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Installation and Servicing

1. 5 5 Diagram 5 1 1055 9 o o d g 1 5 o 1 1 L 1 15kW 0 5 10 15 20 25 30 Flow Rate litres min Diagram 5 2 0020107230 00 06 11 Glow worm Water System Domestic Hot Water 5 7 Domestic Hot Water Cylinder SINGLE FEED INDIRECT CYLINDERS ARE NOT SUITABLE The domestic hot water cylinder must be of the double feed fully indirect coil type 5 8 Unvented DHW System General All domestic hot water circuits connections fittings must be in accordance with the relevant standards and water supply regulations For GB Guidance G17 to G24 and recommendation R17 to R24 of the Water Regulations Guide for Scotland the Water Byelaws 2000 Scotland Document G Sanitation hot water safety and water efficiency section 3 of the building regulations requires that the installation of an unvented system should be notified to the local authority Building Controls Department and that the work must be carried out by a competent person approved at the time by the Health and Safety Executive as defined in the approved document G3 For IE The current edition 1 5 813 Domestic Gas Installations Where a storage system will not have a vent to atmosphere the installation must comply with the buildin
2. 8 5 E 1 oce SS DE FLOW HEATING FLOW THERMISTOR Diagram 14 2 39 14 13 Heating Return Thermistor For access refer to section 14 1 Refer to diagram 14 3 Remove the electrical connections from the thermistor Remove the retaining clip from the return pipe Remove the thermistor from the retaining clip Note that the polarity of the wiring to thermistor is unimportant 14 14 Heat Exchanger For access refer to section 14 1 Drain down the boiler heating circuit Remove the silencer front Pull forwards to remove The silencer is a push fit so no tools or fixings are required for its removal or fitting see diagram 12 8 Remove the flue hood front Ease the securing clips away from the sump to release the retaining catch then push the flue hood up to disengage from the sump see diagram 12 5 To remove swivel flue hood 90 and pull down and out see diagram 12 5 Remove the igniter unit with support bracket Disconnect the electrical connections and ignition lead Release the igniter unit support bracket Remove the igniter unit assembly see diagram 12 9 Remove the gas valve fan Disconnect the tubing nut at the gas valve see diagram 12 7 Remove the fan retaining bracket see diagram 12 10 To ease removal of the securing nut from the fan retaining bracket a flat bladed screwdriver can be used in the position sh
3. Gas Rate m hr OR ft hr Burner Operating Pressure if applicable mbar OR Gas Inlet Pressure mbar Central Heating Flow Temperature C Central Heating Return Temperature C COMBINATION BOILERS ONLY Is the installation in a hard water area above 200 Yes No If yes has a water scale reducer been fitted Yes No What type of scale reducer has been fitted DOMESTIC HOT WATER MODE Measure and Record Gas Rate m hr OR ft hr Burner Operating Pressure at maximum rate mbar Gas Inlet Pressure at maximum rate mbar Cold Water Inlet Temperature C Hot water has been checked at all outlets Yes Temperature C Water Flow Rate I min CONDENSING BOILERS ONLY The condensate drain has been installed in accordance with the manufacturer s instructions and or 55546 56798 Yes ALL INSTALLATIONS If required by the manufacturer record the following CO OR ppm OR CO CO Ratio The heating and hot water system complies with the appropriate Building Regulations Yes The boiler and associated products have been installed and commissioned in accordance with the manufacturer s instructions Yes The operation of the boiler and system controls have been demonstrated to and understood by the customer Yes
4. Position Position of the flue terminal mm Horizontal flues directly below an opening air brick opening windows IB above an opening air brick opening windows windows D below gutter drain soilpipe 25 E beloweaves to a boundary alongside the terminal Mo above adjacent ground or balcony level from surface or a boundary facing the terminal 600 0020107230 00 06 11 Glow worm Diagram 4 2 Position of the flue terminal from opening door window in car port 1200 into dwelling IM vertical from a terminal 1500 horizontally from a terminal Vertical flues P 600 Q 3900 R from adjacent opening window 1000 1 There should be no ventilation opening in the eaves within 300mm distance of the terminal 2 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 11 4 2 Flue configuration description 4 2 1 Horizontal concentric flue 0 60 100 mm or 0 80 125 mm C13 type installation If the terminal is at less than 1 80 m from the ground you must install a terminal protection kit 60 100 Key 1 Gasket fitted 80 125 mm Key 1 Gasket fitted 0 60 100 0 80 125 12 Each time an additio
5. SERVICE 10 Date Energy Efficiency Checklist completed Yes No Engineer Name Engineer Name Company Name Company Name Telephone Number Telephone Number Engineer ID Number Engineer ID Number Comments Comments Signature Signature 0020107230 Subject to engineering changes 0020107230 00 06 11 GLOW WORM Nottingham Road Because of our constant endeavour for Belper Derbyshire improvement details may vary slightly DE56 1 from those shown in these instructions G low e WO rm www glow worm co uk
6. GAS SERVICE ISOLATION VALVE CONDENSATE GAS SUPPLY IN DRAIN Diagram 14 1 0020107230_00 06 11 Glow worm 14 10 For access refer to section 14 1 Remove igniter unit flue hood fan and gas valve assembly and spark electrode lead refer to relevant sections Remove the flanged nuts and studs that secure the burner note that two studs at the rear also hold the fan clamping bracket see diagram 12 10 NOTE The burner gasket should be inspected but will not need replacing unless there are signs of wear or damage IMPORTANT Do not allow fixings nuts screws etc to fall into the open flue hood sump use a temporary cover whilst removing any parts 14 11 Condensate Trap For access refer to section 14 1 Remove securing screw see diagram 12 13 Disconnect the flexible condense drain pipe from the external plastic drain pipe beneath the boiler Carefully pull the condensate trap down and forward so as not to spill its contents The trap shoud be removed complete with the sealing grommet and flexible condensate drain pipe 14 12 Heating Flow Thermistor For access refer to section 14 1 Remove the silencer front fan gas valve assembly and flue hood for access See relevant sections Refer to diagram 14 2 0020107230 00 06 11 Glow worm
7. Diagram 14 9 CONTROL BOX REAR COVER SECURING SCREW vOOEL HINGE SECURING CONTROL BOX Diagram 14 10 0020107230_00 06 11 Glow worm 15 Spare Parts Key No 0020020734 0020020763 0020020781 0020020735 0020059600 0020020731 0020020728 0020059601 0020023826 0020023825 Description Fan Igniter unit Heating flow amp return thermistor 2 Gas valve 12hx 30hx Gas valve 35hx Spark Electrode Burner 12hx 30hx Burner 35hx User interface Main P C B GC No 42723 42773 42792 H42724 H69002 H42720 H42718 H68999 H42784 H42783 15 1 0020107230 00 06 11 Glow worm 43 16 Manual handling IMPORTANT with regards to the Manual Handling Opera tions 1992 Regulations the following lift operation exceeds the recommended weight for a one man lift General recommendations when handling Clear the route before attempting the lift Ensure safe lifting techniques are used keep back straight bend us ing legs Keep load as close to body as possible Do not twist repo sition feet instead If 2 persons performing lift ensure co ordinated movements during lift Avoid upper body top heavy bending do not lean forward sideways Recommend wear suitable cut resistant gloves with good grip to protect against sharp edg
8. CONDENSE TRAP AND SIPHONIC e Turn anti clockwise to remove SERVICE FILL LEVEL Diagram 12 13 31 13 Fault Finding 13 1 Preliminary fault finding The following checks should be performed before proceeding onto specific diagnostics e Check the external electrical supply to the boiler is and a supply of 230V is present at the L and N terminals at the installer interface For access remove and open the electrical cartridge see diagrams 10 3 and 10 1 Test at the L and N terminals on the installer interface refer to diagrams 10 2 and 13 4 e Check the electrical installation and appliance carry out tests for earth continuity polarity short circuit and resistance to earth using a suitable multimeter An aid to test Remove the front casing panel see diagram 13 1 and hinge down the control box Unclip the rear cover to gain access to the main PCB Carry out the tests at connector plug X17 see diagram 13 2 Check chassis earth at a bare metal point on the boiler Check that there is a gas supply to the boiler and the gas service isolation valve is turned on see diagram 8 1 Check pressure at the gas service isolation valve refer to section 13 4 Check that the heating system pressure indicates at least 1mb if not fill and vent the system as described in section 1
9. 2 z m 4 T 1000mm Y a A z E gt Q sk o 2 lt 150mm gt 1 5m MIN BOILER Diagram 5 3 245 Water System Sealed Central Heating System 5 12 Sealed Water Systems The installation must comply with the appropriate requirements of the current issue of BS4814 BS5449 BS6759 BS6798 BS7074 Part 1 and 2 See diagram 5 4 for a suggested layout 5 13 Safety Valve A safety valve must be fitted to a sealed system It shall be preset non adjustable with a lift pressure of 3 bar incorporating seating of a resilient material a test device and a connection for drain The drain from the safety valve must be routed outside the building must not discharge above an entrance or window or any type of public access area be clear of any electrical fittings and positioned so that any discharge can be seen 5 14 Expansion Vessel A diaphragm type expansion vessel conforming to the current issue of BS4814 see also BS7074 Part 1 and 2 must be con nected at a point close to the inlet side of the circulating pump see the diagrammatic layout diagram 5 4 The expansion vessel volume depends on the total water system volume and the initial system design pressure For any System an accurate calculation of vessel size is given in the cur rent issue of BS5449 and BS7074 Part 1 Example For an initial design pressure of 0 7 bar the minimum total vessel volume required i
10. Warnings Important Information Statutory Requirements INTRODUCTION Boiler Design Safety Devices Servicing Maintenance and Spare Parts Boiler Specification 1 7 Boiler Dimensions and Hydraulic Schematic 2 8 Boiler Location Clearances and Ventilation 3 9 Evacuation of Combustion Gas 4 10 Water Systems 5 14 INSTALLATION Installation Preparation 6 18 Boiler Fixing 7 19 Gas Water and Appliance Connection 8 20 Condensate Connections 9 21 Electrical Connection 10 23 Commissioning 11 24 Servicing 12 27 Fault Finding 13 32 Replacement of Parts 14 38 Spare Parts 15 43 MAINTENANCE Manual Handling 16 44 Declaration of Conformity 17 45 Commissioning Checklist 46 Service Interval Record 47 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 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 Important Information Gas Category This boiler is for use only on G20 natural gas Gas Safety Installation and Use Regulations In your own interests and that of safety it is the Law that ALL gas appliances are install
