain service, please call your installer or Heatcall (Glow-
worm’s own service organisation) using the telephone number
behind the controls cover door.
Please be advised that the ‘Benchmark’ logbook should be
completed by the installation engineer on completion of
commissioning and servicing.
All CORGI Registered Installers carry a CORGI ID card, and
have a registration number. Both should be recorded in your
boilerLogbook. YoucancheckyourinstallerisCORGIregistered
by calling CORGI direct on: 01256 372300.
Servicing and Maintenance
Cleaning
WARNING: Thisappliancecontainsmetal parts(components)
and care should be taken when handling and cleaning with
particular regard to edges of sheet metal parts to avoid any
possiblity of personal injury.
The boiler casing can be cleaned using a mild liquid detergent
with a damp cloth, followed by a dry cloth to polish.
Do not use any form of abrasive or solvent cleaner as you
may damage the paint work.
Boiler casing
CAUTION. Do not remove or adjust the casing in any way, as
incorrectfittingmayresultinfaultyoperation.Ifindoubt,consult
your installation/service company.
1 Technical Data
Heating output ajustable from ... (kW) 10,4 11,7
to ... (kW) 27,6 34,6
from ... (BTU/H) 35,485 39,920
to ... (BTU/H) 94,170 118,053
Efficiency (%) ** **
Maximum heating temperature (°C) 87 87
Expansion vessel effective capacity (l) 7 12
Expansion vessel charge pressure (bar) 0,5 0,5
Maximum system capacity at 75°C(l) 160 275
Safety valve,
maximum service pressure (bar) 3 3
Products outlet diameter (mm) 60 60
Fresh air inlet diameter (mm) 100 100
XTRAFAST 96
XTRAFAST 120
Ø Burner injector (mm) 1,20 1,20
Inlet pressure (mbar) 20 20
Burner pressure (mbar) 13,8 14,1
Gas rate maximum (m3/h) 3,20 3,98
Gas rate minimum (m3/h) 1,32 1,48
Heating
Hot water output
automatically variable from ... (kW) 10,4 11,7
to ... (kW) 27,6 34,6
from ... (BTU/H) 35,485 39,920
to ... (BTU/H) 94,170 118,053
Maximum hot water temperature (°C) 60 60
Specific flow rate (for 30°C temp rise)
(l/min.) 13,2 16,5
Threshold flow rate (l/min.) 1 1
Nominal water flow rate (l/min.) 11,3 16,5
Maximum supply pressure (bar) 8 8
Minimum operating pressure (bar) 0,7 0,7
Hot water
Electrical supply (V) 230 230
Maximum absorbed power (W) 220 220
Level of protection IP44 IP44
Fuse rating 125mAT 125mAT
Natural Gas (G20)
XTRAFAST 96
XTRAFAST 120
Lift weight 51.2kg (112.9lb) **.*kg (**.**lb)
Total weight
(inclusive water) **.*kg (**.**lb) **.*kg (**.**lb)
Xtrafast 96 Xtrafast 120
The Seasonal Efficiency Domestic Boilers UK (SEDBUK) is
**.*%.
The value is used in the UK Government's Standard
Assesssment Procedure (SAP) for energy rating of dwellings.
The test data from which it has been calculated have been
certified by B.S.I.

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2000221595
1 Technical Data
0
10
20
30
40
50
60
120010008006004002000
1
2
3
4
5
Pom 010 a
Flow rate through heating system (I/h)
(10 kPa = 1 m WG)
123 4 5
Bypass fully shut Open 1/4 turn Open 1/2 turn Open 1 turn Open 2 turns
PUMP 96
0
10
20
30
40
50
60
70
80
120010008006004002000
1
2
3
4
5
Pom 058
Available pressure (kPa) between
heating supply and return lines
PUMP 120
Flow rate through heating system (I/h)
Available pressure (kPa) between
heating supply and return lines
(10 kPa = 1 m WG)
Diagram 4

