Glow-worm Ultrapower sxi Series Installation And Servicing
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Glow-worm Ultrapower sxi Series Installation And Servicing

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Installation and Servicing
Ultrapower sxi
High Efficiency System Store
100sxi
G.C. No. 41-019-09
170sxi
G.C. No. 41-019-10
www.glow-worm.co.uk
1

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  • Page 1 Installation and Servicing Ultrapower sxi High Efficiency System Store 100sxi G.C. No. 41-019-09 170sxi G.C. No. 41-019-10 www.glow-worm.co.uk...
  • Page 2 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.

  • Page 3: 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.

  • Page 4: Warnings

    Glow- Manual Handling worm. Any alteration not approved by Glow-worm, could invalidate With regards to the “Manual Handling Operations, 1992 the certification, boiler warranty and may also infringe the Regulations”, it should be noted that each appliance module current issue of the statutory requirements.
  • Page 5 Statutory Requirements CE Mark In GB, the following Codes of Practice apply: This boiler meets the requirements of Statutory Instrument, BS4814, BS6798, BS5440 Part 1 and 2, BS5546 Part 1, No. 3083 The Boiler (Efficiency) Regulations, and therefore BS5449, BS6891, BS6700, BS7074 Part 1 and 2, BS7593, is deemed to meet the requirements of Directive 92/42/EEC BS7671.

  • Page 6: Boiler Design

    Should there be any discharge from the pipes, isolate the conditions this may be due to the forming of ice in the boiler electrical supply and call your installer or Glow-worm’s condense drain external to the house. Release an ice...

  • Page 7: Boiler Specifications

    1 Boiler Specifications Data All dimensions are given in millimetres (except as noted). See diagram 1.1 and the Boiler Specification Table below. The data label is positioned inside the boiler module on the base. BOILER SPECIFICATION 100sxi 170sxi Lift weight - Tank Module 39kg (86Ib) 48kg (106Ib) - Boiler Module...
  • Page 8 1 Boiler Specifications 106.5 FLUE 1331 (100sxi) 1260 1591 (100sxi) (170sxi) 1520 BOILER (170sxi) DISCHARGE SIPHON DISCHARGE DISCHARGE 70 80 Diagram 1.1...
  • Page 9 1 Boiler Specifications HEATING WATER EXPANSION PRIMARY HEAT VESSEL EXCHANGER PRIMARY CIRCUIT PRIMARY CIRCUIT FLOW THERMISTOR RETURN THERMISTOR SAFETY DISCHARGE AUTOMATIC VALVE AIR VENT 3 BAR CONTROL HEATING PRESSURE VALVE PUMP SENSOR 3 WAY VALVE CONNECTOR BYPASS FILTER CONNECTOR AUTOMATIC PLATE TO PLATE ADJUSTABLE HEAT EXCHANGER...

  • Page 10: Boiler Location, Clearances & Ventilation

    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 local gas undertaking or Glow-worm. 2.4 Room Ventilation The boiler is room sealed so a permanent air vent is not required.

  • Page 11: Flue Options And Terminal Clearances

    3 Flue Options and Terminal Clearances 3.1 Flue Options There are various flue options to choose from as illustrated in diagram 3.3. The flue lengths and installation of various flue types are described in section 10. 3.2 Flue Terminal Position The minimum acceptable siting dimensions for the terminal from obstructions, other terminals and ventilation openings are shown in diagram 3.1.
  • Page 12 3 Flue Options and Terminal Clearances Flue Options Plume Management Kit - page 27 Basic set, concentric flue Ø60/100 White - Part No. A2044100 Black - Part No. A2044000 for use with Part No. A2043400 and Part No. A2043600 Top horizontal telescopic flue Ø60/100 Top horizontal standard flue Ø60/100 - page 23 - page 27...

  • Page 13: Heating System

    4 Heating System General 4.7 ‘Hard’ Water Areas The boiler is for use only with sealed central heating systems. The temperatures within the heat exchanger are limited by the boiler control system to minimise scale formation within The digital readout on the controls fascia indicates the the hot water pipework.