11. light Consult the State List Diagram 13 5 0020107230 00 06 11 Glow worm 34 In all circumstances press the reset button to clear the fault If the fault persists consult the table below FAULT CODES CODE DESCRIPTION POSSIBLE CAUSE F1 Boiler has attempted to light 5 times Gas tap is closed and failed on all occasions Gas valve connector is loose unconnected faulty or wires are trapped Ignitor connectors are loose unconnected faulty trapped Faulty Ignitor Low gas inlet pressure Incorrect gas valve adjustment Electrode Ignition leads loose unconnected faulty trapped Electrode broken defective or position incorrect Air inlet blocked flue inlet blocked flue duct leaking Earthing connection loose disconnected Condensate blocked F3 Fan fault Fan speed incorrect Fan connector loose unconnected faulty or wires trapped Faulty fan Flame goes out whilst during a demand Gas tap is closed Gas valve connector is loose unconnected faulty or wires are trapped Ignitor connectors are loose unconnected faulty trapped Faulty Ignitor Low gas inlet pressure Incorrect gas valve adjustment Electrode Ignition leads loose unconnected faulty trapped Electrode broken defective or position incorrect Air inlet blocked flue inlet blocked flue duct leaking Earthing connection loose disconnected Condensate block
12. 2 5 Inclined 44mm metre 9 Extended flue length Standard of M flue length DIA 125 E 2 Horizontal ieee Diagram 6 2 0020107230 00 06 11 Glow worm 7 Boiler Fixing 7 1 Wall Hanging Bracket The Wall Hanging Bracket is supplied in the main boiler packaging Reposition the wall template over the flue hole and mark the position of the fixing holes for the hanging bracket see diagram 7 4 NOTE Due to the varied site conditions we do not supply fixings and advise that the installer should supply those which are suitable Drill fixing holes and insert suitable wall plugs Direct Rear Flue only If external access is not available the flue to be used should be assembled as described in the separate flue instructions and inserted through the hole in the wall before fitting the wall hanging bracket 7 2 Boiler Hanging IMPORTANT With regards to the Manual Handling Operations 1992 Regulations the following lift operation is deemed to be a one man lift refer to section 16 Manual Handling IMPORTANT Direct Rear Flue only The direct rear flue must be fitted before hanging the boiler refer to the separate flue instructions and the rear outlet cover plate should be removed 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 push back and engage onto the hanging bracket making sure the boil
13. 20 C can be achieved across flow and return NOTE Allow the system to reach maximum temperature then switch off the boiler by isolating from the electrical supply Drain the entire system rapidly whilst hot using the drain tap at the lowest part of the system Fill and vent the system as described previously in section 11 2 Lock or remove the handle from controls valve if fitted Adjust the boiler temperature controls and any system controls to their required settings 11 8 Completion Ensure that the magnetic lighting instruction label is placed on the surface of the boiler casing GB It is a requirement that the Benchmark Installation Commissioning and Service Record is completed and left wth the user IE it is necessary to complete a Declaration of Conformity to indicate compliance to 1 5 813 An example of this is given in the current edition of S 813 11 9 Instruct the User e Demonstrate then instruct the User about the lighting procedure and heating system controls operation e Advise that to ensure the continued efficient and safe operation of the boiler it is recommended that it is checked and serviced at regular intervals The frequency of servicing will depend upon the installation conditions and usage but in general once a year should be enough e Draw attention if applicable to the current issue of the Gas Safety Installation and Use Regulations Section 35 which imposes a duty of care on all pers
14. 600 D GAS Condense 246 5 Drain Point Diagram 2 1 e amp GAS CONTROL C H 0 C H RETURN GAS FLOW Diagram 2 2 2 Boiler Dimensions and Hydraulic Schematic dimensions are given in millimetres except as noted The general arrangment of the boiler is shown in diagram 2 1 and the hydraulic and gas schematic diagram 2 2 The data label is positioned on the front of the inner casing panel 0020107230 00 06 11 Glow worm 3 Boiler Location Clearances and Ventilation 3 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 This boiler is suitable for installation in bathroom zones 2 and 3 In GB this is the current WIRING REGULATIONS and BUILDING REGULATIONS In IE reference should be made to the current edition of 1 5 813 Domestic Gas Installations and the current ETCI rules 3 2 Clearances The boiler should be positioned so that at least the minimum operational and servicing clearances are provided see diagram 3 1 Increased clearances would be beneficial for the installation Where external access is not practicable for flue installations consideration should be given for the space required to insert the flue internally which may necessitate
15. NUMBER NUMBER Diagram 13 3 0020107230 00 06 11 Glow worm BROWN BLUE GREEN YELLOW GREY GREEN BLACK YELLOW RED WHITE ORANGE PURPLE PINK _ INSTALLER INTERFACE O REFER TO SECTION 10 ELECTRICAL CONNECTION HEATING FLOW FAN THERMISTOR Tp r bk HEATING RETURN K IGNITION ELECTRODE br 4166 o EEEREN ERES mooom dl zm COLE fa pooooooo nu MAIN CONTROL BOARD APPLIANCE INTERFACE BOARD FLEXICOM HX Diagram 13 4 0020107230 00 06 11 Glow worm 33 START Is there anything displayed on the LCD Switch the power on Is the power switched on Consult the Fault Codes Check wires between main PCB and display H 4 1 10 Is the display flashing F PCB Yes Initiate a CH demand Does the boiler light Does the display flash F Successful ignition during or after a CH demand Adjust CH setpoint to 829C and make sure external control is calling for a demand Does the boiler
16. The manufacturer s literature including Benchmark Checklist and Service Record has been explained and left with the customer Yes Commissioning Engineer s Signature Customer s Signature To confirm satisfactory demonstration and receipt of manufacturer s literature installations in England and Wales must be notified to Local Authority Building Control either directly or through Competent Persons Scheme A Building Regulations Compliance Certifi cate will then be issued to the customer COLLECTIVE MARK and Hotwater Industry Council HHIC THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS www centralheating co uk SERVICE INTERVAL RECORD It is recommended that your heating system is serviced regularly and that you complete the appropriate Service Interval Record Below Service Provider Before completing the appropriate Service Interval Record below please ensure you have carried out the service as described in the boiler manufacturer s instructions Always use the manufacturer s specified spare part when replacing all controls SERVICE 1 Date Energy Efficiency Checklist completed Yes No SERVICE 2 Date Energy Efficiency Checklist completed Yes No Engineer Name Engineer Name Company Name Company Name Telephone Number Tel
17. damage the surface of the burner DO NOT use wire or sharp instruments to clean the mesh of the burner NOTE The burner gasket should be inspected but will not need replacing unless there are signs of wear or damage Follow the tightening sequence when re fitting the burner see diagram 12 12 0020107230 00 06 11 Glow worm Az 8 p A a Diagram 12 5 SPARK ELECTRODE S SECURING HEAT EXCHANGER SPARK GAP Diagram 12 6 29 SECURING SCREW 3 9 NY D 6 0 Sc 5 ELECTRICAL GAS CONNECTION PIPE removed Diagram 12 7 o SILENCER S FRONT Diagram 12 8 30 ELECTRICAL CONNECTIONS 60tv IGNITION LEAD SPADE IGNITER EARTH CONNECTOR UNIT CONNECTION Diagram 12 9 SECURING Diagram 12 10 SILENCER REAR FAN GAS VALVE ASSEMBLY Diagram 12 11 0020107230 00 06 11 Glow worm 12 6 Heat Exchanger NOTE If the functional checks did not indicate poor combustion then it is not necessary to service this component Remove loose debris from insid
18. e the gas service isolation valve diagram 11 1 is open As an option a chargeable boiler performance and function service can be provided by Glow worm Service by calling telephone No 01773 828100 DO NOT operate the boiler without water The lighting procedure of the boiler is fully automated Refer to diagram 11 2 e With no demand from any external controls switch on the electrical supply to the boiler e Open the gas service isolation valve see diagram 11 1 e The appliance will enter a self checking routine then the fan should start and the ignition will commence The boiler if necessary will automatically repeat the ignition sequence a further 4 times 0020107230 00 06 11 Glow worm e lf the burner fails to ignite F1 will be displayed initially this may be due to air in the gas supply line e Once the system has been purged of air Press and hold the Mode button of the boiler user controls for 2 seconds the Central Heating symbol will flash Use the SELECTOR buttons to adjust CH temperature After 10 seconds of inactivity the display will reset to indicate the water temperature e Turn ON your external controls and select the room temperature required The boiler will operate automatically NOTE The display will indicate the Heating system water temperature or a fault code if in a fault condition 11 5 Check the Gas Inlet Pressure amp Gas Rate The supply from the governed meter must b
19. for an overheat lockout and will shutdown before this happens To restart the boiler press the reset button on the controls fascia If the boiler fails to resume normal operation and all external controls are calling for heat then call your Installation Servicing company or Glow worm service 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 8 C A timer is used so that the temperature can be checked periodically After 10 minutes the pump will be stopped if the temperature is higher than 109 or has already reached 35 C The burner will activate if the boiler temperature does not reach 10 after 30 minutes or at any time if the temperature drops to 5 The burner will switch off when the temperature reaches 35 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 Servicing Maintenance and Spare Parts Servicing and Maintenance To ensure the continued efficient and safe operation of the boiler it is recommend