92000221595
2 Dimensions
3 Heating System Design
The XTRAFAST is delivered in three separate
packages:
- the boiler
- the fixing jig
- the flue system
7422
Diagram 5
380
X
890
65
234
Lifting Weight:
51,2 kg
X = 470 (96)
552 (120)
• The XTRAFAST is compatible with any type of installation.
•Heating surfacesmay consistof radiators,convectors orfan
assisted convectors.
• The
XTRAFAST can be piped directly to an underfloor
heating system without the need for a mixing bottle. The
maximum central heating flow temperature can be set to
53°C.ontheboilerprintedcircuitboardduringcommissioning.
•Pipe sectionalareas shallbe determinedin accordancewith
normal practices, using the output/pressure curve (diagram
4). The distribution system shall be calculated in accordance
with the output requirements of the actual system, not the
maximum output of the boiler. However, provision shall be
madetoensuresufficientflowsothatthetemperaturedifference
between the flow and return pipes be less than or equal to
20°C. The minimum flow is 400 l/h.
• The piping system shall be routed so as to avoid any air
pockets and facilitate permanent venting of the installation.
Bleed fittings must be provided at every high point of the
system and on all radiators.
• The total volume of water permitted for the heating system
depends, amongst other things, on the static head in the cold
condition. The expansion vessel on the boiler is pressurised at
0,5 bar (corresponding to a static head of 5 m w.g.) and allows
a maximum system volume of 160 litres for an average
temperatureof75°Candamaximum servicepressureof 3bar.
This pressure setting can be modified at commissioning stage
ifthe static headdiffers. An additionalexpansion vessel canbe
fitted to the system if required, see diagram 8.2.
•Provision shall bemade foradrain valveatthe lowestpointof
the system.
• Where thermostatic radiator valves are fitted, not all radiators
mustbefittedwiththistypeofvalve,andinparticular,wherethe
room thermostat is installed.
•Inthecaseofanexistinginstallation,itisESSENTIAL thatthe
system is thoroughly flushed prior to installing the new boiler.
Filling the system
Afillingdevicemustbeprovidedtofillthesystem,seediagram
8.2.

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2000221595
AB CDE
2
3
6
4
7
5
8
9
1
12
14
13
15
16
18
17
19 20
22
21
23
11
25
24
10
Diagram 5.1
4 Domestic Hot Water System Design
• Copper tubing or plastic hep2o may be used for the domestic
hot water system. Unnecessary pressure losses should be
avoided.
• A flow restrictor limiting the flow through the boiler to a
maximum of 12 l/min is fitted to the boiler.
• The boiler will operate with a minimum supply pressure of 0,7
bar,but under reducedflow rate. Bestoperatingcomfort willbe
obtained from a supply pressure of 1 bar.
'Hard Water Areas'
In areas where the water is 'hard', more than 200mg/litre, it is
recommended that a proprietary scale reducer is fitted in the
cold water supply to the boiler.
1 - Domestic thermistor
2 - Three way valve
3 - Gas valve
4 - Ignition module
5 - Heating element
6 - Micro accumulation vessel
7 - Burner
8 - Ignition electrode
9 - Combustion chamber
10 - Micro accumulation vessel thermistor
11 - Main heat exchanger
12 - Air pressure switch
13 - Heating safety valve (3 bar)
14 - Electronic control (PCB)
15 - Domestic water flow sensor
16 - Bypass
17 - Domestic heat exchanger
18 - Pump
19 - Expansion vessel
20 - Heating thermistor
21 - Overheat safety thermostat
22 - Flame sense electrode
23 - Fan
24 - Domestic safety valve (10 bar)
25 - Loss of water sensor
A - Heating return
B - Cold water inlet
C - Heating flow
D - Domestic hot water outlet
E - Gas
10026
5 Boiler Schematic