  • Page 14: Domestic Hot Water

    4 Heating System automatic bypass - closed automatic bypass - factory setting automatic bypass - open pump speed 1 pump speed 2 1000 1200 1400 1600 1800 Volumeflow (Litres/hr) Diagram 4.2 5 Domestic Hot Water General 5.4 Safety Valves All domestic hot water circuits, connections, fittings must be The safety valves are factory fitted and are an integral part in accordance with the relevant standards and water supply of this boiler and they must not be adjusted or used for any...
  • Page 15 5 Domestic Hot Water 5.5 SYSTEM REQUIREMENTS – Domestic Hot NOTE: The tundishes are factory fitted during manufacture. The discharge pipe (D2) from the tundish should terminate in Water a safe place where there is no risk to persons in the vicinity of the discharge, preferably be of metal and: Domestic Hot Water Requirements a) Be at least one pipe size larger than the nominal outlet...
  • Page 16 5 Domestic Hot Water NOTE: The discharge will consist of scalding water and TABLE 1 steam. Asphalt, roofing felt and non-metallic rain water goods may be damaged by such discharges. Valve outlet Worked example of discharge pipe sizing G 1/2 size The example given in diagram 5.2 is for a G1/2 temperature relief valve with a discharge pipe (D2) having 4 No.
  • Page 17 6 Condensate Drain INTERNAL SOIL BOILER BOILER EXTERNAL SOIL AND VENT STACK AND VENT STACK EXTERNAL MAX. 3M Ø22mm MIN. Ø22mm MIN. NO RESTRICTION NO RESTRICTION ON LENGTH ON LENGTH Internal Soil and Vent Pipe External Soil and Vent Pipe or Rainwater Pipe BOILER BOILER SINK...

  • Page 18: Installation Preparation

    7 Installation Preparation PLUMBING JIG TANK / BOILER MODULE CONNECTION WASHERS Retaining screws TANK / JIG stored in cartridge CONNECTION WASHERS LOOSE ITEMS PACK Installation booklet (not illustrated) 1 OFF User Instructions (not illustrated) 1 OFF Condensate Connection Pipe 1 OFF 22mm Copper Tails 4 OFF 15mm Copper Tail...
  • Page 19 7 Installation Preparation 7.1 Loose Items Pack Please check the contents of loose items pack as shown in diagram 7.1. The plumbing jig is located within the tank module polystyrene top pack. 7.2 Site Requirements The appliance should be sited on a level floor, however slight adjustment can be made using the adjustable feet at the base of the tank module.

  • Page 20: Gas, Water & Boiler Connection

    8 Gas, Water & Boiler Connection 8.1 Systems Connection IMPORTANT: With regards to the Health and Safety Manual Handling requirements, two persons shall be required The water and gas isolation valve connections are on the jig. to lift the appliance. It should be noted that the appliance is The condense drain and safety discharges connections are made up of two modules each module requiring two persons not on the jig but their pipe runs are shown on the template.
  • Page 21 8 Gas, Water & Boiler Connection 8.3 Boiler Module Connection BOILER MODULE Unpack the boiler module from its carton. FRONT PANEL Position the boiler on top of the tank ensuring the correct engagement of the locating pins, see diagram 8.3. Remove the front panel securing screws and lift the panel off at the top locating bracket, see diagram 8.2.