20. front and sides of appliance lift upwards ensure stable balance achieved and lift upwards to drop into place onto bracket If 2 persons positioning onto bracket obtain firm grip at front and sides base of boiler Ensure co ordinated movements during 2 person lifts to ensure equal spread of weight of load If 1 person positioning onto bracket recommend obtain firm grip supporting base of boiler Ensure safe lifting techniques are used keep back straight bend using legs when lifting load from floor level Do not twist reposition feet instead Keep boiler as close as possible to body throughout lift to minimise strain on back Always use assistance if required Recommend wear suit able cut resistant gloves with good grip to protect against sharp edges and ensure good grip when handling appliance lt is recommended a risk assessment of the roof space area be carried out before moving the appliance into the area to take into account access stability of flooring lighting and other factors and appropriate measures taken 0020107230 00 06 11 Glow worm 17 Declaration of conformity 0 9 Glow worm EC declaration of conformity Name and Address of the Glow worm manufacturer Nottingham Road Belper Derbyshire DE56 1JQ Identification of product Glow worm Flexicom Series Condensing Wall Hung Heating only Boilers Appliance type Flexicom 12hx 15hx 18hx 24hx 30hx amp 35hx The appliance types satisfy the essential
21. removed To remove undo the two screws on the underside of the front casing and lift off The side panels can be removed to aid replacement of parts To hinge a side panel undo and remove the four screws securing each side panel to the boiler two below and two at the top 14 2 Igniter Unit For access refer to section 14 1 Remove ignition lead and electrical connections then remove igniter unit by removing two securing screws see diagram 12 9 14 3 Ignition Lead For access refer to section 14 1 Pull the spark plug style connector off the spark electrode and the spade connector connected to the igniter unit see diagrams 12 6 and 12 9 14 4 Silencer Assembly front For access refer to section 14 1 Pull forwards to remove The silencer is a push fit so no tools or fixings are required for its removal or fitting see diagram 12 8 14 5 Gas Valve Remove the three securing screws holding the gas valve to the fan see diagram 12 7 Remove the gas valve After re fitting check the combustion CO2 and adjust if necessary refer to section 12 1 Combustion Check After assembly test for gas tightness and purge in accordance with the current issue of BS6891or in IE the current edition of 1 5 813 Domestic Gas Installations 38 14 6 Flue Hood For access refer to section 14 1 Pull the flue hood securing clips away from the flue hood sump and push flue hood up slightly towards flue hood top see diag
22. spark electrode plug and earth lead Remove the two securing screws and withdraw the spark electrode carefully from the combustion chamber see diagram 12 6 Inspect the tips for damage Clean away any debris and check the spark gap is 4mm Check the electrode gasket for signs of damage and replace if necessary 12 5 Burner NOTE If the functional checks did not indicate poor combustion then it is not necessary to service this component Disconnect the gas supply at the gas valve and electrical connections see diagram 12 7 The Silencer front is a push fit so there is no need for tools to remove or fit see diagram 12 8 Release the igniter unit support bracket see diagram 12 9 Remove the fan retaining bracket To ease removal of the securing nut from the fan retaining bracket a flat bladed screwdriver can be used in the position shown and gently levered down as indicated see diagram 12 10 Remove the fan and gas valve assembly The silencer rear is a push fit so no tools are required for its removal or fitting see diagram 12 11 Check the spark electrode gap is 4mm Clean and adjust as necessary see diagram 12 6 It should not be necessary to remove the spark electrode from the burner during servicing Remove the flanged nuts and studs that secure the burner note that two studs at the rear also hold the fan clamping bracket see diagram 12 12 Clean the burner with a soft brush taking great care not to
23. the required CO2 refer to diagram 12 4 and the SETTING column in the table e Exit the minimum rate function press the mode and buttons simultaneously this will reset the boiler to the default display 3 Re Check CO2 and check the CO CO2 combustion ratio e Re check the maximum and minimum CO2 values to ensure that they are within the setting limits in the table then check the CO CO2 combustion ratio does not exceed the value in the CO CO2 column of the table If the CO CO2 ratio exceeds the value in the table a complete servicing of the appliance will be necessary refer to section 12 1 If the CO2 and the CO CO2 ratio falls within the tolerances quoted exit the function press the mode and buttons simultaneously this will reset the boiler to the default display Remove the analyser probe and replace the cap on the sampling point replace the controls fascia inner and front casing panels IMPORTANT Remember to replace the sample point cap on completion of the test GAS RATE CHECK Check the gas rates as described in the commissioning section COMPLETION If it is not possible to achieve the required results for either the combustion or gas rates it will be necessary to complete a full service of the appliance and then repeat the combustion check procedure If after servicing and adjustment of the appliance the combustion values are still unacceptable and after further remedial work has been carr
24. then handed to the customer to keep for future reference Failure to install and commission this equipment to the manufacturer s instructions will invalidate the warranty but does not affect statutory rights Customer Name Telephone Number Address Commissioned by print name Engineer ID Number Company Name Telephone Number Company Address Commissioning Date To be completed by the customer on receipt of a Building Regulations Compliance Certificate Building Regulations Notification Number if applicable CONTROLS Tick the appropriate boxes Time and Temperature Control to Heating Room Thermostat and Programmable Load Weather Optimum Start Programmer Timer Room Thermostat Compensation Control Time and Temperature Control to Hot Water Cylinder Thermostat and Programmer Timer l Combination Boiler Heating Zone Valves Fitted Not Required Hot Water Zone Valves Fitted Not Required Thermostatic Radiator Valves Fitted Not Required Automatic Bypass to System Fitted Not Required Boiler Interlock Provided ALL SYSTEMS The system has been flushed and cleaned in accordance with BS7593 and boiler manufacturer s instructions Yes What system cleaner was used What inhibitor was used Quantity litres CENTRAL HEATING MODE Measure and Record
25. 3 2 Check that all external controls are on e Check the functional flow diagram 13 5 13 2 Fault Codes Fault codes take priority over all other display functions in the event of a fault occuring refer to diagram 13 6 If multiple faults occur the codes will be displayed for approx 2 seconds alternatively 13 3 Fault Memory The Fault memory stores details of the ten most recent faults To access this menu refer to diagram 13 3 a Press and hold MODE and buttons for 5 seconds b The display will stop flashing and alternate between the fault memory number and the fault code C Press button to scroll through the fault memory Position 1 is most recent see fault codes To exit this menu press the MODE button 13 4 Diagnostic Menu The Diagnostic Menu provides the ability to view and change certain parameters See diagram 14 8 for available parameters 13 5 Status Codes The status codes provide information about the current operating condition of the boiler and can be accessed through the diagnostic display refer to diagram 13 7 2325 R 8 FRONT PANEL i SECURING gt SCREWS Diagram 13 1 MAIN PCB BOARD A NEUTRAL 1 TEST POINT AT MAIN PCB BOARD POSITION X17 Diagram 13 2 FAULT FAULT E MEMORY CODE
26. 92 03 0 004 0 3 0020107230 00 06 11 Glow worm COMBUSTION CHECK AND SETTING THE AIR GAS RATIO VALVE e Remove the front casing panel see diagram 12 2 and hinge down the control box Taking care not to touch any internal components proceed as follows e Connect the CO2 combustion analyser to the relevant test point see diagram 12 1 587 COMBUSTION x COMBUSTION ANALYSER SAMPLE POINT Diagram 12 1 1 Maximum Rate Check and Adjustment NOTE To verify the maximum gas rate 2 setting the appliance must be checked at the maximum rate first Press the reset button on the controls fascia release and immediately press and hold in the button After approximately 5 seconds Hi will be displayed Pressing the mode button when is selected will force the boiler to maximum rate the display will flash between and the default display this will indicate the boiler has been forced to maximum Wait until the CO2 value is stable and check that the value is within the range specified in table in the check column If the combustion reading is not within the acceptable values AND the integrity of the complete flue system and combustion circuit seals have been verified and the inlet gas pressure and gas rate have been verified then it will necessary to adjust the combustion rate of the appliance NOTE Adjustment is made by turning the gas valv
27. Gloweworm Installation and Servicing Condensing Boilers Flexicom hx 12 hx G C No 41 315 28 15 hx G c No 41 315 29 18 hx G c No 41 315 42 24 hx 41 315 61 30 hx 41 315 67 G C No 41 315 68 Guarantee Registration Thank you for installing a new Glow worm appliance in your home Glow worm appliances are manufactured to the very highest standard so we are pleased to offer our customers a Comprehensive Guarantee This product is guaranteed for 24 months from the date of installation or 30 months from the date of manufacture whichever is the shorter for parts and labour The second year of 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 benefit 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 Se
28. ance if required Recommend wear suitable cut resistant gloves with good grip to protect against sharp edges and ensure good grip when handling appliance Positioning of Appliance for Final Installation within compartment etc restricting installation This appliance is deemed to be a one person lift when removed from the carton Fit bracket securely onto wall before lifting appliance into posi tion Obtain firm grip on front and sides of appliance lift upwards onto worktop if practicable Ensure stable balance achieved and lift upwards to drop into place onto bracket If 2 persons positioning onto bracket obtain firm grip at front and sides base of boiler Ensure co ordinated movements during 2 person lifts to ensure equal spread of weight of load If 1 person positioning onto bracket recommend obtain firm grip supporting base of boiler Ensure safe lifting techniques are used keep back straight bend using legs when lifting load from floor level Do not twist reposition feet instead Keep boiler as close as possible to body throughout lift to minimise strain on back Always use assistance if required Recommend wear suitable cut resistant gloves with good grip to protect against sharp edges and ensure good grip when handling appliance Positioning of Appliance for Final Installation in roof space restricting installation This appliance is deemed to be a one person lift when removed from the carton Obtain firm grip on
