Glow-worm Ultracom₂ Installation guide

Brand: Glow-worm

Model: Ultracom₂

Category: Water heaters & boilers

Type: Installation guide

condens

Ultracom2 cxi

24cxi

G.C. No. 47-019-10

30cxi

G.C. No. 47-019-11

35cxi

G.C. No. 47-019-12

Installation

and Servicing

- 1 -



1 Instructionsguidance.........................................................................................................................3

1.1 Productdocumentation...........................................................................................3

1.2 Associateddocuments..........................................................................................3

1.3 Explanationofsymbols...........................................................................................3

1.4 Guaranteeregistration............................................................................................3

2 Appliancedescription.........................................................................................................................3

2.1 Safetydevices.......................................................................................................3

2.2 Datalabel...............................................................................................................4

2.3 Gascategory.........................................................................................................4

2.4 Regulationandstatutoryrequirements..................................................................4

2.5 Hydraulicschematic..............................................................................................5

3 Safetyinstructionsandregulations....................................................................................................6

3.1 Safetyinstructions..................................................................................................6

3.2 Regulations............................................................................................................6

4 Recycling...........................................................................................................................................7

4.1 Appliance................................................................................................................7

4.2 Packaging...............................................................................................................7



5 Ultracom2cxi......................................................................................................................................8



6 Appliancelocation..............................................................................................................................9

6.1 Location..................................................................................................................9

6.2 Clearances.............................................................................................................9

6.3 Ventilation..............................................................................................................9

7 Applianceinstallation......................................................................................................................10

7.1 Scopeofdelivery..................................................................................................10

7.2 Recommendationsbeforeinstalling.....................................................................10

7.3 Dimensions...........................................................................................................12

7.4 Mounting..............................................................................................................12

8 Hydraulicconnection........................................................................................................................13

8.1 Gasandwaterconnections..................................................................................13

8.2 SafetyDischargeValve........................................................................................14

8.3 Connectiontothecondensatetrap......................................................................15

9 Evacuationofcombustiongas.........................................................................................................17

9.1 Regulation............................................................................................................17

9.2 Fluecongurationdescription..............................................................................19

10 Removethefrontpanel....................................................................................................................20

11 Electricalconnections......................................................................................................................20

11.1 Accesstomainboard..........................................................................................21

11.2 Mainboard............................................................................................................21

11.3 Electricalwiring.....................................................................................................21

11.4 Externalaccessories............................................................................................23

11.5 Testingtheelectricalconnections.........................................................................23

11.6 Wiringdiagram.....................................................................................................24



- 2 -

12 Commissioning...............................................................................................................................25

12.1 Switchingon.........................................................................................................25

12.2 FillingtheCHsystem(Centralheating)................................................................25

12.3 FillingDHWCircuit...............................................................................................26

12.4 FillingtheCondensateTrap.................................................................................26

12.5 Initiallighting.........................................................................................................26

12.6 Gasrates..............................................................................................................27

12.7 Testingheatingsystem.........................................................................................27

12.8 Testingdomestichotwatersystem.......................................................................27

12.9 Completion...........................................................................................................27

13 Specicadjustment.........................................................................................................................28

13.1 Heatingcircuitadjustment....................................................................................28

13.2 Appliancetechnicalsettingsandparameterlist...................................................28

13.3 CO2measurement...............................................................................................31

13.4 Re-checkandrestart............................................................................................32

14 Userinformation...............................................................................................................................32



15 Trouble-shooting..............................................................................................................................33

15.1 Faultdiagnosis.....................................................................................................33

15.2 Faultmemory........................................................................................................34

15.3 Faultcodes...........................................................................................................34

15.4 Functionalowdiagram........................................................................................36

16 Gasconversionadjustments............................................................................................................37

16.1 Settings.................................................................................................................37

16.2 Restart-re-checkcommissioning........................................................................38

17 Draining...........................................................................................................................................38

17.1 Heatingcircuit......................................................................................................38

17.2 DomesticHotwatercircuit...................................................................................38

18 Servicing..........................................................................................................................................38

18.1 AnnualMaintenance.............................................................................................39

18.2 Casingremoving...................................................................................................40

18.3 Combustioncheckandsettingtheair/gasratiovalve..........................................40

18.4 Servicing...............................................................................................................42

18.5 Silencer................................................................................................................42

18.6 Expansionvessel..................................................................................................42

18.7 Heatinglter.........................................................................................................43

18.8 Condensatetrap...................................................................................................43

18.9 Combustionblock.................................................................................................44

18.10 Servicecompletion...............................................................................................45

19 ReplacementofParts......................................................................................................................46

19.1 General.................................................................................................................46

19.2 BoilerAccess........................................................................................................46

19.3 Viewingwindow....................................................................................................46

19.4 Hydraulicblock.....................................................................................................48

19.5 Combustionblock.................................................................................................50

19.6 Condensatetrap...................................................................................................52

19.7 PCB......................................................................................................................53

20 Spareparts......................................................................................................................................54

20.1 ShortListofParts.................................................................................................54

20.2 ShortListofParts.................................................................................................55



0020112601_02-10/12-Glow-worm

- 3 -

INTRODUCTION



 

 

Theinstructionsareanintegralpartoftheapplianceandmust

behandedtotheuseroncompletionoftheinstallationinorder

tocomplywiththecurrentregulation.