  • Page 22: Condensate & Safety Discharge Valve Connections

    9 Condensate & Safety Discharge Valve Connections 9.1 Safety Discharge Valve 9.2 Condensate Drain Connection The pipes must be extended, using not less than 22mm o.d. A flexible condensate hose runs from a push-fit connection pipe, to discharge, in a visible position, outside the building, at the bottom of the heat exchanger and terminates on the facing downwards, preferably over a drain.
  • Page 23 10 Telescopic Flue - Length, Preparation and Installation 10.1 Flue Length When extension pipes are used the flue system must be designed to have a continuous fall to the boiler of at least 2.5 The maximum achievable rear and side flue length for a 44mm/metre to allow condensate to run back into the boiler telescopic flue, diagram 10.2, is as shown in diagram 10.1.
  • Page 24 10 Telescopic Flue - Length, Preparation and Installation Top Outlet Horizontal Concentric Flue Packs: FLUE A2043600 Horizontal telescopic flue pack. ELBOW SECURING SCREW x 4 COLLAR SEALING SCREW x 2 TAPE (telescopic only) SCREW x 2 GASKET (fitted) TRIM RING SCREW x 1 TELESCOPIC TERMINAL ASSEMBLY...
  • Page 25 10 Telescopic Flue - Length, Preparation and Installation 10.2 Horizontal Telescopic Flue Refer to diagram 10.2 for kit contents. 10.3 REAR Flue BUTT JOINT If a wall thickness is between 233mm min. to 522mm max. then the flue can be used without extensions. With the flue elbow temporarily fitted, measure the distance from the outside wall to the butt joint, see diagram 10.4.
  • Page 26 10 Telescopic Flue - Length, Preparation and Installation Diagram 10.7 Diagram 10.8 Diagram 10.9...
  • Page 27 10 Standard Flue - Length, Preparation and Installation 10.6 Flue Length When extension pipes are used the flue system must be designed to have a continuous fall to the boiler of at least The maximum achievable rear and side flue length for a 2.5 o 44mm/metre to allow condensate to run back into the standard flue, diagram 10.12, is as shown in diagram 10.11.
  • Page 28 10 Standard Flue - Length, Preparation and Installation Top Outlet Horizontal Concentric Flue Packs: FLUE A2043400 Standard horizontal flue pack. ELBOW SECURING SCREW x 4 COLLAR SCREW x 2 SCREW x 2 GASKET (fitted) TRIM RING STANDARD TERMINAL ASSEMBLY SEALING Diagram 10.12 COLLAR Bend...
  • Page 29 10 Standard Flue - Length, Preparation and Installation 10.7 Standard Horizontal Flue Refer to diagram 10.12 for kit contents. 10.8 REAR Flue BUTT JOINT With the flue elbow temporarily fitted, measure the distance from the outside wall to the butt joint, see diagram 10.14.
  • Page 30 10 Standard Flue - Length, Preparation and Installation Draw the flue assembly from wall and engage the flue duct into the elbow and butt fit between the air duct and flue elbow. Ensure the correct alignment of the terminal. Fit the securing collar into position, mark through two of the pre drilled holes in the securing collar.
  • Page 31 10 Vertical Flue - Length, Preparation and Installation 10.11 Vertical flue The vertical flue system is available as an option where the boiler position does not permit the use of the top outlet horizontal concentric flue pack. The system is made up of accessories. The accessories include terminal assembly, bends 45º...
  • Page 32 10 Vertical - Flue Length, Preparation and Installation NOTE: 2x45º bends can replace 1x90º bend if necessary. When using 90º bends any horizontal extension pipe should be inclined by a minimum of 44mm/metre (2.5°) towards the boiler to facilitate condense removal, see (a) in diagram 10.19.
  • Page 33 10 Vertical Flue - Length, Preparation and Installation Flue Terminal Installation (a) Pitched Roof Fit the required pitched roof weather collar over the 150mm hole in the roof. Make good the tiling or slating around the collar incorporating the flashing of the weather collar. Position the angle cap over the weather collar in the correct orientation to attain the correct angle for your roof.
  • Page 34 10 Twin Flue - Length, Preparation and Installation WALL SEAL WALL SEAL Diagram 10.25...
  • Page 35 10 Twin Flue - Length, Preparation and Installation 10.12 Twin flue The twin flue system is available as an option when the top outlet horizontal concentric rear or vertical flue system is not appropriate, see diagram 10.25. The system is made up of accessories. The accessories include terminal assembly, bends 45º...
  • Page 36 10 Twin Flue - Length, Preparation and Installation Installation Details The parts available for a twin flue system installation are shown in diagram 10.26. Boiler Connection Push the twin flue adaptor onto the outlet of the boiler with the air inlet to the left hand side. Secure the adaptor to the top panel with the screws provided.