11 2000221595
If the appliance has to be stored for any length of time before
installation it should be kept in a safe place where it will not be
a hazard to persons or obstruct any access. Care should be
takenwhenhandlingormovingtheappliancetakingnote ofthe
trucking points on the sides of the carton.
6.1 Clearances
The position of the boiler must be such that there is adequate
space for servicing.
The recommended clearances are:
20 mm either side of the boiler.
600 mm at the front of the boiler.
300 mm below the boiler.
25 mm above the flue elbow.
Note: The boiler must be mounted on a flat wall which is
sufficiently robust to take its weight when full, that is, ** kg. If in
doubt,expertadviceshouldbeobtained. Intheeventofthewall
being found not suitable.
Note:Itispermissibletoinstalltheboilerwithsmallerclearances
than those quoted above PROVIDING that adequate
consideration is given for Servicing/Repairs at a later date. If
anydoubt exists,contact theGlow-worm TechnicalHelpline
01773 828100.
The minimum acceptable spacings from the terminal to
obstructions and ventilation openings are shown in diagram
6.1.
The boiler must be installed so that the terminal is exposed to
the external air.
Should any doubt exist as to the permissible position of the
terminal, contact the Glow-worm Technical Helpline 01773
828100.
6 Boiler Location, Flue and Ventilation
6.2 Terminal guard
A terminal guard is required if persons could come into contact
with the terminal or the terminal could be sublject to damage.
If a terminal guard is required, it must be positioned to provide
aminimumof50mmclearancefromanypartoftheterminaland
to be central over the terminal.
Teminal guard type K3 supplied by:
Tower flue components Ltd.
Morley road
Tonbridge
Kent
TN9 1RA
6.3 Flue options
There are various flue systems to choose from as follows:
Standard horizontal flue pack.
Standard horizontal extended flue pack.
Vertical flue pack.
Twin flue pack.
Extentions, 90°and 45°bends.
Flue options and accessories.
For detailed information refer to flue guide Part No. 223278.
6.4 Cupboard or compartment ventilation
The boiler can be fitted in a cupboard or compartment without
the need for permanent ventilation.
A
A
FGEA
G
G
G
B,C B,C
FF
K
K
K
C
G
LL
UNDER CAR PORT etc.
H,I
JD
F
K
Diagram 6.1
2816
MINIMUM SITING DIMENSIONS FOR THE
POSITIONING OF FLUE TERMINALS MM
ADIRECTLY BELOW, ABOVE OR
HORIZONTALLY TO AN OPENING, AIR
BRICK, OPENING WINDOWS, AIR VENT, OR
ANY OTHER VENTILATION OPENING 300
BBELOW GUTTER, DRAIN/SOIL PIPE 75
CBELOW EAVES 200
DBELOW A BALCONY OR CAR PORT 300
EFROM VERTICAL DRAIN PIPES AND
SOIL PIPES 300
FFROM INTERNAL CORNERS AND
EXTERNAL CORNERS 300
G ABOVE ADJACENT GROUND OR
BALCONY LEVEL 300
HFROM SURFACE FACING THE
TERMINAL 600
IFACING TERMINALS 1200
JFROM OPENING (DOOR/WINDOW)
IN CAR PORT INTO DWELLING 1200
KVERTICAL FROM A TERMINAL 1500
LHORIZONTALLY FROM A TERMINAL 600

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2000221595
7 Fixing Jig Pack
The fixing jig is made up, from left to right, as follows:
A - Heating return fitting with isolating valve(v) and
drain knob (u).
B - Cold water inlet fitting with isolating valve (m)and
factory fitted flow regulator and filter (not shown).
C - Heating flow fitting with isolating valve (q), drain
knob (r) and safety valve (s1).
D - Domestic hot water outlet fitting with safety valve
(s2).
E - Gas fitting.
Diagram 7.1
8.1 Fixing jig
• Remove the contents of the fixing jig pack.
•Securetheleftandrighthandsupportbracketstotheisolating
valve plate with the securing screws (4 OFF) supplied, see
diagram 7.1.
• Connect the six copper connections and sealing washers to
the isolating valves, see diagram 7.1.
• Heating system connections - Pipe diam. 22mm
• Hot water system connections - Pipe diam. 15mm
• Gas connection - Pipe diam. 22mm
• Domestic safety valve connection - Pipe diam.15mm
• Heating safety valve connection - Pipe diam. 15mm
8.2 Wall template
•Removethe walltemplate,follow theinstructionsgiven onthe
wall template.
• Note: It is important the hanging bracket and service cock
8 Piping System Installation
v
AB
m
C
q
D
r
E
u
s1
s2
COPPER
CONNECTIONS
AND WASHERS
(7 OFF)
H
G
F
KJ
THE FIXING JIG SHOWN ASSEMBLED
Other components within the fixing jig pack.
F - Hanging bracket
G - wall template
H - copper connections
J - sealing washers
K - sealant (putty)
RIGHT
HAND
SUPPORT
BRACKET
LEFT
HAND
SUPPORT
BRACKET
ISOLATING
VALVE PLATE
SCREW
(4 OFF)
bracketarefittedtoaflatandtruewallareaforcorrectalignment
with the boiler. If this is cannot be achieved it is acceptable to
packouttheservicecockbrackettoobtainthecorrectalignment.
• Position the wall template, see diagram 8.1.
• Mark the position of the holes for the hanging bracket and jig.
•Drill,plugandfixthehangingbrackettothewallusingsuitable
screws.
• Check that the hanging bracket is level.
• Drill plug and fix the fixing jig to the wall.
• For horizontal flue system, mark the position for the flue hole
as follows:
8.3 Flue to rear of boiler
• Mark correct position of hole from template.
8.4 Flue to side of boiler
• Mark the horizontal centre line for the hole on the rear wall.
Extend the horizontal centre line to the side wall and mark the
vertical centre line of flue hole as shown in diagram 8.1.
9880
9959