• Carefullyreadthemanual,tounderstandalltheinformation

toenablesafeinstallation,useandservicing.Noliabilitycan

beacceptedintheeventofdamagefornotcomplyingwith

theguidanceinthisinstructionmanual.

Theseinstructionsconsistof,Installation,Servicing,FaultFinding,

ReplacementofPartsandSpares.Theinstructionsareanintegral

partoftheapplianceandmust,tocomplywiththecurrentissueof

theGasSafety(InstallationandUse)Regulations,behandedto

theuseroncompletionoftheinstallation.

 

- 1Instructionsforuse

- 1magneticlightinginstructionlabel

- 1ueguide

- 1extendedguaranteeleaet

- 1guaranteeenvelopepack

- 1walltemplate

- 1gasconversionlabel

 

aDANGER: Risk of injuries.

eDANGER: Risk of electric shock.

bATTENTION: Risk of damage to the appliance or

to its surroundings.

iIMPORTANT: Important information.

 

ThankyouforinstallinganewGlow-wormapplianceinyourhome.

Glow-wormappliancesaremanufacturedtothevery

higheststandardsowearepleasedtoofferourcustomersa

ComprehensiveGuarantee.

Thisproductisguaranteedfor24monthsfromthedate

ofinstallationor30monthsfromthedateofmanufacture,

whicheveristheshorter,forpartsandlabour.

Thesecondyearofguarantee,fromthebeginningofthe13th

monthonwardsafterinstallationormanufacture,isconditional

upontheboilerhavingbeenservicedbya

approvedatthetimebytheHealthandSafetyExecutive,in

accordancewiththemanufacturer’srecommendations.We

stronglyrecommendregularservicingofyourgasappliance,

butwheretheconditionisnotmet,anychargeablespareparts

orcomponentsissuedwithintheapplicableguaranteeperiod

stillbenetfroma12monthwarrantyfromthedateofissueby

themanufacturer.

Werecommendyoucompleteandreturnassoonaspossible

yourguaranteeregistrationcard.Ifyourguaranteeregistration

cardismissingyoucanobtainacopyorrecordyourregistration

bytelephoningtheGlow-wormCustomerServicenumber

01773828100.

 

 

 

Theapplianceisdesignedtorecognisethepotentialforan

overheatlockoutandwillshutdownbeforethishappens.

 

Asafetydischargevalveanddischargepipearettedtothe

boiler.Thisvalvemustnotbetouched.

- Theheatingsafetyvalveopenswhenthepressureinthe

heatingcircuitexceeds2.5bars.

• Shouldtherebeanydischargefromthepipe,isolatethe

boilerelectricalsupplyandcallyourinstallerorGlow-worm’s

ownserviceorganisation.

 

Thefrostprotectionsystemoperatesthepumptostartassoon

asthetemperatureintheheatingcircuitfallsbelow12°C.The

pumpstopsassoonasthetemperatureofthewatercontained

intheheatingcircuitreaches15°C.

Ifthetemperatureintheheatingsystemfallsbelow7°C,the

burnerignitesuntilitreaches35°C.

Thefrost-protectionsystemisactivewhentheapplianceis

switchedon.

Thesystemalonecannotensurethattheinstallationis

protectedagainstfrost.Anseparatefrostthermostatis

necessarytocontrolthetemperatureofthesystem.

aYour domestic water circuit (hot or cold) is not

protected by the boiler.

 

Duringfreezingconditionsthismaybeduetotheformingof

iceinthecondensedrainexternaltothehouse.Inthiscase,a

safetydeviceshutsdowntheappliance.

0020112601_02-10/12-Glow-worm

- 4 -

INTRODUCTION

 

Thedatalabelcertiesthecountrywheretheapplianceis

intendedtobeinstalled.

Datalabellocation:



 

Thedatalabelcontainsthefollowingdata:

- Thenameofthemanufacturer

- Thecountryofintendeddestination

- Thecommercialnameoftheapplianceanditsserialnumber

- Thetypesofuesinstallationsauthorised

- Theappliance'sgascategory

- Thegastype,groupandpressure,setinthefactory

- TheDHWspecicowrate(D)

- Themaximumpressureintheheatingcircuit(PMS)

- Themaximumpressureinthedomesticwatercircuit(PMW)

- TheNOxclassoftheappliance

- Thetypeandvoltageofelectricitysupply

- Themaximumpowerrating

- Theelectricalprotectionclass

- Theminimumandmaximumheatinput(Q)

- Theminimumandmaximumpoweroutput(P)

- TheCEnumberandlogo

aThe appliance shall only be connected to the gas

type(s) indicated on the data label.

 

ThisboilerisforuseonlyonG20,butcanbeconvertedforuse

onG31.

• Toadapttheappliancetoanothertypeofgas,seethe

chapter"Gasconversion".

 

 

ThisboilermeetstherequirementsofStatutoryInstrument,

No.3083TheBoiler(Efciency)Regulations,andthereforeis

deemedtomeettherequirementsofDirective92/42/EECon

theefciencyrequirementsfornewhotwaterboilersredwith

liquidorgaseousfuels.

TypetestforpurposesofRegulation5certiedby:Notied

body1312.

Product/productioncertiedby:Notiedbody0086.