29. and water connections e System pressure e the combustion performance refer to the following procedure e The operational gas inlet pressure and gas rates refer to the commissioning section paragraph 11 5 Correct any fault before continuing COMPETENCY TO CARRY OUT THE CHECK OF COMBUSTION PERFORMANCE NOTE BS 6798 2009 Specification for installation and maintenance of gas fired boilers of rated input not exceeding 70kW net advises that e The person carrying out a combustion measurement must be assessed as competent in the use of a flue gas analyser and the interpretation of the results e The flue gas analyser used should be one meeting the requirements of BS7927 or BS EN50379 3 and be calibrated in accordance with the analyser manufacturers requirements e Competence can be demonstrated by satisfactory completion of the CPA1 ACS assessment which covers the use of electronic portable combustion gas analysers in accordance with BS 7967 parts 1 to 4 e Ensure that the gas analyser is set to the correct fuel setting e Press and hold the Mode button of the boiler user controls for 2 seconds the Central Heating symbol will flash refer to commissioning section The boiler should fire automatically NOTE Safe combustion can only be verified by measuring CO 2 ratio This must not exceed the value shown in the table below G20 BURNER CO2 MODEL CHECK SETTING gt ratio All MODELS 8 8 109 8
30. ards to position in place on bracket Ensure safe lifting techniques are used keep back straight bend using legs when lifting load from floor level Do not twist repo sition feet instead Keep boiler as close as possible to body throughout lift to minimise strain on back Ensure co ordinated movements to en sure equal spread of weight of load Always use assistance if required Recommend wear suitable cut resistant gloves with good grip to protect against sharp edges and ensure good grip when handling appliance Positioning of Appliance for Final Installation above worktop foreseeable obstructions etc This appliance is deemed to be a one person lift when removed from the carton Fit bracket securely onto wall before lifting appliance into posi tion Obtain firm grip on front and sides of appliance lift upwards onto worktop if practicable Ensure stable balance achieved and lift upwards to position in place on bracket If 2 persons positioning onto bracket obtain firm grip at front and sides base of boiler Ensure co ordinated movements during 2 person lifts to ensure equal spread of weight of load Ensure safe lifting techniques are used keep back straight bend using legs when lifting load from floor level Do not twist reposition feet instead Keep boiler as close as possible to body throughout lift to minimise strain on back Avoid upper body top heavy bending do not lean forward sideways Always use assist
31. d Use Regulations The appropriate Buildings Regulations either The Building Regulations The Building Regulations Scotland The Building Regulations Northern Ireland The Water Supply water fittings Regulations 1999 and water byelaws 2000 Scotland The Health and Safety at Work Act Control of Substances Hazardous to Health COSHH The Current I E E Wiring Regulations Where no specific 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 1 5 813 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 54814 BS6798 BS5440 Part 1 and 2 BS5546 Part 1 BS5449 BS6891 56700 BS7074 Part 1 and 2 57593 BS7671 IE 1 5 813 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 specification CheSS and 2 Controls for domestic central heating system and hot water BRECSU 0020107230 00 06 11 Glow worm Gas Supply The gas installation must be in accordance with the relevant standards In GB thi
32. d accessories 44 mm m Standard flue terminal kits have an in built fall back to the boiler to drain the condensate These can be fitted level between the appliance and the termination position All other extended flues must have a fall of at least 44mm m The maximum length of the flue outlet is defined according to its type for example C13 Whatever the kind of flue system chosen observe the minimum distances indicated in the chart below to position the flue terminals To install the flue refer to the separate flue instruction supplied with your appliance Explain these requirements to the user of the appliance If necessary you must install terminal protection Caution The connection between the flue elbow and the flue outlet must be sealed In GB the minimum acceptable siting dimensions for the terminal from obstructions other terminals and ventilation openings are shown in diagram overleaf In IE the minimum distances for flue terminal positioning must be those detailed in 1 5 813 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 flue 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 wal
33. d efficient and safe operation of the boiler it is recommended that it is checked and serviced at regular intervals The frequency of servicing will depend upon the particular installation and usage but in general once a year should be enough It is the Law that any servicing is carried out by a competent person approved at the time by the Health and Safety Executive Before commencing with a service or replacement of parts the boiler should be isolated from the electrical supply and the gas supply should be turned off at the gas isolation valve When replacing a part on this appliance use only spare parts that you can be assured conform to the safety and performance specification that we require Do not use reconditioned or copy parts that have not been clearly authorised by Glow worm If any electrical connections have been disconnected and after their connection checks to the earth continuity polarity short circuit and resistance to earth must be repeated using a suitable multimeter as described in section 13 After servicing complete the relevant Service Interval Record section of the Benchmark Checklist located in the inside back pages of this document 12 Servicing General Inspection Prior to during servicing and after any maintenance or changed parts the following must be checked e The integrity of the flue system and flue seals e The integrity of the appliance combustion circuit and relevant seals e Electrical gas
34. e 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 fluid purge as necessary NOTE Due to the modulating operation of the boiler and the need to check the gas inlet pressure and measure the gas rate at maximum rate it will be necessary to force it to maximum Press the reset button on the controls fascia release and immediately press hold in the button After approximately 5 seconds will be displayed Pressing the mode button when is selected will force the boiler to maximum rate the display will flash between and the default display this will indicate the boiler has been forced to maximum 25 Operational Gas Inlet Pressure With ALL other gas appliances operating check the operational supply pressure at the gas service isolation valve test point see diagram 11 1 The nominal supply pressure for Natural Gas G20 is 20mbar Turn the taps and appliances off then disconnect the pressure gauge Additionally the safe nominal maximum heat input of the appliance can be achieved at an inlet pressure down to 15mbar NOTE The BURNER PRESSURE cannot be measured Gas Rate Make sure that ALL other gas burning appliances and pilot lights are off Check the gas rate using the gas meter test dial and stop watch at least 10 minute
35. e the heat exchanger using a soft brush and vacuum cleaner Carefully flush by spraying water into the heat exchanger any remaining debris should pass through the condensate trap Ensure the water is kept away from electrical components 12 7 Condense Trap and Siphonic Drain The condensate trap and siphonic drain does not normally need servicing unless material deposits exceed beyond the service fill level see diagram 12 13 To clean the condense trap remove the sump and rinse with water 12 8 Casing panel seal check NOTE If the functional checks did not indicate poor combustion then it is not necessary to service this component Check the condition of the seal and replace if worn or damaged To replace remove the old seal and thoroughly clean the casing surfaces Fit the new seals these are supplied to the correct lengths and are in four pieces for use on the sides top and bottom 12 9 Service Completion Re check the combustion as described at the beginning of this section On completion of the service the Benchmark Service Record should be completed FAN CLAMPING rx BRACKET E SECURING NUTS 6 x A S Suggested tightening sequence for burner fitting 35hx only Diagram 12 12 0020107230 00 06 11 Glow worm 6807 LOCATING SCREW
36. e throttle an of a turn waiting 1 minute to allow the appliance to stabilise before checking or making further adjustments 27 e Rotate the throttle anti clockwise to increase to the required CO2 refer to diagram 12 4 and the SETTING column in the table e Exit the forced rate function press the mode and buttons simultaneously this will reset the boiler to the default display Now proceed to check the minimum rate adjustment 2 Minimum Rate Check and Adjustment e Now check the minimum gas rate 2 setting Press and release the reset button on the controls fascia then immediately press and hold in either of the buttons After approximately 5 seconds will be displayed Pressing the or buttons will toggle between and Lo Press the mode button when Lo is selected this will force the boiler to minimum rate and the display will flash Lo indicating the boiler is operating at minimum e Wait until the CO2 value is stable and check that the value is within the range specified in table in the check column If adjustment is necessary proceed as follows NOTE Adjustment of the CO2 at minimum rate is very coarse and should not be adjusted more than an of a turn at a time Wait 1 minute to allow the appliance to stabilise before checking or making further adjustments e Gradually rotate the offset adjustment anti clockwise to decrease to
37. ed F5 Overheat Boiler has overheated allow to cool then press reset button F6 CH Flow Thermistor connection fault Thermistor wires unconnected faulty trapped F10 CH Return Thermistor connection fault Thermistor wires unconnected faulty trapped F11 Flow and or return NTC faulty Thermistor wires unconnected faulty trapped F13 PCB Memory or sensing fault Loose connections on Main PCB or display PCB Central Heating Flow or Return Thermistor wires unconnected faulty trapped Electrode Ignition leads loose unconnected faulty trapped Earthing connection loose disconnected F14 Gas Valve control Gas valve connector loose wires unconnected faulty defective or trapped Faulty main board Faulty gas valve F15 eBus Voltage failure Short circuit on eBus overload on eBus F22 Low Water pressure or Ignition temperature Not enough water in the system rise too slow CH flow or return thermistor wire loose faulty trapped CH flow or return thermistor not connected to pipe correctly Air in the system Faulty pump or pump speed too fast F25 CH Flow temperature rise too high during Check thermistors are connected to pipes correctly operation Air in the system CH Return temperature rise or temperature System is too restrictive difference too high during operation CH Temperature difference between Flow and Return too high during operation F43 Generic error Check all electrical connections internal amp external F70 Software incompatible T
