Glowworm Xtramax HE User manual

www.glow-worm.co.uk
Xtramax HE
G.C. No. 47-047-29
Installation and Servicing
www.glow-worm.co.uk
High Effi ciency
Condensing
Boilers

2
Guarantee Registration
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 competent persons 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.
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 the parts guarantee, from the beginning of the 13th month onwards after
installation or manufacture, is conditional upon the boiler having been serviced by a
competent person approved at the time by the Health and Safety Executive,
in accordance with the manufacturer’s recommendations. We strongly recommend regular
servicing of your gas appliance, but where the condition is not met, any chargeable spare parts or
components issued within the applicable guarantee period still benet from a 12 month warranty
from the date of issue by the manufacturer.
We recommend you complete and return as soon as possible your guarantee registration card.
If your guarantee registration card is missing you can obtain a copy or record your registration by
telephoning the Glow-worm Customer Service number 01773 828100.
Customer Service:
01773 828100
Technical Helpline:
01773 828300
General and Sales enquiries:
Tel. [phone]
Fax: [phone]
To register your Glow-worm appliance call:
0800 0732142

3
CONTENTS DESCRIPTION SECTION PAGE
Important Information 4
Statutory Requirements 5
Boiler Design 6
Safety Devices 6
Servicing, Maintenance and Spare Parts 6
Technical Information 1 7
Boiler Location and Ventilation 2 10
Flue Location and Ventilation 3 11
Heating System 4 13
Domestic Hot Water System 5 13
Installation Preparation 6 14
Gas/Water and Appliance Connection 7 15
Safety Discharge, Condensate and
Tundish Connection 8 16
Electrical Connection 9 20
Commissioning 10 21
Servicing 11 26
Fault Finding 12 33
Replacement Parts 13 36
Spare Parts 14 43
Manual Handling 15 45
Declaration of Conformity 16 46
INTRODUCTION
INSTALLATION
INSTRUCTIONS
MAINTENANCE
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.

4
WARNINGS
Gas Leak or Fault
Turn off the gas emergency control valve immediately. Eliminate all sources of ignition, i.e.smoking, blowlamps, hot
air guns etc. Do not operate electrical lights or switches either on or off. Open all doors and windows,ventilate the
area.
Sheet Metal Parts
This boiler contains metal parts (components) and care should be taken when handling and cleaning, with particular
regard to edges.
Sealed Components
Under no circumstances must the User interfere with or adjust sealed parts.
Gas Category
This boiler is for use only on G20 natural gas, but may be
converted for use on G31 gas (propane L.P.G.).
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.
Manual Handling
With regards to the “Manual Handling Operations, 1992
Regulations”, the appliance exceeds the recommended weight
for a one man lift, refer to section 16 for more information.
The handling of the boiler may involve lifting, pushing and pulling,
the use of a sack truck may be required.
The following handling techniques and precautions should be
considered:
- Grip the boiler at its base
- Be physically capable
- 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.
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).
Testing and Certication
This boiler is tested and certicated for safety and performance.
It is, therefore, important that no alteration is made to the boiler,
without permission, in writing, by Glow-worm.
Any alteration not approved by Glow-worm, could invalidate the
certication, boiler warranty and may also infringe the current
issue of the statutory requirements.
Important Information

5
CE Mark
This boiler meets the requirements of Statutory Instrument,
No. 3083 The Boiler (Efciency) Regulations, and therefore is
deemed to meet the requirements of Directive 92/42/EEC on
the efciency requirements for new hot water boilers red with
liquid or gaseous fuels.
Type test for purposes of Regulation 5 certied by: Notied
body 0087.
Product/production certied by: Notied body 0049 or 1312.
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 harmonisation of the Laws of
the Member States relating to 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.
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
in accordance 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, 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 Fittings Regulations or Water byelaws in Scotland.
The Health and Safety at Work Act, Control of Substances
Hazardous to Health (COSHH).
The Current I.E.E. Wiring Regulations.
Where no specic instructions are given, reference should be
made to the relevant British Standard Code of Practice.
In IE, the installation must be carried out by a competent
person, approved at the time by the Health and Safety Executive,
and installed in accordance with the current edition of I.S.813
“Domestic Gas Installations”, the current Building Regulations
and reference should be made to the current ETCI rules for
Electrical Installation.
GB: the following Codes of Practice apply:
BS4814, BS6798, BS5440 Part 1 and 2, BS5546 Part 1, BS5449,
BS6891, BS6700, BS7074 Part 1 and 2, BS7593, BS7671.
IE: I.S.813, BS5546, BS 5449, BS 7074, BS 7593.
NOTE: For further information, see the current issue of the
Building Regulations, approved document L1 ( in the UK) and
the following current issues of:
1) Central heating system specication (CheSS)
and
2) Controls for domestic central heating system and hot water.
BRECSU.
Statutory Requirements
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.