TheCEmarkindicatesthattheappliancesdescribedinthis

manualareincompliancewiththefollowingdirectives:

- Europeandirectiven°2009-142relativetogasappliances

- Europeandirectiven°2004-108fromtheEuropean

ParliamentandCouncilrelativetoelectromagnetic

compatibility

- Europeandirectiven°2006-95fromtheEuropeanParliament

andCouncilrelativetolowvoltage

- Europeandirectiven°92-42relativetotheyieldofboilers

 

Benchmarkplacesresponsibilitiesonbothmanufacturers

andinstallers.Thepurposeistoensurethatcustomersare

providedwiththecorrectequipmentfortheirneeds,thatitis

installed,commissionedandservicedinaccordancewiththe

manufacturer’sinstructionsbyacompetentpersonapprovedat

thetimebytheHealthandSafetyExecutiveandthatitmeets

therequirementsoftheappropriateBuildingRegulations.

TheBenchmarkChecklistcanbeusedtodemonstrate

compliancewithBuildingRegulationsandshouldbeprovidedto

thecustomerforfuturereference.

Installersarerequiredtocarryoutinstallation,commissioning

andservicingworkinaccordancewiththeBenchmarkCode

ofPracticewhichisavailablefromtheHeatingandHotwater

IndustryCouncilwhomanageandpromotetheScheme.

• Visitwww.centralheating.co.ukformoreinformation.

0020112601_02-10/12-Glow-worm

- 5 -

INTRODUCTION

 



 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

0020112601_02-10/12-Glow-worm

- 6 -

INTRODUCTION

 

 

Ifthegaspressureattheinputoftheapplianceisoutsidethe

rangespecied,theappliancemustnotbeputintooperation.

eIncorrect installation can cause electric shock or

appliance damage.

• Neverdisablesecuritydevicesanddonottrytoadjustthem.

Withregardstothe“ManualHandlingOperations,1992

Regulations”,theapplianceexceedstherecommendedweight

foraonepersonlift.

Thehandlingoftheboilermayinvolvelifting,pushingand

pulling,theuseofasacktruckmayberequired.

• Besuretoconsiderthefollowinghandlingtechniquesand

precautions:

- Griptheapplianceatitsbase

- Usesafetyclothingwhereappropriate,e.g.gloves,safety

footwear.

• Ensuresafeliftingtechniquesareused:

- Keepbackstraight.

- Avoidtwistingatthewaist.

- Avoidupperbody/topheavybending.

- Alwaysgripusingthepalmofthehand.

- Usedesignatedhandholds.

- Keeploadasclosetobodyaspossible.

- Alwaysuseassistanceifrequired.

• Undernocircumstancesmusttheuserinterferewithor

adjustsealedparts.

• Whenassemblingtheconnections,correctlypositionthe

sealstoavoidanyleakageofgasorwater.

• Thisappliancecontainsmetalparts(components)andcare

shouldbetakenwhenhandlingandcleaning,withparticular

regardtoedges.

Thebasicsafetyinstructionsmustbefollowedbefore

attemptingtomaintainorreplacespareparts:

• Stoptheappliance.

• Electricallyisolatetheappliancefromthepowersupply.

• Turnofftheappliancegasisolationvalve.

• Hydraulicallyisolatetheapplianceusingtheisolationvalves

ifprovided.

• Shouldyouneedtoreplacehydrauliccomponents,drainthe

appliance.

• Protectalltheelectricalcomponentsfromwaterwhile

workingontheappliance.

• Useonlyoriginalspareparts.

• UseonlynewO-ringsandgaskets.

• Afterhavingcompletedworkongasorwatercarrying

components,checkfortheirtightness.

• Whenworkontheapplianceiscompleted,performan

operationaltestandcheckforsafety.

 

 

IMPORTANT

WherenoBritishStandardsexists,materialsandequipment

shouldbetfortheirpurposeandofsuitablequalityand

workmanship.

Theinstallationofthisboilermustbecarriedoutbyacompetent

personapprovedatthetimebytheHealthandSafetyExecutive

andinaccordancewiththerulesinforceinthecountriesof

destination.

Manufacturer’sinstructionsmustnotbetakenasoverriding

statutoryrequirements.

Statutory Requirements

InGB,theinstallationoftheboilermustcomplywiththe

requirementsofthecurrentissueofBS6798andbecarriedout

byacompetentpersonapprovedatthetimebytheHealthand

SafetyExecutiveandasdescribedinthefollowingregulations:

-Themanufacturer’sinstructionssupplied.

-TheGasSafety(InstallationandUse)Regulations.

-TheappropriateBuildingsRegulationseitherTheBuilding

Regulations,TheBuildingRegulations(Scotland),TheBuilding

Regulations(NorthernIreland).

-TheWaterSupply(waterttings)Regulations1999andwater

byelaws2000,Scotland.

-TheHealthandSafetyatWorkAct,ControlofSubstances

HazardoustoHealth(COSHH).

-AnyelectricalworkmustconformtoBS7671andwhere

applicablePartPofthebuildingregulations.

Wherenospecicinstructionsaregiven,referenceshouldbe

madetotherelevantBritishStandardCodeofPractice.

InIE,theinstallationmustbecarriedoutbyacompetentperson

approvedatthetimebytheHealthandSafetyExecutiveand

installedinaccordancewiththecurrenteditionofI.S.813

“DomesticGasInstallations”,thecurrentBuildingRegulations

andreferenceshouldbemadetothecurrentETCIrulesfor

ElectricalInstallation.