38. ed 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 wiring regulations External wiring must be correctly earthed polarised and in accordance with the rele
39. ed 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 After servicing complete the relevant Service Interval Record section of the Benchmark Checklist located on the inside back pages of these instructions 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 specification 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
40. ed to meet the equivalent requirements of the BEAB e Do not interrupt the mains supply with a time switch or programmer e Connection of the whole electrical system and any heating system controls to the electrical supply must be through a common isolator CABLE STRAIN e Isolation should preferably be by a double pole switched SECURING RELIEF fused spur box having a minimum contact separation of 3mm 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 2 e A fused three pin plug and shuttered socket outlet may be N used instead of a fused spur box provided that it is not used in S room containing a fixed bath or shower 2 e The boiler is suitable for installation in bathroom zones 2 and 2 3 10 1 Electrical Wiring Remove the electrical cartridge from the fittings pack Remove the securing screw to open the cartridge see diagram Diagram 10 1 10 1 NOTE There are two screws supplied loose in the electrical cartridge these will be required to secure the cartridge into the 2 electrical interface housing 2 Slacken the cable strain relief screws in the electrical cartridge see diagram 10 1 Route the mains supply and system cables through the strain O relief and connect to the relevant plug see diagram 10 2 10 2 Wiring x INSTALLER INTERFACE NOTE This appliance Ensure that a seperate pump supply cable is routed thro
41. elephone Group Service F77 Condensate pump error Option Trapped faulty wiring blockage in condensate pump NO DISPLAY or Er displayed Check connection from display PCB to main PCB connector X51 Diagram 13 6 0020107230 00 06 11 Glow worm 235 620v State list To access the state lists the button must be pressed for longer than 5 seconds until it begins to flash S and then a number to indicate the state The state numbers are given below STATE LISTS LELEL Central heating mode Possible Causes no heating required fan pre run pump pre run ignition burner on pump fan overrun fan overrun pump overrun Anti cycling period Diagram 13 7 0020107230_00 06 11 Glow worm 36 To enter the diagnostics menu follow the procedure below Press and hold the MODE and buttons for approx 5 seconds until the screen changes Use the or button to select the number 96 this is the password Hold the MODE for approx 5 seconds when 96 is selected when the screen changes release the button The screen will flash between L1 and a number L1 indicates you have level 1 access the number indicates the diagnostic number below Use the and cycle through the selections below To select a diagnostic number press the MODE button when the correct number is selected The display will show the parameter value of the diagnost
42. ephone Number Engineer ID Number Engineer ID Number Comments Comments Signature SERVICE 3 Date Energy Efficiency Checklist completed Yes No Signature SERVICE 4 Date Energy Efficiency Checklist completed Yes No Engineer Name Engineer Name Company Name Company Name Telephone Number Telephone Number Engineer ID Number Engineer ID Number Comments Comments Signature Signature SERVICE 5 Date Energy Efficiency Checklist completed Yes No SERVICE 6 Date Energy Efficiency Checklist completed Yes No Engineer Name Engineer Name Company Name Company Name Telephone Number Telephone Number Engineer ID Number Engineer ID Number Comments Comments Signature Signature SERVICE 7 Date Energy Efficiency Checklist completed ves No SERVICE 8 Date Energy Efficiency Checklist completed Telephone Number Telephone Number Engineer ID Number Engineer ID Number Comments Comments Signature Signature SERVICE 9 Date Energy Efficiency Checklist completed Yes No
43. er is located over the retaining bosses secure with screw provided see diagram 7 2 0020107230 00 06 11 Glow worm a e SECURING oNE OF THESE HOLES SECURING HOLES MUST USED HANGING BRACKET SECURING HOLES SECURING HOLES Diagram 7 1 MOUNTING e LUGS i SECURING SCREW LOCATE BOILER OVER RETAINING BOSSES Diagram 7 2 19 8 Gas Water Appliance Connection 8 1 Gas Connection Before connection check the supply of local gas The gas supply connection is below the boiler see diagram 8 1 The whole of the gas installation including the meter should be inspected tested for tghtness and purged in accordance with the current issue of BS6891 and in IE the current edition of 1 5 813 Domestic Gas Installations 14507 PRESSURE TEST POINT m 2 L GAS SERVICE GAS SUPPLY ISOLATION PIPE IN VALVE Gas Connection 20 8 2 Water Connections Provision is made for the water connections to be made from above the boiler see diagram 8 1 The position is shown on the wall template Flush out the domestic hot water and the heating systems be fore connecting to the boiler U U i 22mm compression is the recommended fixing for servicing not supplied Water Connections Diagram 8 1 0020107230_00 06 11 Glow worm 9 Co
44. es and ensure good grip Always use assistance if required Removal of carton from delivery van Recommend 2 person lift or 1 person with use of sack truck If 1 person is performing lift straddle the load tilt and place carton into po sition on truck Recommend secure appliance onto truck with suitable straps Ensure safe lifting techniques are used keep back straight bend using legs Keep load as close to body as possible If 2 persons performing lift ensure co ordinated movements during lift Always use assistance if required Carriage of carton from point of delivery to point of installation ground floor Recommend 2 person lift or 1 person with use of sack truck If 1 person is performing lift straddle the load tilt and place carton into position on truck Recommend secure appliance onto truck with suitable straps Ensure safe lifting techniques are used keep back straight bend using legs Keep load as close to body as possible If 2 persons per forming lift ensure co ordinated movements during lift Clear the route before attempting the lift If removing boiler from truck straddle the load and tilt forwards to facilitate secure grip Ensure safe lifting techniques are used keep back straight bend using legs Do not twist repo sition feet instead Take care to avoid trip hazards slippery or wet surfaces and when climbing steps and stairs Always use assistance if required Carriage of carton fro
45. et Remove the heat exchanger by pulling forward then pulling to the right to disengage the return pipe and tilting backwards to ease removal complete with sump Discard the heat exchanger and flanged elbows G8erl SECURING HEAT EXCHANGER with the burner and flow pipe removed for clarity Diagram 14 6 Remove the burner Remove the six flanged nuts and two studs that secure the burner note that the two studs also hold the fan clamping bracket see diagram 14 7 Taking great care not to damage the surface of the burner NOTE Replace the burner gasket and follow the tightening sequence when re fitting the burner see diagram 14 7 NOTE Fit all replacement gaskets and seals when re fitting parts Refer to Section 11 Fill the boiler heating system Re pressurise sealed sysem only Check for any leaks Vent all air from the system Test for gas tightness earth continuity polarity short circuit and resistance to earth Light the boiler and carry out functional checks FAN CLAMPING BRACKET STUDS 2 cOvv e 9 o m T FLANGED NUTS 6 TOP VIEW OF BURNER Suggested tightening sequence for burner fitting 35hx only Diagram 14 7 0020107230_00 06 11 Glow worm 41 14 15 Casing Seal Refer to Section 12 8 14 16 Access to User inter
46. face and Main PCB For access refer to section 14 1 Hinge down the control box and unclip the rear cover to gain access Remove electrical connections from main PCB noting their positions for replacement Unclip main PCB and remove see diagram 14 8 Unclip user interface and remove For replacement see diagram 14 9 and ensure that the user interface connection cable is refitted NOTE When re fitting any of the control boards make sure you support the control box to avoid straining hinges as you push down and clip back into place 14 17 Control Box For access refer to section 14 1 Hinge down the control box and unclip the rear cover to gain access Remove relevant electrical connections from main PCB and grommets from the control box MPORTANT Support the control box whilst undoing the hinges Remove the hinge securing screws accessed from beneath the boiler and remove the control box see diagram 14 10 RETAINING CLIPS S MAIN PCB RETAINING CLIPS Diagram 14 8 42 14 18 Fuse Main PCB Control Box For access refer to section 14 16 The fuse is located at the top left hand corner of the main PCB see diagram 14 8 14 19 Installer Interface Electrical Cartridge Remove the Installer Interface securing screw accessed from beneath the boiler Carefully pull down the electrical cartridge disconnect the cables 00 USER USER INTERFACE INTERFACE CONNECTION CABLE
47. filling loop 5 17 Filling a Sealed Water System Provision for filling the system at low level must be made see diagram 5 5 There must be no permanent connection to the mains water supply even through a non return valve 0020107230 00 06 11 Glow worm SUPPLY 9 PIPE BOILER CONTROL VALVE DOUBLE CHECK VALVE FLOW RETURN HOSE UNION 1 qr HEATING TEMPORARY CIRCUIT CONTROL HOSE CONNECTION VALVE UNION DRAIN POINT Method 1 BOILER FLOW RETURN CABACKFLOW PREVENTION DEVICE CONTROL CONTROL VALVE VALVE SUPPLY PIPE HEATING CIRCUIT AR GAP TUNDISH Method 2 Diagram 5 5 17 6 Installation Preparation 6 1 Appliance Pack Please check the contents of packs as shown in diagram 6 1 The packs are located in the top polystyrene packing Remove the carton sleeve and top pack then lift the boiler and its polystyrene base support out of the lower pack 6 2 Site Requirements The boiler mounting wall should be suitable for the weight of the appliance and be true and flat NOTE Due to the varied site conditions we do not supply fixings and advise that the installer should supply those which are suitable 6 3 Wall Template Take the wall template from the document pack located within the top polystyrene packing and place in the desired position on the wall giving due consideration to the required boiler clearances see section 3 and the flue you are fitting Mark the posit