  • Page 37: Electrical Connection

    2 x 45 bends the maximum length of the Plume Management Kit must be reduced by 1m. For more information contact Glow-worm, refer to page 2. The Plume Management Kit is supplied with installation instructions. Refer to BS5546 or BS6798 for advice on disposal of boiler AIR BRICK condensate.
  • Page 38 11 Electrical Connection 11.1 Electrical Connection ELECTRICAL Take the peviously laid electrical cable and route along the CARTRIDGE left hand side of the tank module through the two grommets and the cable ties and across to the installers interface as shown in diagram 11.1.
  • Page 39 11 Electrical Connection 11.2 System Controls 24V WARNING: UNDER NO CIRCUMSTANCES MUST ANY MAINS VOLTAGE BE APPLIED TO ANY OF THE TERMINALS ON THE 24V CONNECTION PLUG. Connect the mains supply and system heating controls e.g. room thermostat as diagram 11.4. External controls should be fitted in accordance with the rules in force.

  • Page 40: Commissioning

    12 Commissioning GAS SERVICE COCK CLOSED Diagram 12.1 12.1 Filling Domestic Water Circuit QUICK FILLING Make sure that the isolation valves are securely tightened. RELEASE TAP "B" Open all domestic hot water taps. Fully open the DHW outlet and DCW inlet valves, see diagram 12.1.
  • Page 41 12 Commissioning AUTOMATIC DOMESTIC AIR VENT PUMP VENT DOMESTIC PUMP Diagram 12.4 Diagram 12.3 4. Fully open the taps on the filling loop to fill the Once the system has been purged of air set the hot water to heating system to a pressure of 1.0bar. Close the filling the desired temperature by using the hot water “+”...
  • Page 42 12 Commissioning 12.7 Water Systems 12.5 Gas Rate The gas valve is factory set for natural gas G20 and should need Check that all external controls are calling for heat, the boiler no adjustment. will fire automatically. Fully open all radiator valves and the Should any doubt exist about the gas rate, check it using the flow control valve, if fitted, see diagram 4.1.
  • Page 43 12 Commissioning 12.8 Benchmark 12.9 Instruct the User It is necessary to complete the appropriate sections of the Demonstrate, then instruct the User about the lighting “Benchmark” document. procedure and heating system controls operation. For IE, it is necessary to complete a “Declaration of Advise the user on the use and maintenance of any scale Conformity”...