13 2000221595
Sch 173a
Diagram 8.2
Flow
control valve Drain point
Filling device
Bypass
valve
Domestic
water
Heating
circuit
Return
Additional
expansion
vessel
(if required)
Boiler
Hot
Cold supply
9684
Diagram 8.1
105
234
20
65
890
470 (96)
552 (120)
8.5 Cutting the flue hole
•Making allowance for theslope of theflue,cut hole inexternal
wall, preferably using a core drill. For installations with internal
and external access use a 105 mm diameter core drill.
For installations with internal access only use a 125 mm
diameter core drill.
8.6 Important
When cutting the flue hole and when extending the flue centre
line to a side wall, remember that the flue system must have a
fallofabout35mmpermetreofflue DOWNWARDtowards the
terminal. There must NEVER be a downward incline towards
the boiler.
8.6 Terminal position
The minimum acceptable spacings from the terminal to
obstructions and ventilation openings are shown in diagram
6.1.
The boiler must be installed so that the terminal is exposed to
the external air.
Should any doubt exist as to the permissible position of the
terminal, contact the Glow-worm Technical Helpline 01773
828100.
8.7 Water connection
Connectthesystempipeworktothecopper connectionsonthe
fixing jig observing the correct flow and return format as shown
in diagram 8.2. Do not subject the isolating valves to heat.
8.8 Heating safety valve and domestic safety
valve discharge, refer to diagram 8.3.
Tee the domestic safety valve outlet pipe to the heating safety
valve outlet pipe and extend horizontally to the outside wall.
WARNING.Itmustnotdischargeaboveanentranceorwindow
or any type of public access area.
Connect the safety valve discharge pipe to the outlets of both
the heating safety valve and the domestic water safety valve,
the discharge must be extended using not less than 15mm.
pipe, to discharge in a visible position outside the building,
facing downward preferably over a drain.
Thepipemusthaveacontinuousfallandberoutedtoaposition
sothatanydischargeofwater,possiblyboilingorsteam,cannot
create any danger to persons, damage to property or external
electrical components and wiring. Tighten all pipe connection
joints.
8.9 Gas connection
•Thesupplyfromthe governedgasmetermustbe ofadequate
size to provide a constant inlet working pressure of 20 mbar (8
in w.g.).
Toavoidlowgaspressureproblems,itisrecommendedthatthe
gas supply is connected using 22 mm pipe.
• On completion, the gas installation must be tested using the
pressure drop method and purged in accordance with the
current issue of BS6891.
8.10 Gas Safety (Installation and use)
Regulations
Inyourinterestsandthatofgas safety,itisthelawthatALL gas
appliancesareinstalledandservicedbya competentpersonin
accordance with the above regulations.
8 Piping System Installation
Diagram 8.3
DOMESTIC
SAFETY
VALVE
(10bar)
HEATING SAFETY
VALVE 3 bar)

