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Summary of Contents for Glowworm Ultimate 3 25r-A
- Page 1 Ultimate 3 25r -A (H-GB) en Installation and maintenance instructions...
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Page 2: Table Of Contents
Installation and maintenance Switching on the product ........26 Flushing the heating installation for the first instructions time ("cold") ............26 Filling the heating installation ......26 Contents Checking the gas setting ........26 Thoroughly flushing the heating installation Safety ..............3 ("hot").............. -
Page 3: Safety
Safety Qualification The person carrying out the work described Intended use here must have completed professional train- The product is intended as a heat gener- ing. The competent person must demon- ator for open heating installations and for do- strably have all of the knowledge, skills and mestic hot water generation. - Page 4 ▶ Do not use any electrical switches, mains To prevent electric shocks, proceed as fol- plugs, doorbells, telephones or other com- lows before working on the product: munication systems in the building. ▶ Disconnect the product from the power ▶ Close the emergency control valve or the supply by switching off all power supplies main isolator.
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Page 5: Regulations (Directives, Laws, Standards)
▶ Observe local regulations on neutralising condensate. 1.3.9 Frost To prevent material damage: ▶ Do not install the product in rooms prone to frost. 1.3.10 Safety devices ▶ Install the necessary safety devices in the installation. Regulations (directives, laws, standards) ▶... -
Page 6: Guarantee And Customer Service
Guarantee and Customer Service 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. To maintain your guarantee, the boiler must be serviced annually by a competent person who holds the required qualifications in accordance with the rules in force of the country where the product is installed and in accordance with the manufactures recommendations. -
Page 7: Technical Data
Technical data – G20 power/load G20 Technical data ULTIMATE Technical data – General 3 25r -A (H- ULTIMATE Maximum heat output 25 kW 3 25r -A (H- Effective output range (P) 6.5 to Gas category at 40/30 °C 27.0 kW Effective output range (P) 6.4 to Diameter of the gas pipe... -
Page 8: Notes On The Documentation
Notes on the documentation Information on the data plate The data plate is mounted on the underside of the product at ▶ Always observe all operating instructions enclosed with the factory. the installation components. ▶ Store these instructions and all other applicable docu- Information on the Meaning ments for further use. -
Page 9: Functional Elements
Functional elements 5.6.3 Frost protection The appliance has a built in frost protection device that pro- tects the boiler from freezing. With the gas and electric sup- plies ON and irrespective of any room thermostat setting, the frost protection device will operate the pump when the tem- perature of the boiler water falls below 12 °C. -
Page 10: Set-Up
Set-up Dimensions Checking the scope of delivery ▶ Check that the scope of delivery is complete and intact. 6.1.1 Scope of delivery Number Designation Heat generator Unit mounting bracket Flue adapter 183,5 Gas stopcock Gas pipe 33,5 Condensate discharge hose 133,5 Mounting template Enclosed documentation... -
Page 11: Minimum Clearances
– Minimum clearances 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 44 mm/m. - Page 12 6.5.2 Position of the air/flue terminal 6.5.2.1 Positioning the terminal of a fan-supported flue system Installation site Dimensions Adjacent to a boundary. 300 mm The dimension below eaves, balconies and car ports can be reduced to this value, as long as the flue terminal is 25 mm extended to clear any overhang.
- Page 13 Installation site Dimensions The dimension below eaves, balconies and car ports can be reduced to this value, as long as the flue terminal is 25 mm extended to clear any overhang. External flue joints must be sealed with suitable silicon sealant. Above adjacent ground or balcony.
- Page 14 6.5.3.3 Vertical Concentric Flue ⌀ 60/100 mm or 6.5.3 Flue Configuration Description ⌀ 80/125 mm (C33 type installation) 6.5.3.1 Horizontal Concentric Flue ⌀ 60/100 mm or ⌀ 80/125 mm (C13 type installation) Note If the terminal is at less than 1.80 m from the ground, you must install a terminal protection kit.