GB:thefollowingCodesofPracticeapply:BS4814,BS6798,

BS5440Part1and2,BS5546Part1,BS5449,BS6891,

BS6700,BS7074Part1and2,BS7593,BS7671.

IE:I.S.813,BS5546,BS5449,BS7074,BS7593.

NOTE:Forfurtherinformation,seethecurrentissueofthe

BuildingRegulations,approveddocumentL1(intheUK)and

thefollowingcurrentissuesof:

1)Centralheatingsystemspecication(CheSS)and

2)Controlsfordomesticcentralheatingsystemandhotwater.

BRECSU.

0020112601_02-10/12-Glow-worm

- 7 -

INTRODUCTION

Gas Supply

Thegasinstallationmustbeinaccordancewiththerelevant

standards.

InGB,thisisBS6891.

InIE,thisisthecurrenteditionofI.S.813“DomesticGas

Installations”.

Thesupplyfromthegovernedmetermustbeofadequatesize

toprovideasteadyinletworkingpressureof20mbar(8inwg)at

theboiler.Oncompletion,testthegasinstallationfortightness

usingthepressuredropmethodandsuitableleakdetection

uid,purgeinaccordancewiththeabovestandard.

Domestic Hot Water

Alldomestichotwatercircuits,connections,ttingsmustbe

inaccordancewiththerelevantstandardsandwatersupply

regulations.

GB:GuidanceG17toG24andrecommendationR17toR24of

theWaterRegulationsGuide.

IE:ThecurrenteditionofI.S.813“DomesticGasInstallations”.

Heating System

InGB,itisnecessarytocomplywiththeWaterSupply(Water

Fittings)Regulations1999(forScotland,theWaterByelaws

2000,Scotland).TocomplywiththeWaterregulationsyour

attentionisdrawnto:TheWaterRegulationsguidepublished

bytheWaterRegulationsAdvisoryService(WRAS)givesfull

detailsoftherequirements.

InIE,therequirementsgiveninthecurrenteditionofI.S.813

“DomesticGasInstallations”andthecurrentBuilding

Regulationsmustbefollowed.

Electrical Supply

TheboilerMUSTbeearthed.Allsystemcomponentsshall

beofanapprovedtypeandallwiringtocurrentI.E.E.wiring

regulations.Externalwiringmustbecorrectlyearthed,polarised

andinaccordancewiththerelevantstandards.

InGB,thisisBS7671.

InIE,thisisthecurrenteditionofETCIrules.

TheboilerMUSTbeconnectedtoapermanent230Vac,50Hz

supply.

Connectionofthewholeelectricalsystemoftheboiler,including

anyheatingcontrols,totheelectricalsupplyMUSTbethrough

onecommonisolatorandmustbefused3Ampmaximum.

Isolationshouldbebyadoublepoleswitchedfusedspurbox,

withaminimumgapof3mmforbothpoles.Thefusedspur

boxshouldbereadilyaccessibleandpreferablyadjacenttothe

appliance.Itshouldbeidentiedastoitsuse.

Alternativelyconnectioncanbemadethroughanunswitched

shutteredsocketand3Afused3-pinplugbothtothecurrent

issueofBS1363,providedtheyarenotusedinaroom

containingabathorshower.

WiringtotheboilermustbePVC85OCinsulatedcable,notless

than0.75mm2(24/0.20mm).

 

Gas Safety (Installation and Use) Regulations

Inyourowninterestsandthatofsafety,itistheLawthatALL

gasappliancesareinstalledbyacompetentpersonapprovedat

thetimebytheHealthandSafetyExecutiveinaccordancewith

thecurrentissueoftheseregulations.

Control of Substances Hazardous to Health

UnderSection6ofTheHealthandSafetyatWorkAct1974,we

arerequiredtoprovideinformationonsubstanceshazardousto

health.Theadhesivesandsealantsusedinthisapplianceare

curedandgivenoknownhazardinthisstate.

InsulationPads:

Thesecancauseirritationtoskin,eyesandtherespiratory

tract.Ifyouhaveahistoryofskincomplaintyoumaybe

susceptibletoirritation.Highdustlevelsareusualonlyifthe

materialisbroken.

Normalhandlingshouldnotcausediscomfort,butfollownormal

goodhygieneandwashyourhandsbeforeeating,drinkingor

goingtothelavatory.

• Ifyoudosufferirritationtotheeyesorsevereirritationtothe

skinseekmedicalattention.

 

iThe recycling of the packaging must be carried

out by the qualied professional who installed the

appliance.

 

Mostoftheapplianceismadeofrecyclablematerials.

This symbol indicates that this appliance must not

be disposed of with household waste, that it should

be selectively collected for energy recovery, reuse

or recycling.

• Taketheappliancetoanappropriatecollectionpoint.

iBy complying with this directive, you will contribute

to the preservation of natural resources and the

protection of human health.

 

Werecommendthatyourecyclethepackagingoftheappliance

inaresponsiblefashion.

• Sortthewasteinordertoseparatethoseelementswhich

canberecycled(cardboard,plastics...)andthosewhich

cannotberecycled.

• Eliminatethewasteinaccordancewithexistingregulations.