14
2000221595
9.1 Statutory requirements
The installation of this boiler must be carried out by a qualified
registeredpersoninaccordancewiththerelevantrequirements
of the current issue of:
The Gas Safety (Installation and Use) Regulations
The Building Regulations
The local water company Byelaws
The Building Standards Regulations (Scotland)
The Health and Safety at Work Act
9.2 Sheet metal parts
WARNING.Wheninstallingorservicingthisboiler,careshould
betakenwhenhandlingtheedgesofsheetmetalparts toavoid
the possibility of personal injury.
9.3 Installing the boiler
Prior to starting work, the system must be thoroughly flushed
using a propriety cleanser such as Sentinel X300 to eliminate
any foreign matter and contamination e.g. metal filings, solder
particles, oil, grease etc.
Note. Solvent products could cause damage to the system.
The boiler pack consists of the boiler, base panel, literature,
sealing washers and securing screws.
• Lay boiler on its back.
• Remove all packaging from around the boiler.
• Remove front panel, put in a safe place to avoid damaging it.
• Ensure the plastic plugs are removed from water and gas
pipes. NOTE: There will be some spillage of water.
•Removetransportationtimber supportbarfrombottom rearof
boiler.
• If required the boiler can be stood upright supported by
extending the legs at the front bottom of the boiler.
• Engage boiler upper part onto the hanging bracket.
• Fit the washers between the boiler pipes and the inlet and
outletfittingson thefixingjigandconnect thevariouscouplings
between the boiler and jig.
•Fitthebase panel, hook in at the rear secure with thefourself
tapping securing screws at the front.
9 Boiler installation

15 2000221595
10 Flue Installation
10.1 Top outlet flue - kit 86285
The boiler is only suitable for top outlet flue connection.
10.2 Rear flue systems
(Refer to diagram 10.1). To calculate the length when flueing to
the rear measure wall thickness e plus 160 mm for the outer air
duct and eplus 244 mm for the inner flue duct measurement.
10.3 Flue systems Right or Left
(Refer to diagram 10.1). Tocalculate the lengthwhenflueing to
the side measure wall thickness e plus inside of wall to side of
boiler aadd 145(mm) for the outer air duct and wall thickness e
plusinsideofwalltosideofboileraadd229(mm)fortheinnerflue
duct measurement.
• Refer to diagram 10.2 (Table A) for cutting lengths of both flue
duct and air duct pipes for each of the various flue options
available.
Important: All flue cutting lengths must be measured from the
terminal end of the flue pipes, see diagram 10.2 (D).
WhenthedimensionXmeasuredonsiteisgreaterthanthatgiven
in diagram 10.2 ( Table B ), extensions will be required as
necessary.
Calculation of flue cutting lengths for extended flue
•Usingthecorrectnumberofextensionkitsas(TableB),measure
dimensionsaande,seediagram10.1.Cutboththe flueductand
air duct pipes to the dimensions given in (Table C)
Important:All cuttinglengthsshouldbemeasuredfromthe push
fitjointendofthe extension pipe. Do not leave any burrs or sharp
edges on the cut ends of the pipes. Note : maximum horizontal
flue length without bends is 3.5m.
9659
Diagram 10.1
ee a
a
70mm 70mm
X
X
Rear flue
Air Duct pipe : e + 160, Flue duct pipe : e + 244
Note : maximum distance 'x' without extension 756 mm
Side flue (right or left)
Air Duct pipe : e + a + 145, Flue duct pipe : e + a + 229
Note : maximum distance 'x' without extension 990 mm
Ven 089
Diagram 10.2
Cutting length
Outer pipe
Inner pipe
Cutting length
AIR DUCT PIPE
FLUE DUCT PIPE
Flue option Dimension 'X' No. of extension kits
Side flue 991 to 1991 mm 1
(left or right) 1991 to 2991 mm 2
Note: Maximum flue length for 120 model is 2 metres
Table B: Number of extension kits required
(D)Table A: Flue cutting lengths (mm)
Rear flue option
Air Duct pipe : e + a - 755, Flue duct pipe : e + a -755
Note : maximum distance 'x' without extension 990 mm
Table C: Flue extention cutting lengths (mm)