  • Page 44: Servicing

    4. 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. 5. On completion of servicing the “Benchmark” log book should be completed.
  • Page 45 13 Servicing BRACKET CONTROL BOX SERVICE FLEXIBLE BRACKET HOSE CONTROL BOX UNION NUT (Do not loosen) LOCK NUT DOMESTIC CONTROL BOX EXPANSION VESSEL SERVICE BRACKET Diagram 13.5 BOILER SERVICE SUPPORT MODULE CONTROL BOX BRACKET MOUNTING BRACKETS DOMESTIC EXPANSION To move the control box into its service position VESSEL carefully pull the control box forwards and upwards to release from its mounting brackets.
  • Page 46 13 Servicing SILENCER HEAT BRACKET EXCHANGER SILENCER IGNITION LEAD SECURING SCREW EARTH LEAD HEAT EXCHANGER Diagram 13.9 Diagram 13.7 13.6 Burner NOTE: If the functional checks did not indicate poor SPARK GAP combustion then it is not necessary to service the burner. GASKET The following procedure will require that you replace the burner door seal and nyloc nuts.
  • Page 47 13 Servicing 13.7 Heat Exchanger GAS SUPPLY PIPE NOTE: If the functional checks did not indicate poor SECURING CLIP combustion then it is not necessary to service the heat exchanger. Refer to diagram 13.11. Remove loose debris from inside the heat exchanger using a soft brush and vacuum cleaner.
  • Page 48 13 Servicing 13.9 Condense Trap & Siphonic Drain FLUE ELBOW The condense trap and siphonic drain does not normally need servicing unless material deposits exceed beyond the service fill level, see diagram 13.15. To clean the condense trap remove the sump, see diagram 13.15 and rinse with water.
  • Page 49 14 Fault Finding Electrical Testing WARNING Should there be any doubt about the voltage supply to any of Always isolate the boiler from the electrical supply before carrying out any electrical replacement work. the components, it is possible to carry out a simple electrical test.
  • Page 50 14 Fault Finding CENTRAL HEATING START Is there anything displayed Is the power switched on? Switch the power on on the LCD? Check wires between main PCB and display Is the display flashing 'F'? Consult the Fault Table Initiate a CH demand. Does the boiler light? Does the display flash 'F' Successful ignition...
  • Page 51 14 Fault Finding Fault Codes Diagram 14.3...
  • Page 52 14 Fault Finding Fault Codes (continued) Diagram 14.3a Fault Memory The Fault memory stores details of the ten most recent faults. To access this menu: a) Press and hold ‘MODE’ for 5 seconds. b) When the display shows a flashing ‘0’ press ‘MODE’ button.
  • Page 53 14 Fault Finding Diagnostic Menu The Diagnostic Menu provides the ability to view and change certain parameters. See Diagram 14.4 for available parameters. To enter the diagnostic menu: a) Press and hold the ‘MODE’ button for 5 seconds. The display will change to flashing ‘0’. b) Use the ‘+’...
  • Page 54 14 Fault Finding Diagnostic Menu - Level 1 Installer Access Description Range Domestic hot water flow temperature reading Tank temperature Flow temperature setpoint Domestic hot water setpoint Tank setpoint intelligent control Domestic hot water demand d.24 System water pressure in bar. d.27 Option Relay 1 Reserved for future use...
  • Page 55 14 Fault Finding State list - Accessed through Diagnostic Codes - Level 1, Installer Access d.99 STATE LISTS Central heating mode Description S.00 no heating required S.01 fan pre-run S.02 pump pre-run S.03 ignition NORMAL OPERATING S.04 burner on STATE FOR CH S.05 pump / fan overrun S.06...