6
Boiler Design
Boiler Design
This boiler is designed to provide central heating and
instantaneous hot water for use as part of a sealed water central
heating system with fully pumped circulation.
The pumps , expansion vessel and associated safety devices are
all tted within the boiler. The integral programmer is designed for
both simple operation and maximum control. Once the controls
are set the boiler will operate automatically.
Glow-worm has specially designed accessories for your appliance
depending on yourrequirements, please contact your supplier
or visit our website www.glow-worm.co.uk.
Condensate Drain
A plastic drain pipe must be tted to allow discharge of condensate
to a drain.
Condensate should, if possible, be discharged into the internal
household draining system. If this is not practical, discharge
can be made externally into the household drainage system or
a purpose designed soak away, see section 9 for more details
Pluming from ue terminal
Like all condensing boilers this appliance will produce a plume
of condensation from the ue terminal in cool weather. This is
due to the high efciency and hence low ue gas temperature
of the boiler.
This is normal and not an indication of a fault.
Maintenance and Servicing
To ensure the continued efcient 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.
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 approved at the time by the Health and Safety Executive
in accordance with the rules in force in the countries of destination.
To obtain service, please call your installer or Glow-worm’s own
service organisation using the telephone number on the inside
front cover of this literature.
Please be advised that the ‘Benchmark’ logbook should
be completed by the installation engineer on completion of
commissioning and servicing.
Spare Parts
Remember, when replacing a part on this appliance, use only
spare parts that you can be assured conform to the safety
and performance specication that we require. Do not use
reconditioned or copy parts that have not been clearly authorised
by Glow-worm.
If a part is required contact Glow-worm’s own service organisation
using the telephone number on the inside front cover of this
booklet.
Please quote the name of the appliance, this infomation will be
on the name badge on the front of the appliance.
If in doubt seek advice from the local gas company or Glow-
worm’s own service organisation using the telephone number
on the inside front cover of this booklet.
Servicing, Maintenance and Spare Parts
Electrical Supply Failure Reset Switch
In the event of a power supply failure the boiler will not work.
Normal operation of the boiler should resume when the electrical
supply is restored.
However, if the boiler does not resume normal operation turn
the mains reset switch off and on. If the boiler does not resume
normal operation after this operation the overheat stat may have
operated.
Overheating safety
In the event of the boiler overheating the safety devices will
cause a safety shutdown. If this happens, call your Installation/
Servicing company.
Discharge and Relief Valves
Heating and Domestic discharge safety valves and a
Domestic hot water pressure relief valve are tted to this
appliance. The valves must not be touched except by a
competant person.
If the valves discharges at any time, switch the appliance off
and isolate it from the electrical supply.
Frost protection
The appliance has a built in frost protection device that protects
the boiler from freezing. With the gas and electric supplies ON and
irrespective of any room thermostat setting, the frost protection
device will operate the pump when the temperature of the boiler
water falls below 7°C.
The burner will re if the temperature inside the boiler falls to 3°C.
When the temperature reaches 10°C the boiler stops.
Any other exposed areas of the system should be protected by
a separate frost thermostat.
Condensate Drain Blockage
As a safety feature the boiler will stop working if the condensate
drain becomes blocked. During freezing conditions this may be
due to the forming of ice in the condense drain external to the
house. Release an ice blockage by the use of warm cloths on
the pipe. The boiler should then restart. Contact your installation/
servicing company if the fault persists.
Safety Devices

7
1.1 Technical Data
All dimensions are given in millimetres (except as noted).
See diagrams 1.1, Table 1, Table 1 continued and Table 2.
700
890
301
480
12907
Diagram 1.1
1 Technical Information
Description Unit Xtramax HE
Gas category ll2H3P
SEDBUK rating 90.6% Band A
Boiler flue type C13, C33, C53
Heating
Heating output at 80°C/60°C (P) kW 7.6 - 28
Efficiency calculated on net calorific value at 80/60°C % 95.8 - 97.8
Heating output at 50°C/30°C (P) kW 8.6 - 30.6
Efficiency calculated on net calorific value at 50/30°C % 107
Minimum calorific flow rate (Q min) kW 8
Maximum calorific flow rate (Q max) kW 28.6
Heating minimum flow rate l/h 500
Maximum heating temperature C° 80
Minimum heating temperature C° 22
Expansion vessel, useful capacity l 12
Expansion tank initial pressure bar 0.75
Maximum system capacity at 75°C l 240
Safety valve, maximum service pressure (PMS) bar 3
Domestic hot water
Heating output (P) kW 7.6 - 33.2
Minimum calorific flow rate (Q min) kW 8
Maximum calorific flow rate (Q max) kW 34.2
Minimum hot water temperature °C 38
Maximum hot water temperature °C 63
TABLE 1