16
2000221595
10 Flue Installation
10.4 Installation of flue assembly
• Fit rubber sealing collar (F), see diagram 10.3, into groove
at the outer end of pipe (A).
• Fit air duct pipe (A) into wall with groove to the outside.
• Pull pipe inwards to bring rubber sealing collar hard up
against external wall, see diagram 10.4.
•Fitinternalplasticflange(G)ontoairductpipe.Pushalongthe
pipe until engaged against internal wall.
• From inside, insert flue duct pipe (B) into air duct pipe.
• Fit both ‘O’ rings (J) into the flue elbow (C), one at the inlet,
oneattheoutlet.Bynecessity,theyarealoosefit,applyasmall
amount of silicone grease to each ‘O’ ring when fitting.
•Fixingcollar (D)overairductpipe(A)andelbow(C)ensuring
it is the correct way round (Note: the fixing collar can only be
fitted one way due to different diameters of the flue elbow and
air duct).
•Takeholdoftheflueductpipeandpushgentlyontotheelbow
outlet taking care not to tear the ‘O’ ring.
• Open fixing collar (D) and locate between elbow and air duct
pipe (A). Close fixing jig.
• Engage the two fixing clips (E) onto the collar (D) and press
down to lock into position. Secure clips with screws provided.
Important: If the flue has been cut, ensure that there are no
burrs that could damage the ‘O’ ring.
•For flue systemsless than1,5m long,leave therestrictor (a)
fitted in the fan outlet, see diagram 10.5.
• Remove the backing from the self adhesive gasket (H) and
carefully fit gasket to base of flue elbow.
• Fit elbow onto boiler and secure with the four screws (I).
Concentric flue system
The maximum permissible length (L) for the
concentric flue system is 3.5 m. For flue systems up to 1,5 m length, the restrictor (a) supplied fitted to the boiler,
inside the fan outlet, must be left in place. For longer flue systems, the restrictor must be removed.
For each 90°flue elbow used, (or two 45°elbows) the maximum permissible length (L) must be reduced by 1
metre.
Pho 087
Diagram 10.5
Pho 451
B
C
J
I
H
FG
A
D
The flue kit 86285 is 1000 mm long and comprises:
- Air duct pipe .......................................................... A
- Flue duct pipe ........................................................ B
- Flue elbow .............................................................. C
- Fixing collar............................................................. D
- Locking clips ............................................................ E
- External rubber sealing collar ............................... F
- Internal flange ....................................................... G
- Gasket ..................................................................... H
- Screws ....................................................................... I
- 'O' rings..................................................................... J
Diagram 10.3
E
Diagram 10.4
Hab 249a
234
65
L
a
Gasket

17 2000221595
11 Electrical Connection
Warning. This boiler must be earthed
The boiler is supplied with a mains lead attached.
Standard colours are Brown - Live, Blue - Neutral, Green and
Yellow - Earth.
All system components must be of an approved type.
Electrical components have been tested to meet the equivalent
requirements of the BEAB.
Connection of the whole electrical system and any heating
system controls to the electrical supply must be through a
common isolator.
Isolation should preferably be by a double pole switched fused
spurbox having a minimumcontact separation of3mm on each
pole. The fused spur box should be readily accessible and
preferably adjacent to the boiler. It should be identified as to its
use.
A fused three pin plug and shuttered socket outlet may be used
instead of a fused spur box provided that:
a)Theyarenotusedinaroomcontainingafixedbathorshower.
b) Both the plug and socket comply with the current issue of
BS1363.
The mains electrical supply must be maintained at all times in
order to provide domestic hot water.
Donotinterruptthemainssupplywithatimeswitchorprogrammer.
WARNING: ON NO ACCOUNT MUST ANY EXTERNAL
VOLTAGE BE APPLIED TO ANY OF THE TERMINALS ON
THE HEATING CONTROLS CONNECTION PLUG.
Warning:Thisappliancemustbewiredinaccordancewiththese
instructions.Anyfaultarisingfromincorrectwiringcannotbe put
right under the terms of the Glow-worm guarantee.
11.1 External controls
The XTRAFAST boiler is designed to operate at maximum
efficiency at all times, but will be most efficient and economical
when connected to a room thermostat.
To gain access to the external control connections, unclip side
clips and hinge up control panel cover, see diagram 11.2.
The boiler will work for heating without a room thermostat being
connected provided that the wire link fitted between the two
terminals of the connector (E) is left in place, see diagram 11.3.
Alternatively, a 230V room thermostat can be used but do not
makeanyconnectiontothecompensatingresistor,seediagram
11.3.
ONNOACCOUNT must anyelectricalvoltagebeappliedtoany
of the terminals of the external controls plug.
Remote Control
A remote control is available for the Xtrafast. Part no. xxxxxx. If
the remote control is fitted the wire link must be in place on
connector (E), and the Switch SW3 must be adjusted, see
diagram 11.4.
11.2 Electrical test
Carry out preliminary electrical system checks as below:
1. Test insulation resistance to earth of mains cables.
2. Test earth continuity and short circuit of all cables.
3. Test the polarity of the mains.
Note: For further information, see the building regulations 1991
- Conservation of Fuel and Power - 1995 edition - appendix G,
Table 4b.
9881
Diagram 11.1
9879
E
Leave link in place for no external controls.
Diagram 11.3
Diagram 11.4
9878
12
ON
SW3
TOGGLES
ON OFF
1 - Remote Control with without
2 - Parameters open locked
Set 1 & 2 OFF
for normal
operation
The boiler is supplird with a mains lead
attached. Connect this to the electrical supply.
°C
Without room
thermostat
IMPORTANT
With
VOLTAGE FREE
room thermostat
10023
EE
Diagram 11.2
10036
SIDE CLIPS