0020112601_02-10/12-Glow-worm

- 8 -

TECHNICALDATA



 

Boiler,typeC13,C33,C43

    

Gascategory ll2H3P ll2H3P ll2H3P

SEDBUK2005rating % 90.3 90.3 90.4

SEDBUK2009rating % 89.0 89.3 89.3



Maximumheatinginputpower kW 18.5 25 30.6

Minimumheatingoutput

powerat80/60°C(Pmin.) kW 4.9 5.9 8.5

Maximumheatingoutput

powerat80/60°C(Pmax.) kW 18.2 24.6 30

Minimumheatingoutput

powerat50/30°C(Pmin.) kW 5.4 6.6 9.3

Maximumheatingoutput

powerat50/30°C(Pmax.) kW 19.6 26.7 32.8

Minimumheatingtemperature °C 10 10 10

Maximumheating

temperature °C 80 80 80

Minimumheatingowrate l/h 400 400 400

Contentofheatingexpansion

vessel

l 8 8 8

gallons 1.76 1.76 1.76

Heatingexpansionvessel

presetpressure

bar 0.75 0.75 0.75

psi 10.9 10.9 10.9

Maximumheatingsystem

volume(approx) l 160 160 160

Heatingsafetyvalvepreset

pressure(PMS)

bar 3 3 3

lbf/in² 36/3 36/3 36/3



MinimumDHWoutputpower

(Pmin.) kW 5.1 6.1 8.7

MaximumDHWoutputpower

(Pmax.) kW 25.5 30.6 35.7

MaximumDHWtemperature °C 60 60 60

Specicowrate(∆Tof35K)

EN13203 l/min 10.4 12.5 14.6

Minimuminletwaterpressure bar 0.3 0.3 0.3

psi 4.3 4.3 4.3

Maximuminletwaterpressure bar 10 10 10

psi 145 145 145



ApplianceNOxclass 5 5 5



Electricalsupply V/Hz 230V

50Hz

230V

50Hz

230V

50Hz

Standbymodeelectrical

power W 6 6 6

Operationalmodeelectrical

power(Max) W 151 151 151

Internalfuseratingonmain

PCB A 2 2 2

Indexofelectricalprotection

(EN60529) IPX4D IPX4D IPX4D

    

GasconnectionØO.D. mm 15

(copper)

15

(copper)

15

(copper)

Heatingflowandreturn

connectionØO.D. mm 22

(copper)

22

(copper)

22

(copper)

DomesticHotWater

connectionØO.D. mm 15

(copper)

15

(copper)

15

(copper)

CondensateconnectionØI.D. mm 21.5

(plastic)

21.5

(plastic)

21.5

(plastic)

Safetyvalvedischarge

connectionØO.D. mm 15

(copper)

15

(copper)

15

(copper)

Liftweight kg 37 38 38

lb 82 83 84.5

Totalweight(installed) kg 42 43 43

NumberofCEcerticate

1312

BU

5334

1312

BU

5335

1312

BV

5336

    



MaximumDHWgasowrate m/h 2.70 3.24 3.77

Maximumheatinggasow

rate m/h 1.96 2.65 3.24

Minimumgasowrate m/h 0.54 0.65 0.92

CO2atQmaxDHW+

"tolerancecaseON" %9.2±

0.3%

9.2±

0.3%

9.2±

0.3%

CO2atQmaxDHW+

"tolerancecaseOFF" %9±

0.2%

9±

0.2%

9±

0.2%

CO2atQmin+

"tolerancecaseON" %8.9±

0.3%

8.9±

0.3%

8.9±

0.3%

CO2atQmin+

"tolerancecaseOFF" %8.7±

0.2%

8.7±

0.2%

8.7±

0.2%

Inletpressure mbar 20 20 20



MaximumDHWgasowrate kg/h 1.98 2.38 2.77

Maximumheatinggasow

rate kg/h 1.44 1.94 2.37

Minimumgasowrate kg/h 0.4 0.47 0.67

CO2atQmaxDHW+

"tolerancecaseON" %10.3±

0.3%

10.3±

0.3%

10.3±

0.3%

CO2atQmaxDHW+

"tolerancecaseOFF" %10.1±

0.2%

10.1±

0.2%

10.1±

0.2%

CO2atQmin+

"tolerancecaseON" %9.8±

0.3%

9.8±

0.3%

9.8±

0.3%

CO2atQmin+

"tolerancecaseOFF" %9.6±

0.2%

9.6±

0.2%

9.6±

0.2%

Inletpressure mbar 37 37 37

0020112601_02-10/12-Glow-worm

- 9 -

INSTALLATION



iAll the drawings dimensions are shown in mm.

 

 

 

Beforechoosingasitefortheappliance,carefullyreadthe

safetywarningsandinstallationmanual.

• Ensurethatwalltowhichtheappliancewillbemountedonis

structurallysafeinordertosupporttheweightoftheappliance.

• Ensurethatthespacethattheapplianceistobeinstalled

withinallowstheappliancetobeinstalledandtheclearances

maintained.Thiswillensurethattheconnectionstothe

water,gasanduecanbeaccessedandinspected(see

chapterClearances).

• Explaintheserequirementstotheapplianceuser.

• Donotinstalltheapplianceaboveanotherappliancethat

coulddamageit(forexample,aboveacookerthatmight

emitsteamorgrease)orinaroom,whichhasalotofdustin

theatmospherewhichiscorrosive.

• Theboilermustbettedinsidethepropertyandexposed

pipeworkmayneedtobeprotectedfromfrostbyttinga

frostthermostat.