48. g regulations and the Water Supply water fittings regulations 1999 and water byelaws 2000 Scotland see also the current issue of 55546 and BS6700 If fitting to an existing system the local authority should be informed 5 9 Vented DHW System General All domestic hot water circuits connections fittings must be in accordance with the relevant standards and water supply regulations For GB Guidance G17 to G24 and recommendation R17 to R24 of the Water Regulations Guide for Scotland the Water Byelaws 2000 Scotland For IE The current edition 1 5 813 Domestic Gas Installations 0020107230 00 06 11 Glow worm Water System Open Vented Central Heating System 5 10 Open Vented Central Heating System The boiler must be supplied from an unrestricted water supply taken from a feed and expansion cistern situated at a maximum height of 27 metres 90ft above the boiler The cold feed must be 15mm minimum size The vent must rise continuously and be unrestricted It is important that the relative positions of the pump cold feed and open vent are as shown in diagram 5 3 5 11 Combined Feed and Vent For combined feed and vent a 22mm pipe must be fitted in accordance with BS 5449 Open vented system amp Recommended S relationship between 450mm pump cold feed and vent MIN 22mm MIN VENT FEED AND EXPANSION CISTERN d 15mm MIN COLD FEED 15mm MIN AUTOMATIC BY PASS
49. he relevant standards EN 13384 1 and 2 C43 flue systems Ground floor only with reference to the table below and the manufacturers instructions supplied The appliance maximum flue length must be included when calculating the overall design of the flue system NOTE The horizontal flue terminal must be removed DU poBRoONMXx Each time an additional 90 bend is necessary or 2 at 45 the length L must be reduced by 1 m Flexicom Flexicom Flexicom Flexicom Flexicom Flexicom 12hx 15hx 18hx 24hx 30hx 35hx Exhaust mass rate g s At Min Thermal Load 40C 30 C At Max Thermal Load 80C 60 C Exhaust temperature At Min Thermal Load 40C 30 C At Max Thermal Load 80C 60 C 0020107230 00 06 11 Glow worm 13 5 Water Systems General 5 1 General This boiler is designed to provide central heating from a fully pumped open vented or sealed water system and domestic hot water using a fully indirect vented or unvented cylinder 5 2 Draining Points Draining taps must be provided at all low points of the system which will allow the entire system to be drained Draining taps shall be to the current issue of BS2879 5 3 Pump The pump should be fitted on the flow pipe from the boiler and have isolating valves each side A variable duty pump should be set to give a temperature difference of no greater than 20 between the flow and return with the thermostat
50. ic number selected To return to the diagnostic number selector simply press the MODE button To change the parameter use the or buttons Once the value has been changed it must be saved by holding the MODE button for approximately 5 seconds This will return to the diagnostic number selector DIAGNOSTIC CODES LEVEL 1 Installer Access W 40 5 EH d 2 Max burner anti cycling period at 209 C Flo w temperature 3 60 min factory setting 20 min d 4 N A N A d 5 Flow temperature setpoint In 9C min 28 and max 82 d 8 External controls heat demand 0 no heat request open 1 heat request closed d 9 Flow target temperature from external In C intelligent control dio d 13 Hot water circulation pump via accessory module 1 to 100 on 0 off d 23 Summer Winter function 1 Winter 0 Summer d 25 Hot water activation via eBUS Control yes 02 no i27 _ Option Relay 1 Reserved for future use d 28 Option Relay 2 d34 Fan speed actual valve da0_ Flow temperature d 44 lonisation current Actual value 10nA gt 8 no flame lt 4 good flame d 60 Number of safety temperature limiter cut offs Quantity d 61 Number of lock outs Number of unsuccessful ignitions in the last attempt d 64 Average ignition time In seconds d 65 Maximum ignition time In seconds d 67 Remaining burner anti cycling time block time d 68 Unsuccessful ignitions in the first attemp
51. ied out the appliance must be disconnected until the CO CO2 ratio is acceptable Advice can be sought from the Glow worm Technical Helpline 12 1 Servicing NOTE If the Combustion CO2 2 ratio amp Gas rate checks did not require adjustment then it will not be necessary to complete a full service All routine servicing requirements can be achieved by the removal of the front panel see diagram 12 2 Position the control box into the service position see diagram 12 3 28 Before commencing with a service or replacement of parts The boiler should be isolated from the electrical and gas supplies 2 FRONT PANEL SECURING gt SCREWS Diagram 12 2 A CORD CONTROL BOX SERVICE POSITION Diagram 12 3 OFFSET Diagram 12 4 0020107230_00 06 11 Glow worm 12 4 Spark Electrode NOTE If the functional checks did not indicate poor combustion then it is not necessary to service this component Ease the securing clips away from the sump to release the retaining catch then push the flue hood up to disengage from the sump see diagram 12 5 To remove swivel flue hood 90 and pull down and out see diagram 12 5 Check seal for wear or damage and replace if necessary IMPORTANT Do not allow fixings nuts screws etc to fall into the open flue hood sump use a temporary cover whilst removing any parts Disconnect the
52. ion of the flue centre if fitting a side flue extend the flue centre line into the corner then 149mm along the adjacent wall see diagram 6 2 For extended side flues the flue hole centre should be determined by extending the dashed inclined line on the template to the side wall then 149mm along the adjacent wall see diagram 6 2 This dashed line is drawn at 44mm metre 2 5 rise from the boiler To allow for the flue passing through the wall at this angle a 125mm hole should be drilled irrespective of internal or external installation Remove the wall template whilst drilling the flue hole 6 4 Flue Hole Cutting External access flue installation can use a 105mm diameter core drill Internal access only flue installation will need a 125mm diameter core drill NOTE The flue is designed with an internal fall of 44mm metre 2 5 therefore the hole can be drilled horizontally If flue extension pipes are to be used then a core drill size of 125mm is required This will allow the extension pieces to slope at 44mm metre 2 5 towards the boiler 18 BOILER S SECURING GAS PIPE SCREW HANGING BRACKET 0 0 GAS SERVICE ISOLATION VALVE Documentation Pack not illustrated Wall Template User Instructions Installation and Servicing Instructions Flue Installation Instructions Diagram 6 1 d e
53. l require special consideration with respect to any openings doors vents or windows under the roof Care is required to protect the roof if made of plastic sheeting If the carport comprises of a roof and two or more walls seek advice from the local gas supply company before installing the boiler 10 If the flue terminal is positioned near a light source insects may enter the flue system Where safe and practical to do so advise the homeowner to check the flue outlet and clear visible insects from the terminal end H and J See diagram 4 2 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 Terminal Guard A terminal guard is required if persons could come into contact with the terminal or the terminal could be subject to damage If a terminal guard is required it must be positioned to provide minimum of 50mm clearance from any part of the terminal and be central over the terminal The guard should be similar to that shown in diagram 4 1 A suitable guard is manufactured by Tower Flue Components Morley Rd Tonbridge Kent TN9 1RA Size 280mm x 165mm Part No CGDK3 6864 Diagram 4 1 0020107230 00 06 11 Glow worm G A i UNDER CAR PORT etc
54. lly Range Rating The boilers are fully modulating for central heating and it is therefore not necessary to range rate the boiler However if desired it is possible to range rate the boiler between 10 and Max output according to the model in 1kW increments refer to section 11 Condensate Drain A plastic drain pipe must be fitted 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 8 for more details Pluming from flue terminal Like all condensing boilers this appliance will produce a plume of condensation from the flue terminal in cool weather This is due to the high efficiency and hence low flue gas temperature of the boiler This is normal and not an indication ofa fault Safety Devices Electrical Supply Failure The boiler will not work without an electrical supply Normal operation of the boiler should resume when the electrical supply is restored Reset any external controls to resume normal operation of the central heating If the boiler does not resume normal operation press the reset button If the boiler does not resume normal operation after this call your Installation Servicing company or Glow worm service Overheating Safety The boiler software is designed to recognise the potential
55. m point of delivery to point of installation first or higher floor cellar Recommend 2 person lift or 1 person with use of sack truck If 1 person is performing lift straddle the load tilt and place carton into position on truck Recommend secure appliance onto truck with suitable straps Ensure safe lifting techniques are used keep back straight bend us ing legs Keep load as close to body as possible If 2 persons perform ing lift ensure co ordinated movements during lift Avoid upper body top heavy bending do not lean forward sideways Clear the route before attempting the lift If removing boiler from truck straddle the load and tilt forwards to facilitate secure grip Ensure safe lifting techniques are used keep back straight bend using legs Do not twist reposition feet instead Take care to avoid trip hazards slippery or wet surfaces and when climbing steps and stairs Always use assistance if required Carriage of carton from point of delivery to point of installation roofspace Recommend 2 person lift Ensure co ordinated movements during lift Avoid upper body top heavy bending do not lean forward side ways Clear the route before attempting the lift Take care to avoid trip hazards slippery or wet surfaces and when climbing steps and stairs When transferring appliance into roofspace recommend 1 person to be in roofspace to receive the appliance and other person to be below to pass up and suppo
56. nal 90 bend is necessary 2 at 45 the length L must be reduced by 1 m 4 2 2 Telescopic direct rear flue 60 100 mm 0 60 100 mm Te Maxlength 0 60 100 512mm 4 2 3 Vertical concentric flue 60 100 mm 80 125 mm C33 type installation If the terminal is at less than 1 80 m from the ground you must install a terminal protection kit ax ena 0 2 60 100 2 80 125 Each time an additional 90 bend is necessary 2 at 45 the length L must be reduced by 1 m 0020107230 00 06 11 Glow worm 4 2 4 Multiple boiler chimney flue 60 100 mm C43 type installation The flue connecting from the appliance to the flue system must be supplied from the manufacturer of the boiler C43 flue systems must not be a pressurised system but act under natural draught principles C43 type flue systems must have their own condensate drain fitted and not allow condensate to mix into other appliances lt Pressure balancing system Air inlet pipe Collector pipe Boiler Inspection hatch Multiple Boiler Chimney Flue Length The flue length must be calculated and installed according to Final storey t