18
2000221595
12 Commissioning
3
Undo cap on
automatic air
vent on top of
pump and
leave undone.
Please ensure the “Benchmark” logbook is completed and left
with the user.
The commissioning and first firing of the boiler must only be
done by a qualified registered person.
Gas valve settings. Refer to Section 15 "Settings".
Gas installation
It is recommended that any air is purged from the supply at the
gas inlet test point on the gas valve, see diagram 12.1.
Filling the system 1 to 8
4
Hab 265
1Press the mains 'On/Off' button
Hab 265
Open the system filling loop and fill the
system until the pressure indicated
on the display is between 1 and 2 bar.
Reg 008
9323
1.5 bar
mo
d
The pressure must be between 1 and 2 bar
Diagram 12.1
Open the boiler isolating valves
(v and q), the slot of the screw
corresponds to flow direction.
Fully open valve m by turning
anti-clockwise.
➜
vm
q
2
IO
mode
0
1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
0.0 bar
The display will indicate 0 bar pressure in the system
The warning light will illuminate
➜
GAS INLET
TEST POINT

19 2000221595
12 Commissioning
Make sure the display indicates a system pressure of between 1 and 2 bar. Re-fill
system as necessary. (The warning light will extinguish at 1 bar).
Hab 265
8
57
6
➜
➜
Bleed each radiator to
remove the air, re-tighten
bleed screws.
Open various hot water
taps to bleed system.
Leave the cap on the
pump auto air vent open.
Reg 008
Ins 061
Ins 062
IO
1.5 bar
mode
0
1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
The pressure must be between 1 and 2 bar

20
2000221595
12 Commissioning
Lighting the boiler:
Make sure that:
• The boiler is connected to the electrical supply. • The gas service cock is open.
Then follow the instructions below :
Press the On/Off button (1)
Hab 264
The pressure must be between 1 and 2 bar. If not, the system must be filled by a competent person.
Appuyer sur +ou -pour ajuster la température
maximale souhaitée du circuit chauffage
60
°C
Visualisation de la température demandé
e
Appuyer sur mode pour sélectionner la position hiver
Température actuelle
dans le circuit chauffage
1.5 bar
10
°C
Apparaît lorsque le
brûleur fonctionne
mode
mode
Adjusting the heating temperature
Setting to the WINTER position
(Heating + hot water)
The actual temperature
of the heating system Illuminates when the
boiler lights
Hab 261
Press + or - to adjust the maximum
temperature of the heating (38°C to 87°C)
Visual indication of set temperature
A
C
B
• Adjust heating temperature to maximum 87°C.
• Check that any external controls, if fitted, are calling for heat
(set room thermostat to maximum).
• Allow the temperature to rise to the maximum value, with all
radiator valves open. The temperature rise will cause release
of the gases contained in the water of the central heating
system.
•Gasesdriventowardstheboilerwillbeautomaticallyreleased
through the automatic air vent.
•The gases trappedatthe highest pointofthe system mustbe
released by bleeding the radiators. Check the burner gas rate
required, ten minutes from lighting. Refer to Data Label on
electrical controls box. Should there be any doubt about the
gas rate it should be checked at the meter.
On reaching maximum temperature, the boiler should be
turned off and the system drained as rapidly as possible whilst
still hot.
• Refill system to a pressure of between 1 and 2 bar and vent
as before.
• Restart boiler and operate until a maximum temperature is
reached.Shutdownboilerandventheatingsystem.Ifnecessary,
topupheatingsystemandmakesurethatapressureofatleast
1 bar is indicated when system is COLD.
To stop the boiler: Press button 1.
Press the mode button to select
the winter symbol
IO
1.5 bar
mode
0
1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
1