 

Location

Thisboilerisnotsuitableforoutdoorinstallation.

Thisboilermaybeinstalledinanyroom,althoughparticular

attentionisdrawntotheinstallationofaboilerinaroom

containingabathorshowerwherereferencemustbemadeto

therelevantrequirements.

Thisboilerissuitableforinstallationinbathroomzones2and3.

thisisthecurrentI.E.E.WIRINGREGULATIONSand

BUILDINGREGULATIONS.

referenceshouldbemadetothecurrenteditionofI.S.813

“DomesticGasInstallations”andthecurrentETCIrules.

Timber Frame Buildings

Iftheboileristobeinstalledinatimberframebuildingitshould

bettedinaccordancewiththeInstituteofGasEngineers

documentIGE/UP/7/1998.

 

• Toallowperiodicmaintenance,ensurethedistances

indicatedonthediagram.

Additionalclearancesmaybebenecialaroundtheboilerfor

installationandservicing.

Forueinstallationswhereexternalaccessisnotpracticable,

considerationshouldbegivenforthespacerequiredtoinsert

theuefrominsidetheproperty,whichmaynecessitate

clearancelargerthanthosespeciedindiagrambelow.

ØA

ØA + 5 min.

600*

min.

200

min.

150

min.

600*

min.

200

min.

150

min.



 





Theboileranduearesuitableforinstallationontoandthrough

combustiblematerialsprovidedthat:

- Minimum5mmclearanceismaintainedaroundthe

circumferenceoftheue(airintake).

- Thecombustiblesurfaceandxingsaresuitablefor

supportingtheload.

- Theminimumclearancesfromtheboilercaseare

maintained.

 

 

Theboilerisroomsealedsoapermanentairventisnotrequired.

 

Duetothehighefciencyandlowcasingtemperatureofthis

boiler,cupboardorcompartmentventilationisnotnecessary.

• Existingventilationshouldbeinvestigatedforitspurpose

beforeremoving.

0020112601_02-10/12-Glow-worm

- 10 -

INSTALLATION

 

 

Theapplianceisdeliveredinasinglecartonwithadocument

packandttings.

iThe ues package will be ordered according to the

conguration of the installation.

• Pleasecheckthecontents.

44.1

4.2

4.3

4.4

4.5

4.6

2.1

2.2

2.3 2.5

2.4

4.7



  

  

   

   

   

   

   

   

   

   

   

   

   

   

   

  

  

   

   

   

   

   

   

   

 

 

Water pressure

Theminimumworkingpressuretoobtainthemaximum

domesticowis1,0bar.

Themaximumworkingpressureofthedomestichotwater

circuitis10bar.Ifthecoldwatersupplypressureexceedsthis,

thenapressure-reducingvalvemustbettedinthesupplyto

theboiler.

‘Hard’ water areas

Thetemperatureswithintheheatexchangerarelimitedbythe

boilercontrolsystemtominimisescaleformationwithinthehot

waterpipework.However,inareaswherethewateris‘hard’(i.e.

morethan200mg/Lofcalciumcarbonate),itisrecommended

thatthehotwatersettingisreducedandthatascalereducer

istted,refertothemanufacturer’sinstructionsorconsultthe

localwatercompanyforadditionaladvice.

Domestic water ow rate

Thedomestichotwaterowhasarestrictor,factorytted,

whichreducestheowtoamaximumof:

- 24cxi8l/min,

- 30cxi10l/min,

- 35cxi12l/min.

0020112601_02-10/12-Glow-worm

- 11 -

INSTALLATION

 



 

 

 

 

 

 

 

 

 

 

General

Thisboilerisdesignedforuseaspartofasealedwatercentral

heatingsystemwithfullypumpedcirculation.Thepump,

expansionvesselandassociatedsafetydevicesarealltted

withintheboiler.

Safety valve

Thesafetyvalveisanintegralpartoftheboileranditcannot

beadjusted.Thepipefromthesafetydischargevalvemust

dischargesafelyinaccordancewithstandards. 



Expansion vessel

Theboilerhasanintegralexpansionvesselwithacapacityof8

litres(1.76gallons),withachargepressureof0.75bar.

iThe heating system volume should be calculated to

ensure that the expansion vessel is suitable, it may

be necessary to add an additional vessel.

- InGB,Guidanceonvesselsizingisalsogiveninthecurrent

issueofBS5449andBS7074Part1.

- InIE,currenteditionofI.S.813“DomesticGasInstallations”.

Bypass

Theboileristtedwithanautomaticbypasswhichcanbe

adjustedtosuityoursystemrequirements.

• Ensurethatundernocircumstancesdoestheowratedrop

belowthegurespecied,refertochapter"Technicaldata".

Filling the sealed system

iThe water pressure at the boiler must be at least

1.2bar to operate the lling loop. If the pressure

is less than 1.2bar an external lling loop must be

tted. If this pressure is not available contact the

local water authority.

Suitableexternalllingsystemsareshowndiagrammatically,

seediagrambelow.



 

 

 

 

 

 

 

 

 

Thesystemshouldbepressurisedto0.8bar,indicatedonthe

digitaldisplaywithnoheatingdemand.

Drain points

Draintapsmustbeprovidedatalllowpointsofthesystem,

whichwillallowtheentiresystemtobedrained.

DraintapsshallbetothecurrentissueofBS2879.