57. ndensate Connections 9 1 Condensate Drain Connection The condensate drain connection is positioned below the boiler as shown in diagram 9 1 To discharge condensate to a drain the drain pipe should have a fall of a least 44mm metre 2 5 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 9 2 It is recommended that any external condensate drain pipe is protected and also preferably of 32mm diameter to prevent freezing in adverse weather conditions The condensate is discharged periodically in slugs by siphonic action It is not necessary to provide air breaks or extra traps in the discharge pipe as there is already a trap inside the boiler Fitting an extra trap may cause the boiler siphon to work incorrectly Refer to 55546 or BS6798 for advice on disposal of boiler condensate 0020107230 00 06 11 Glow worm CONDENSATE DRAIN CONNECTION Diagram 9 1 21 INTERNAL SOIL EXTERNAL SOIL a AND VENT STACK AND VENT STACK 5 EXTERNAL MAX 3M 022mm MIN 022mm MIN NO RESTRICTION NO RESTRICTION ONCENG IN ON LENGTH Internal Soil and Vent Pipe External Soil and Vent Pi
58. ng complete all relevant sections of the Benchmark Checklist located in the inside back pages of this document 11 1 Preliminaries All Systems DO NOT operate the boiler without water The commissioning should be carried out by a competent person approved at the time by the Health and Safety Executive in accordance with the current issue of BS6798 Make sure that the system has been thoroughly flushed out with cold water and that all cleanser if used has been removed With the gas service isolation valve closed with no demand from any external controls and the power supply to the boiler switched off test for gas soundness and purge air from the gas supply 11 2 Filling the Heating Circuit With the gas service isolation valve closed and with no demand from any external controls 1 Fill the heating system Sealed system only fill the system to a pressure of 1 0bar 2 Vent all air from the system repeat as neccessary until the system is full and all the air has been vented 11 3 Gas Supply The gas valve is factory set for natural gas G20 and should need no adjustment Turn on the gas supply at the isolation valve see diagram 11 1 Check the supply pressure at the pressure test point is 20mbar 22d 9 S 4 ELECTRICAL CARTRIDGE Diagram 10 3 14507 PRESSURE TEST POINT GAS SERVICE ISOLATION GAS SUPPLY VALVE PIPE IN Diag
59. ons who let out any property containing a gas appliance in the UK e The user shall not interfere with or adjust sealed components e t is the Law that any servicing is carried out by a competent person approved at the time by the Health and Safety Executive e Advise the user that like all condensing boilers this appliance will produce a plume of condensation from the flue terminal in cool weather This is due to the high efficiency and hence low flue gas temperature of the boiler e Advise the user of the precautions necessary to prevent damage to the system boiler and the building in the event of the heating system being out of use during frost or freezing conditions e Advise the user that the permanent mains electrical supply SHOULD NOT be switched off as the built in frost protection and pump saver program will not operate e Advise the User if the mains electricity and gas are to be turned off for any long periods during severe weather it is recommended that the whole system including the boiler should be drained to avoid the risk of freezing NOTE Sealed System Contact your installation servicing company as draining refilling and pressurising MUST be carried out by a competent person approved at the time by the Health and Safety Executive e Leave these instructions and the Benchmark Installation Commissioning and Service Record with the user 0020107230 00 06 11 Glow worm IMPORTANT NOTES To ensure the continue
60. own and gently levered down as indicated Remove the spark electrode plug and earth connection Remove the fan and gas valve electrical connections Remove the fan and gas valve assembly Remove the condensate trap Remove the drain outlet pipe from the base of the trap see diagram 15 1 Remove the condensate drain securing screw and carefully pull the trap forward see diagram 12 13 Drain the heat exchanger Drain the heat exchanger using the drain point on the right hand side of the heat exchanger see diagram 14 4 40 62 Vl RETURN PIPE xe RETURN PIPE HEATING RETURN THERMISTOR Diagram 14 3 j 9 ane 1j CLIP DRAIN POINT FLANGED ELBOW Diagram 14 4 FLANGED FLow ELBOW 8 cvl RETAINING CLIP EXCHANGER Diagram 14 5 0020107230 00 06 11 Glow worm Remove the heat exchanger Undo the screws securing the flanged elbow on the top right hand side of the heat exchanger and remove the retaining clip from the flanged elbow see diagram 14 5 Remove retaining clip from the flanged elbow on the bottom of the heat exchanger see diagram 14 4 Remove screws securing the heat exchanger one on top and one underneath the heat exchanger see diagram 14 6 Lift up heat exchanger slightly to disengage it from its hanging brack
61. pe SINK CONSTITUTES EXTERNAL LENGTH AIR BREAK OF PIPE 22mm MIN 22mm MIN NO RESTRICTION ON LENGTH OPEN END OF PIPE NOTE FOR EXTENDED Internal Termination into Combined Sink Waste DIRECT INTO GULLEY PIPE RUNS 32mm DIA BELOW GROUND BUT PIPE SHOULD BE USED ABOVE WATER LEVEL External Termination to a Gulley or Hopper EXTERNAL LENGTH OF PIPE 3M MAX 22mm MIN TERMINATION FROM APPLIANCE GROUND either or 22mm MIN 500mm MIN NO RESTRICTION ON LENGTH 25mm MIN 100mm 300mm PLASTIC TUBE MIN BOTTOM OF OPEN END OF PIPE DIRECT INTO TUBE SEALED GULLEY BELOW GROUND LEVEL LIMESTONE CHIPPINGS gt BUT ABOVE WATER LEVEL HOLE DEPTH 40 MIN omm 2 ROWS OF 3 x 12mm HOLES AT 25mm CENTRES 50mm FROM BOTTOM OF TUBE HOLES Internal Termination Downstream of FACE AWAY FROM HOUSE Sink Waste External Termination into Soakaway NOTE PIPEWORK SHOULD ALWAYS FALL AWAY FROM BOILER BY AT LEAST 2 5 44mm FOR EVERY 1M Diagram 9 2 0020107230 00 06 11 Glow worm 22 10 Electrical Connection SO6EL ELECTRICAL WARNING This appliance must be earthed CARTRIDGE e This appliance must be wired in accordance with these instructions Any fault arising from incorrect wiring cannot be put right under the terms of the Glow worm guarantee e All system components must be of an approved type Electrical components have been test
62. ram 11 1 0020107230 00 06 11 Glow worm 1 Press and hold for 2 seconds for Central Heating D CENTRAL HEATING 0 C TEMPERATURE BURNER DEMAND _ DIGITAL DISPLAY SELECTOR BUTTONS 6 E K LU 4 RESET BUTTON MODE BUTTON SELECTOR BUTTON FUNCTION 1 Increase Temperature SELECTOR BUTTON FUNCTION 1 Decrease Temperature 2 Deactivate Central Heating OPERATION Central Heating activated but with no demand target temperature indicated Central Heating active with demand shown by the temperature and burner symbol indicate that the burner is on Holiday Mode Central Heating de activated Diagram 11 2 Commissioning should only be carried out by a competent person approved at the time by the Health and Safety Executive 11 4 Initial Lighting NOTE The combustion for this appliance has been checked adjusted and preset at the factory for operation on natural gas G20 as defined on the appliance data label Do not adjust the Gas Air ratio valve No measurement of the combustion is necessary having checked e the appliance has been installed in accordance with the instructions e the integrity of the flue system and flue seals e thatall internal external controls are calling for heat
63. ram 12 5 To remove swivel flue hood 90 and pull down and out towards front of boiler 14 7 Fan Gas valve assembly For access refer to section 14 1 Undo the tubing nut to remove the gas valve from the gas pipe and any electrical connections see diagram 12 7 Remove the securing nut holding the fan retaining bracket press down on burner to ease removal of securing nut Slide out the fan retaining bracket Lift front of bracket away from stud and pull forward to release the fan see diagram 12 10 Lift fan gas valve assembly up and forward away from locating studs Remove fan gasket and replace To replace the fan and retaining bracket correctly insert into slots on fan clamping bracket and locate onto lugs on the burner see diagram 12 10 14 8 Silencer assembly rear For access refer to section 14 1 Remove the fan gas valve assembly see section 14 7 Pull Silencer rear away from fan gas valve assembly The rear silencer is a push fit so no tools or fixings are required for its removal or fitting see diagram 12 11 14 9 Spark Electrode For access refer to section 14 1 Remove the spark plug lead and earth lead Remove the two securing nuts Withdraw the spark electrode by slowly pulling up and leaning it forward towards the centre of the heat exchanger to ensure that the electrode does not foul on the hole in the burner casing Check spark gap see diagram 12 6 Eger PRESSURE
64. requirements of the relevant directives and Standards 2009 142 EEC including amendments Designed and built to CE type examination certifi Directive on the approximation of the law of the cate member states relating to appliances burning gaseous fuels PIN no 87BQ86 92 42 EEC including amendments Directive of efficiency relating to boiler burning Designed and built according to European Stan gaseous fuels dards 2006 95 EEC including amendments EN 483 Directive on the harmonization of the laws of EN 677 Member States relating to electrical equip EN 625 ment designed for use within certain voltage limits EN 60335 1 EN 60529 2004 108 EEC including amendments EN 50165 Directive on the approximation of the law of the EN 55014 member states relating to electromagnetic com EN 61000 3 2 patibility EN 61000 3 3 Any change to the appliance and or any use not according to the instructions will lead to the invalidation of this Declaration of Conformity Belper March 2010 AX a Ie place date Program Manager Certification Group Manager S Keeton A Beardsley 0020107230 00 06 11 Glow worm 45 Please affix the label positioned on the top panel of your boiler over this area COMMISSIONING CHECKLIST GAS BOILER SYSTEM This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and
65. rt appliance Ensure safe lifting techniques are used keep back straight bend using legs Keep load as close to body as possible Always use assistance if required It is assumed safe access flooring and adequate lighting are provided in the roof space It is recommended a risk assessment of the roof space area be carried out before moving the appliance into the area to take into account access stability of flooring lighting and other factors and appropriate measures taken Unpacking of appliance from carton Recommend 2 persons unpack appliance from carton Always keep working area clear Recommend cut base end of carton and open car 44 ton flaps then tilt boiler forwards from its side onto its base and remove carton by sliding up over the boiler Ensure safe lifting techniques are used keep back straight bend using legs Keep load as close to body as possible Always use assistance if required Dispose of pack aging in a responsible manner Recommend wear suitable cut resistant gloves with good grip to protect against sharp edges and ensure good grip when handling appliance outside packaging Positioning of Appliance for Final Installation no obstructions This appliance is deemed to be a one person lift when removed from the carton Fit bracket securely onto wall before lifting appliance into position Obtain firm grip on front and sides of appliance lift upwards ensure stable balance achieved and lift upw