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Page 15: Using The Mounting Template
Removing/installing the front casing Boiler Final storey Inspection hatch Ground floor 6.8.1 Removing the front casing Note 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 sys- tem' but act under natural draught principles. - Page 16 6.9.2 Installing the side section ▶ Refit the components in the reverse order. Installation and maintenance instructions Ultimate 3 0020239568_04...
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Page 17: Installation
Installation Heating water supply in the open heating system Preparing for installation ▶ Make sure that the existing gas meter and the pipelines are capable of passing the rate of gas supply required. ▶ Consider the maximum heat output given in DHW mode. ▶... -
Page 18: Heating Water Supply In The Sealed Heating System
Heating water supply in the sealed heating Note system A higher initial design pressure requires a larger volume expansion vessel. SUPPLY PIPE In GB, guidance on vessel sizing is also given in the cur- rent issue of BS 5449 and BS 7074 Part 1. In IE refer to the current edition of I.S. -
Page 19: Gas Connection
▶ Gas connection Connect a condensate discharge pipe (21.5 mm, not included in the scope of delivery) to the drain hose (2). ▶ During installation remove all burs from inside of cut pipe work and avoid excessive adhesive which may trap small pockets of water close to the pipe wall which can freeze and build into a larger ice plug. - Page 20 7.8.1.3 External termination to gulley or hopper 7.8.1.6 Internal termination downstream of sink waste Ø22mm 100mm ≤ 3 m Ø22mm Ø 32mm ≤ 3 m Ø32mm Best practice 7.8.1.4 Internal termination into combined sink waste Open end of pipe direct into gulley below ground level but above water level Susceptible to siphonage, must terminate in a gulley 100mm...
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Page 21: Flue Installation
7.8.1.9 Connection of condensate pump 7.10.1 Opening the electronics box Ø32mm ≥ 3 m Ø22mm Preferred option for external connection Flue installation 7.9.1 Installing and connecting the air/flue pipe 7.10.2 Cable route You can find out which air/flue pipes may be used by consulting the enclosed set-up instructions for the air/flue system. - Page 22 If required, shorten the connection cables. ≤ 30 mm ≤ 40 mm ≤ 30 mm 230V~ Strip the flexible cables as shown in the figure. In doing so, ensure that the insulation on the individual conduct- ors is not damaged. Only strip inner conductors just enough to establish stable connections.
- Page 23 Ensure that the product is voltage-free. Connect the cables. (→ Page 21) Connect the individual components depending on the installation type. Condition: If installing a multi-circuit control. ▶ Change the pump mode d.18 from Eco (intermittent pump operation) to Comfort (continuous pump opera- tion).
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Page 24: Operation
Operation Using check programmes By activating various check programmes, you can trigger Using diagnostics codes various special functions on the product. You can use the parameters marked as adjustable in the Check programmes – Overview (→ Page 35) table of diagnostics codes to adapt the product to the install- ation and customer requirements. -
Page 25: Start-Up
Start-up Total Water hardness at specific system volume heating > 20 l/kW output ≤ 20 l/kW Carrying out the initial start-up > 50 l/kW ≤ 50 l/kW Initial start-up must be carried out by a customer service mol/ mol/ mol/ technician or an authorised competent person using the CaCO₃... -
Page 26: Filling The Condensate Trap
Additives for frost protection intended to remain Flushing the heating installation for the first permanently in the installation time ("cold") – Adey MC ZERO Note – Fernox Antifreeze Alphi 11 The complete heating system must be flushed – Sentinel X 500 at least twice: Once with cold water and once ▶... - Page 27 ▶ Ensure that all other gas appliances in the property are Condition: Gas flow pressure not in the permissible range turned off. ▶ Measure the gas flow rate at the gas meter. Caution. ▶ Compare the measured values with the corresponding Risk of material damage and operating values in the table.
- Page 28 10 Adapting the unit to the heating Checking the CO₂ Removed Fitted front content front casing casing installation Natural gas H Natural gas H You can reset/change the system parameters (section "Us- 9.0 ±1.0 vol. % 9.2 ±1.0 vol. % CO₂...