0020112601_02-10/12-Glow-worm

- 12 -

INSTALLATION

Water treatment

-Itisessentialthatpriortoinstallingthenew

boilerthesystemisthoroughlyushed.

-Foroptimumperformanceafterinstallation,the

boileranditsassociatedcentralheatingsystemshouldalsobe

ushed.

FlushingshallbecarriedoutinaccordancewithBS7593,a

chemicalcleansercanbeusedeitherSentinelX300,X400or

FernoxF3aresuitable.

Itisrecommendedtoushexistingsystemsrstbeforetting

thenewboiler.

• Ensureallcleanserisremovedfromthewholesystembefore

addinganinhibitor.

Forlong-termcorrosionprotectionafterushing,aninhibitor

suitableforstainlesssteelheatexchangerscanbeused.Either

SentinelX100orFernoxF1inhibitorcanbeused.

Theboilerissuitableforuseonsystemsusingsoftenedwater.

 

418

344

130

346

740

 

• Makesurethattheequipmentusedforimplementingthe

installationiscompatiblewiththatoftheappliance.

• Determinetheassemblylocation.Seethe"Appliance

location"chapter.

735

709

156

160 160

Ø105*

Ø125*

Ø130**

Ø150**

=246=

170

65 65

 

 

• Takethewalltemplateandplaceinthedesiredposition

onthewall,givingdueconsiderationtotherequiredboiler

clearances,seechapter"Appliancelocation►Clearances",

andtheueyouaretting.

 

130

90°



 

 

 

 

 

 

0020112601_02-10/12-Glow-worm

- 13 -

INSTALLATION

Flue hole cutting

• Markthepositionoftheuecentre.

• Removethewalltemplate,thendrilltheuehole.

iThe ue is designed with an internal fall of 44mm/

metre (2.5o), therefore the hole can be drilled

horizontally.

• Usea105mmdiametercoredrillforexternalaccessue

installation(60/100ue)(80/125ue►Ø130mm).

• Usea125mmdiametercoredrillforinternalaccessonlyue

installation(60/100ue)(80/125ue►Ø150mm).

iIf ue extension pipes are to be used then a core

drill size of 125mm is required. This will allow the

extension pieces to slope at 44mm/metre (2.5o)

towards the boiler.

• Ifttingasideue,extendtheuecentrelineintothecorner

then130mmalongtheadjacentwall.

• Ifttinganextendedsideue,determinetheueholecentre

byextendingthedashedinclinedlineonthetemplatetothe

sidewall.Thisdashedlineisdrawnat44mm/metre(2.5o)

risefromtheboiler.Wherethislinereachesthesidewall,a

horizontallineshouldbemarked.Theverticalcentrelineof

theueshouldthenbemarkedat130mmfromthebackwall.

Toallowfortheuepassingthroughthewallatthisangle

a125mmholeshouldbedrilledirrespectiveofinternalor

externalinstallation.

Hanging bracket xing

Duetothevariedsiteconditions,xingsarenotsuppliedand

advisethattheinstallershouldsupplythosewhicharesuitable.

• Drilltheholesforthexingscrewsinaccordancewiththe

walltemplate.

• Fixthehangingbracketonthewall.

 

aWith regards to the Manual Handling Operations,

1992 Regulations, the following lift operation

exceeds the recommended weight for a one

person lift, refer to chapter "Manual Handling".



 

 

• Liftingtheboilerintoposition,leanthetopoftheboiler

slightlytothewallandpositionjustabovethehanging

bracket.

• Lowertheboilerslowlyandengageontothehangingbracket

 

 

Thewholeofthegasinstallation,includingthemeter,should

beinspected,testedfortightnessandpurgedinaccordance

withthecurrentissueofBS6891andinIEthecurrenteditionof

I.S.813“DomesticGasInstallations”.

iThe appliance may contain a small amount of water,

place a water container beneath the boiler connections.

• Takecaretocleanthepipesbeforeassemblyremovingany

debrisorburrs.Greaseandoilsmayneedtoberemoved

theyarenotpossibletoremovebycleansingandushing.

Foreignbodiesinthesystemmayentertheapplianceand

interruptitsoperation.

• Donotuseanysolventproducts,duetotheriskofdamaging

thecircuit.

aDo not perform any 'hot work' directly under

the appliance, this may cause damage to the

appliance base. Heat may also damage the

isolation valves.

Always pre-solder pipes before tting them to

the boiler.

0020112601_02-10/12-Glow-worm

- 14 -

INSTALLATION

• Onlyuseoriginalsealssuppliedwiththeappliance.

• Checkthattherearenoleaks.Repairifnecessary.



 

 

 



 

 

 

 

 

• UseonlytheoriginalgascockGER/1DN15,CE-0085CL

0082

• Useonlytheoliveandatsealwashersuppliedwiththegas

cock.

• Removetheprotectivecapsfromtheboilerconnections.

• Flushoutthedomestichotwaterandtheheatingsystems.

iBefore turning on the cold mains supply to the boiler

turn off the cold water inlet to the boiler, lock the lling

loop in the closed position and close its lling taps.

 



 

 

 

 

 

Thismustbeextended,usingnotlessthan15mmo.d.pipe,

todischarge,inavisibleposition,outsidethebuilding,facing

downwards,preferablyoveradrain.

Toeasefutureservicingitisadvisabletouseacompression

typettingtoextendthesafetydischargevalvetube.