8
1 Technical Information
Combustion
Fresh air flow rate (1013 mbar - 0°C) m3/h 43
Product outlet flow rate g/s 15.3
Product outlet temperature °C 68
Values of product outlet (measured on nominal heating output with G20 reference gas):
CO ppm 86
mg/kWh 92
CO2 % 9.2
NOx balance ppm 21.1
mg/kWh 37.3
Dimensions:
Height mm 890
Width mm 700
Depth mm 480
Net weight kg 75
Weight of appliance when full kg 120
Supply voltage V/Hz 230/50
Maximum absorbed power W 241
Electrical rating A 1.05
Fuse mA 630
Electric protection IPX4D
Class 1
CE number 1312 BP 4108
Technical data depending on the gas type Unit Xtramax HE
Natural gas G 20 (1)
Sanitary flow rate at maximum input m3/h 3.62
Heating flow rate at maximum input m3/h 3.02
Flow rate at minimum input m3/h 0.68
Inlet pressure mbar 20
Burner injector diameter mm 5.65
(1) 15 °C, 1013,25 mbar
TABLE 1 (continued)
TABLE 2
Specific flow rate (D) (ΔT 30°C) l/min 21
Threshold flow rate l/min 0
DHW storage vessel l 42
DHW storage vessel heat up time min 6
Time to reheat 70% of the storage to 60°C min 4
Maximum supply pressure bar 16
Temp./pressure relief valve operating pressure bar 10
Temp./pressure relief valve operating temperature °C 90
Cold water flow rate regulator l/min 16
Safety valve, maximum service pressure bar 8
Minimum operating pressure bar 0.7
Maximum operating pressure bar 10

9
D2
D1
1 Technical Information
1 Flue outlet
2 Main heat exchanger
3 Burner
4 Ignition and control electrode
5 Fan
6 Gas control valve
7 DHW storage vessel
8 Condensate drain
9 Overheat safety thermostat
10 Temperature sensor for DHW storage vessel
11 Expansion vessel
12 Heating return thermistor
13 Heating ow thermistor
14 Ignition module
15 Heating Pump
16 Water pressure sensor
17 Domestic plate to plate heat exchanger
18 Three way valve
19 Domestic expansion vessel
20 Drain cock
21 Flow switch
22 Heating discharge safety valve
23 DHW temperature sensor
24 DHW discharge safety valve
25 Heating isolating valve
26 Filter on cold water inlet
27 Filling system
28 Filter on heating circuit
29 Heating isolating valve
30 Domestic cold water isolating valve
31 Heating isolating valve
32 Gas isolating valve
33 DHW pump
34 Storage anode protection
35 Non return valve
36 Temperature / pressure relief valve
37 Tapping (plug connection) for the recirculation loop
38 Pressure reducing valve and check valve
A Heating return
B Cold water inlet
C Heating ow
D Domestic hot water outlet
D1 Discharge from HTG safety valves
D2 Discharge from temp / press and expansion valve (to
tundish)
E Gas
F Cold water supply

10
2 Boiler Location
2.1 Location
This boiler is not suitable for outdoor installation.
This boiler may be installed in any room, although particular
attention is drawn to the installation of a boiler in a room containing
a bath or shower where reference must be made to the relevant
requirements.
In GB: this is the current I.E.E. WIRING REGULATIONS and
BUILDING REGULATIONS.
In IE: reference should be made to the current edition of I.S.813
“Domestic Gas Installations” and the current ETCI rules.
2.2 Clearances
The boiler should be positioned so that at least the minimum
operational and servicing clearances are provided, see diagram
2.1.
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 internally, which may necessitate clearance larger than
those specied in diagram 2.1.
2.3 Timber Frame Buildings
If the boiler is to be installed in a timber frame building it should
be tted in accordance with the Institute of Gas Engineers
document IGE/UP/7/1998. If in doubt seek advice from the local
gas undertaking or Glow-worm.
2.4 Combustible Material
The boiler and ue are suitable for installation onto and through
combustible materials provided that:-
1) Minimum 5mm clearance is maintained around the
circumference of the ue (air intake).
2) The combustible surface and xings are suitable for supporting
the load.
3) The minimum clearances from the boiler case are
maintained.
2.5 Room Ventilation
The boiler is room sealed so a permanent air vent is not required.
2.6 Cupboard or Compartment Ventilation
If the boiler is tted into a compartment or cupboard it does not
require ventilation openings.
Do not use the compartment or cupboard for storage. Leave
existing air vents.
12911
+ A removable compartment door can be placed
at least 5mm in front of the appliance
5
5
600 +
200
50
5
150
Diagram 2.1