  • Page 56: Replacement Of Parts

    15 Replacement of Parts 15.1 General 15.3 Silencer assembly IMPORTANT: The following replacement of parts described For access, refer to section 15.1. in sections 15.7 to 15.12 and section 15.14 will require the To aid access to the silencer and securing screw, slacken removal of the burner module assembly and the replacement the locknut at the top of the domestic expansion vessel, see of seal and self locking nuts.
  • Page 57 15 Replacement of Parts 15.4 Ignition Lead SPARK GAP For access, refer to section 15.1. Refer to diagram 13.9. GASKET Pull the spark plug style connector off the spark electrode and the ignition lead connected to the igniter unit, see diagram 15.2. ELECTRODE 15.5 Igniter Unit For access, refer to section 15.1.
  • Page 58 15 Replacement of Parts 15.9 Burner REAR For access, refer to section 15.1. INSULATION WASHER Refer to section 13.6 for removal of the fan, gas valve and burner assembly. SECURING Remove the four screws that secure the burner, see diagram SCREW 13.12.
  • Page 59 15 Replacement of Parts SECURING SECURING SILENCER HEAT SCREW (2 OFF) NUT (4 OFF) BRACKET EXCHANGER SECURING SCREW IGNITION (2 OFF) LEAD IGNITER UNIT EXPANSION VESSEL CLAMP CLAMP CLAMP EARTH LEAD CH PUMP CH PUMP SECURING SCREW (2 OFF) FLEXIBLE HOSE CONNECTION Diagram 15.8 15.13 Heating Expansion Vessel...
  • Page 60 15 Replacement of Parts Remove the two connection clips securing the flow and return pipes to the heat exchanger, see diagram 15.9. Move the pipes away from the heat exchanger. Remove the four heat exchanger securing screws and clamps, see diagram 15.8. CAUTION: There will be water in the heat exchanger.
  • Page 61 15 Replacement of Parts 15.15 Central Heating Pump 15.17 Domestic Pump For access, refer to section 15.1. For access, refer to section 15.1. Drain the boiler heating circuit, see section 15.1. Drain the boiler domestic water circuit, see section 15.1. Unscrew the union nut of the return pipe to the pump Remove the domestic expansion vessel and place in its connection, see diagram 15.11.
  • Page 62 15 Replacement of Parts 15.18 Safety Discharge Valve For access, refer to section 15.1. LOW WATER Refer to section 15.1 and drain the boiler heating circuit. PRESSURE The safety discharge valve is situated towards the RH side of SENSOR the boiler module, refer to diagram 15.14. Unscrew the pipework union nut from the safety discharge valve.
  • Page 63 15 Replacement of Parts AUTOMATIC HEATING AIR VENT RETURN THERMISTOR RETAINING CLIP Diagram 15.18 Diagram 15.17 15.21 Heating Return Thermistor LOW WATER ELECTRICAL For access, refer to section 15.1. PRESSURE LEADS SENSOR Refer to diagram 15.17. Remove the electrical connections from the thermistor. Remove the thermistor and noting its position on the return pipe.
  • Page 64 15 Replacement of Parts 15.24 Plate-to-Plate Heat Exchanger For access, refer to section 15.1. PLATE TO PLATE SECURING Refer to section 15.1 to drain the boiler heating circuit. HEAT EXCHANGER SCREWS (4) Refer to section 15.1 and drain the boiler domestic water circuit.
  • Page 65 15 Replacement of Parts 15.25 Hydroblock and Bypass Tube Grip the LH and RH hydroblocks simultaneously and lift clear of the spigots on the mounting bracket. The RH hydroblock For access, refer to section 15.1. should be drawn upwards past the plastic three way valve IMPORTANT: To replace the bypass tube the LH and body.
  • Page 66 15 Replacement of Parts 15.26 Filling Loop BYPASS AUTOMATIC For access, refer to section 15.1. SCREW BYPASS VALVE Refer to section 15.1 and drain the boiler domestic water circuit. RETAINING Refer to diagram 12.2. CLIP Undo the union nuts on the filling loop valve and the double check inlet valve to remove the filling loop.
  • Page 67 15 Replacement of Parts 15.31 Immersion Heater IMMERSION For access, refer to section 15.1. HEATER Refer to section 5.3 and drain the hot water storage tank. Remove the flexible condensate hose from the condensate trap and siphonic drain, see diagram 13.15. Isolate any electrical connections to the immersion heater.
  • Page 68 15 Replacement of Parts 15.33 Access to Control Box Internals RETAINING For access, refer to section 15.1. CLIPS Carefully pull the control box forwards so that it lies horizontally in its hinges. Do not allow the front of the control box to swing down and be loosely held by its electrical connections.

  • Page 69: Spare Parts

    16.1 Spare Parts When ordering spare parts, 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 and serial number, to be found on the data label. If ordering from British Gas also quote the G.C.
  • Page 70 16 Spare Parts Diagram 16.1...

  • Page 71: Declaration Of Conformity

    17 Declaration of Conformity Glow-worm Glow-worm - Nottingham Road - Belper - Derbyshire - DE56 1JT...
  • Page 72 Glow-worm, Nottingham Road, Belper, Derbyshire. DE56 1JT Because of our constant endeavour for improvement, details may vary slightly from those shown in these instructions.

This manual is also suitable for:

Ultrapower 100sxiUltrapower 170sxi41-019-0941-019-10

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