Thepipemusthaveacontinuousfallandberoutedtoa

positionsothatanydischargeofwater,possiblyboiling,

orsteamcannotcreateanydangertopersons,damageto

propertyorexternalelectricalcomponentsandwiring.

0020112601_02-10/12-Glow-worm

- 15 -

INSTALLATION

 

aCondensate produced by the appliance is mildly

acidic (pH 3.5 - 5.0). Use protective gloves

bCondensate must only be discharged in

accordance with these instructions.

iThe volume of condensates evacuated can reach

about 15 litres per day for a detached house. This

volume is negligible compared to the volume of

waste water discharged by a house, because the

condensates are diluted in this water.

• RefertoBS5546orBS6798foradviceondisposalofboiler

condensate.



 

• Makesurethereisnoprotectiveplugtted.

• Connectthecondensatepipe(1).

iThe pipe should have a fall of a least 2.5° 44mm/

metre away from the boiler.

Condensateshould,ifpossiblebedischargedintothe

householdinternaldrainagesystem.

• Ifthisisnotpracticable,dischargecanbeallowedintothe

externalhouseholddrainsorapurposedesignedsoakaway,

refertodiagramoverleaf.

Itisrecommendedthatanyexternalcondensatedrainpipeis

protectedandalsopreferablyof32mmdiameter,toprevent

freezinginadverseweatherconditions.

• Alwaysensurethepipeisinstalledwiththecorrectfall

• Connecttheboilercondensatedrain(1)toacondensate

dischargepipewhichshouldbeminimumof19mm

internaldiameterandbemadeofanacidresistantmaterial

(e.g.plasticoverowpipe).Donotusemetalpipes.Itis

permissibletouseacondensateneutraliserprovidingthatit

ischeckedforcorrectoperation.

0020112601_02-10/12-Glow-worm

- 16 -

INSTALLATION

0020112601_02-10/12-Glow-worm

- 17 -

INSTALLATION

 

 

bOnly ue accessories supplied by Glow-worm

must be used.

Differentueoutletcongurationscanbecarriedout.

• Consultyoursupplierformoreinformationabouttheother

possibilitiesandassociatedaccessories.

44 mm/m 1 2

4 3

• Standardueterminalkitshaveanin-builtfallbacktothe

boilertodrainthecondensate.Thesecanbettedlevel

betweentheapplianceandtheterminationposition.Allother

extendeduesmusthaveafallofatleast44mm/m

Themaximumlengthoftheueoutletisdenedaccordingtoits

type(forexampleC13).

• Whateverthekindofuesystemchosen,observethe

minimumdistancesindicatedinthechartbelowtoposition

theueterminals.

• Toinstalltheue,refertotheseparateueinstruction

suppliedwithyourappliance.

• Explaintheserequirementstotheuseroftheappliance.

aIf necessary, you must install a terminal

protection kit.

bCaution! The connection between the ue elbow

and the ue outlet must be sealed.

theminimumacceptablesitingdimensionsforthe

terminalfromobstructions,otherterminalsandventilation

openingsareshownindiagramoverleaf.

theminimumdistancesforueterminalpositioningmust

bethosedetailedinI.S.813“DomesticGasInstallations”.

Theterminalmustbeexposedtotheexternalair,allowingfree

passageofairacrossitatalltimes.

Beingacondensingboilersomeplumingmayoccurfrom

theueoutlet.Thisshouldbetakenintoconsiderationwhen

selectingthepositionfortheterminal.

Carportsorsimilarextensionsofaroofonly,oraroofandone

wall,requirespecialconsiderationwithrespecttoanyopenings,

doors,ventsorwindowsundertheroof.Careisrequired

toprotecttheroofifmadeofplasticsheeting.Ifthecarport

comprisesofaroofandtwoormorewalls,seekadvicebefore

installingtheboiler.

bIf the ue terminal is positioned near a light

source insects may enter the ue system.

Where safe and practical to do so advise the

homeowner to check the ue outlet and clear

visible insects from the terminal end.

0020112601_02-10/12-Glow-worm

- 18 -

INSTALLATION

  



Adirectlybelowanopening,airbrick,

openingwindows 300

B aboveanopening,airbrick,openingwindows 300

Chorizontallytoanopening,airbrick,opening

windows 300

D belowgutter,drain/soilpipe 25

E beloweaves 25

F belowabalconyorcarport 25

G fromverticaldrainpipesandsoilpipes 25

H frominternal/externalcorners 25

H* toaboundaryalongsidetheterminal 300

I aboveadjacentgroundorbalconylevel 300

J* fromsurfaceoraboundaryfacingtheterminal 600

  

Lfromopening(door/window)incarport

intodwelling 1200

M verticalfromaterminal 1500

N horizontallyfromaterminal 300



P fromanotherterminal 600

Q aboverooflevel 300

R fromadjacentopeningwindow 1000

S fromadjacentwalltoue 300

(*)Thesedimensionscomplywiththebuildingregulations,

buttheymayneedtobeincreasedtoavoidwallstainingand

nuisancefromplumingdependingonsiteconditions.

Page is loading ...

Glow-worm Ultracom₂ Installation guide

Brand: Glow-worm

Model: Ultracom₂

Category: Water heaters & boilers

Type: Installation guide

Download PDF

report

Glow-worm Ultracom₂ Installation guide

Glow-worm Ultracom₂ Installation guide

Related papers

Other documents