66. rvice 01773 828100 Technical Helpline 01773 828300 General and Sales enquiries Tel 01773 824639 Fax 01773 820569 To register your Glow worm appliance call 0800 0732142 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 THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS TABLE OF CONTENTS 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 CONTENTS DESCRIPTION SECTION PAGE
67. s 0 063 x Total System Volume NOTE A higher initial design pressure requires a larger volume expansion vessel Guidance on vessel sizing is also given in the current issue of BS5449 and BS7074 Part 1 for IE refer to the current edition of 1 5 813 Domestic Gas Installations The charge pressure must not be less than the static head of the system that is the height of the highest point of the system above the expansion vessel 3 LITRES 0 66 gals MAKE UP BOTTLE if required AUTO 1 1 i NON RETURN VALVE FLOW RETURN HEATING CIRCUIT Make up alternatives CONTROL VALVE A CONTROL VALVE A AIR Ei RELEASE FILLING POINT AUTOMATIC uj BYPASS VALVE B BABET EIS CULATING VALVE PRESSURE GAUGE BOILER EXPANSION VESSEL Diagram 5 4 16 0020107230 00 06 11 Glow worm 5 15 Pressure Gauge A pressure gauge with a set pointer and covering at least 0 to 4 bar 0 to 60 Ib in2 shall be fitted permanently to the system in a position where it can be seen when filling the system 5 16 Water Makeup Provision should be made for replacing water loss from the sys tem using a make up bottle mounted in a position higher than the top point of the system connected through a non return valve to the return side of either the heating circuit or the hot water cylinder Alternatively provision for make up can be made using a
68. s after the burner has lit The approximate maximum gas rates are APPROXIMATE GAS RATES MODEL NATURAL GAS G20 m3 h ft3 h 12hx 1 28 45 15hx 1 60 56 5 11 6 Range Rating The boilers are fully modulating therefore it is not necessary to range rate them however if desired you can adjust the boiler in 1KW increments between 10 and maximun output of your appliance as follows a Press and hold the MODE and button for 5 seconds The display will change to flashing Use the or button to scroll to 96 Press and hold MODE 5 seconds to confirm The display now shows a flashing d 0 The part load setting is displayed in kW Press MODE the max rate will be indicated to change the value to the desired setting use the or button f Press MODE for 5 sec to confirm the new setting has been saved g Press and hold MODE and to exit 600 7565 7530 7495 7455 EZE o a0 SS 565 532 495 455 424 26 11 7 Heating System Ensure that the external controls are calling for heat Fully open all radiator valves flow control valve and bypass valve if fitted Balance the radiators as required and if fitted adjust flow control valve to give the required system differential Turn off all radiators that can be shut off by the user and check to see if less than the maximum differential allowed of
69. s is BS6891 In IE this is the current edition of 1 5 813 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 fluid purge in accordance with the above standard Domestic Hot Water All domestic hot water circuits connections fittings 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 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 1 5 813 Domestic Gas Installations and the current Building Regulations must be followed Boiler Design Boiler Design These boilers are designed to provide central heating from a fully pumped open vented or sealed water system and domestic hot water using a fully indirect cylinder Once the controls are set the boiler operates automatica
70. service organisation using the telephone number on the inside front cover of this booklet 0020107230 00 06 11 Glow worm 1 Boiler Specification BOILER SPECIFICATION 12 to 30hx 25kg 66b 35 26 5kg 58410 Total weight installed 12hx to 30hx 28kg 621b 35hx 29 5kg 6516 Gas connection O D 15mm copper Heating Flow and Return connection O D 22mm copper Condensate connection I D 21 5mm plastic Electrical rating 60W fused 3A IP clasification IPX4D Internal fuse rating on main PCB 2A Gas supply governed meter only and cat G20 natural gas Gas Category 2 natural gas Inlet gas working pressure 20mbar Burner CO case on 9 3 nominal Burner 96 CO case off 9 3 nominal Approximate max gas rate after 10 mins from cold Approximate min gas rate after 10 mins from cold Approximate gas rate PLEASE REFER TO THE COMMISSIONING SECTION at part load Heat input NETT kW max 24 4 30 8 Heat output P kW SEDBUK rating 96 SEDBUK rating 96 2009 88 5 88 5 88 4 88 4 88 7 89 2 ROX aimee 0020107230_00 06 11 Glow worm 0 87 LEBEL 280 149 LA gt ud FLUE LY 7 FLUE 522 5 375 6 RETURN FLOW FLUE t 1 FLUE N BOILER
71. set at which is about 80 to give a flow rate as given in the table See chart for pressure loss of the boiler diagram 5 1 High resistance microbore systems may require a higher duty pump 5 4 Flow Rate If itis necessary to alter the flow rate the system can be fitted with a lockable balancing valve in the main flow or return pipes shown in diagram 5 4 The flow rate through the boiler must not be allowed to fall below that given in diagram 5 2 5 5 Bypass A system bypass is required and should be fitted at least 1 5 metres away from the boiler refer to the current issue of the central heating system specifications CHeSS 5 6 Water Treatment Existing system It is ESSENTIAL that prior to installing the new boiler the system is thoroughly flushed New system For optimum performance after installation the boiler and its associated central heating system should also be flushed Flushing should be carried out in accordance with BS7593 2006 using a cleanser such as Sentinel X300 or X400 Fernox Restorer or Salamander corrosion guard cleaner IMPORTANT Ensure all cleanser is removed from the whole system before adding an inhibitor For long term corrosion protection after flushing an inhibitor should be used refer to the current issue of BS 5449 and BS 7593 on the use of inhibitors in central heating systems Examples are Sentinel X100 Fernox Protector or Salamander corrosion guard inhibitor 14
72. t d 69 Unsuccessful ignitions in the second attempt Quantity d 76 Appliance variant device specific number 00 to 99 d 80 Heating operating hours in h d 82 Cycles in heating mode Quantity in hundreds d 90 Digital regulator status 1 identified 0 unidentified eBUS Address lt 10 d 91 Internal Programmer type for use with Options board kit 0 24 hour default 1 7 day E d 97 Activation of the second diagnostic level d 99 State List see diagram 14 7 mlndicates read and write function all other diagnostics are read only Diagram 13 8 0020107230_00 06 11 Glow worm Nd 14 Replacement of Parts 14 1 General Replacement of parts must be carried out by a competent person approved at the time by the Health and Safety Executive Replacement parts that have associated components that need replacing on removal ie O ring seals gasket etc will be supplied and should be fitted Before replacing any parts the boiler should be isolated from the mains electric supply and the gas should be turned off at the gas service isolation valve on the boiler see diagram 14 1 Ensure that components with electrical connections are disconnected before removal Unless stated otherwise parts are replaced in the reverse order to removal After replacing any parts always test for gas tightness and if necessary carry out functional test of the controls For replacement of parts the front casing of the boiler will need to be
73. the clearance to be greater than those specified in diagram 3 1 3 3 Timber Frame Buildings If the boiler is to be installed in a timber frame building it should be fitted 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 3 4 Combustible Material The boiler and flue are suitable for installation onto and through combustible materials provided that 1 Minimum 5mm clearance is maintained around the circumference of the flue air intake 2 The combustible surface and fixings are suitable for supporting the load 3 The minimum clearances from the boiler case are maintained 3 5 Room Ventilation The boiler is room sealed so a permanent air vent is not required 3 6 Cupboard or Compartment Ventilation Due to the high efficiency and hence low casing temperature of this boiler cupboard or compartment ventilation is not necessary Leave existing air vents 0020107230 00 06 11 Glow worm 12792 Aremovable compartment door can be placed a minimum of 5mm in front of the appliance This can be reduced to 20mm for a direct rear flue Diagram 3 1 4 Evacuation of Combustion Gas 4 1 Regulation T Only flue accessories supplied by Glow worm must be used Different flue outlet configurations can be carried out Consult your supplier for more information about the other possibilities and associate
74. ugh the will not operate without strain relief and connected to the relevant plug see diagram a link or system eeleeeeo 10 2 controls fitted LOS SONLRE o 230Vac FROST STAT Slacken the cable strain relief and route the pump electrical supply cable and connect as shown in diagrams 10 1 and 10 2 230Vac SYSTEM CONTROLS KEY DESCRIPTION Zone valve N MAINS NEUTRAL Programmer Room thermostat L MANSEE Cylinder thermostat MAINS EARTH R SWITCH LIVE 230v F FROST STAT 230v switchable Ov LOW VOLTAGE 0v DEMAND EBUS Eb DATA BUS FOR APPROVED JUNCTION u ewaccessonts TT TI BOX sawp Fuse APPLIANCE SHOULD DOUBLE 4 POLE ISOLATOR 230Vac 50Hz E PERMANENT N SUPPLY L Diagram 10 2 0020107230 00 06 11 Glow worm 23 10 3 Electrical Cartridge Securing Close the cartridge and secure with the previously removed screw Push the electrical cartridge into the interface housing on completion of the wiring see diagram 10 3 Secure with the two cartridge retaining screws provided in the cartridge body 10 4 Electrical Connections Testing Carry out preliminary electrical system checks as below 1 Test insulation resistance to earth of mains cables 2 Test the earth continuity and short circuit of cables 3 Test the polarity of the mains NOTE If you require to test the appliance refer to section 13 11 Commissioning IMPORTANT At the time of commissioni
75. vant 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 identified 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 859C insulated cable not less than 0 75 2 24 0 20 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 by Glow worm Any alteration not approved by Glow worm could invalidate the certification boiler warranty and may also infringe the current issue of the statutory requirements 0020107230 00 06 11 Glow worm 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 Directi
76. ve 92 42 EEC on the efficiency requirements for new hot water boilers fired with liquid or gaseous fuels Type test for purposes of Regulation 5 certified by Notified body 0087 Product production certified by Notified body 0086 The CE mark on this appliance shows compliance with 1 Directive 2009 142 EC 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 fit 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 an

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