- Page 29 ▶ 12 Inspection and maintenance Turn the screw (1) to set the CO₂ content (value with front casing removed). ◁ 12.1 Complete Service Interval Record section To increase the CO₂ content: Turn anti-clockwise ◁ To decrease the CO₂ content: Turn clockwise ▶...
- Page 30 12.7 Cleaning the heat exchanger Check the heat exchanger for damage and dirt. If required, clean and replace the heat exchanger. Protect the open electronics box from spraying water. Clean the ribs of the heat exchanger (1) with water. ◁ The water runs out via the condensate tray.
- Page 31 12.10 Cleaning the condensate trap 12.13 Completing inspection and maintenance work Check the gas connection pressure (gas flow pressure). (→ Page 27) Check the CO₂ content. If required, set the maintenance interval. Check the product for tightness. (→ Page 28) Install the front casing.
- Page 32 13.5.1 Procuring spare parts The original components of the product were also certified by the manufacturer as part of the declaration of conformity. If you use other, non-certified or unauthorised parts during maintenance or repair work, this may void the conformity of the product and it will therefore no longer comply with the applicable standards.
- Page 33 13.6.4 Replacing the PCB 13.7 Checking the product for leak-tightness ▶ Check that the product is leak-tight. (→ Page 28) 14 Decommissioning the product ▶ Switch off the product. ▶ Disconnect the product from the power grid. ▶ Close the gas stopcock. ▶...
- Page 34 Appendix Inspection and maintenance work The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals. If na- tional regulations and directives require shorter inspection and maintenance intervals, you should observe these instead of the intervals listed. Each time inspection and maintenance work is carried out, carry out the required preparatory and com- pletion work.
- Page 35 Maintenance work Interval Reassemble the product After each time maintenance work is carried out Open the service valves, carry out the required leak-tightness test Annually Fill the product/heating installation to the filling pressure specified for the Annually system Connect the product to the electrical installation Annually Run the test operation on the product/heating installation including hot Annually...
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Page 36: C Overview Of Diagnostics Codes
Overview of diagnostics codes Setting level Values Default set- Unit Increment, select, explanation Own setting ting Min. Max. – – → Section d.00 Heating maximum output The maximum heating output varies Adjustable depending on the product. "Technical data" → Section "Technical data" d.01 Pump overrun time in Adjustable heating mode... - Page 37 Setting level Values Default set- Unit Increment, select, explanation Own setting ting Min. Max. – d.27 Function of relay 1 (multi- 1 = Circulation pump Adjustable functional module) 2 = External pump 3 = Cylinder charging pump 4 = Extraction hood 5 = External solenoid valve 6 = External fault message 7 = Solar pump (omitted)
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Page 38: D Status Codes - Overview
Setting level Values Default set- Unit Increment, select, explanation Own setting ting Min. Max. – – – d.68 Number of unsuccessful Current value ignitions at 1st attempt adjustable – – – d.69 Number of unsuccessful Current value ignitions at 2nd attempt adjustable ℃... -
Page 39: E Overview Of Fault Codes
Status code Meaning S.20 Domestic hot water mode: Requirement S.21 Domestic hot water mode: Fan prerun S.22 Domestic hot water mode: Pump prerun S.23 Domestic hot water mode: Burner ignition S.24 DHW mode: Burner on S.25 DHW mode: Pump/fan overrun S.26 DHW mode: Fan overrun S.27... - Page 40 Fault code Meaning Possible cause F.28 Fault: Ignition unsuccessful when starting Gas meter defective or gas pressure switch has triggered, air in gas, gas flow pressure too low, thermal cut-out has triggered, incorrect gas injector, incorrect spare gas valve assembly, fault on the gas valve assembly, mul- tiple plug on PCB incorrectly plugged in, break in cable harness, ignition sys- tem (ignition transformer, ignition cable, ignition plug, ignition electrode) de- fective, ionisation flow interrupted (cable, electrode), incorrect earthing of...
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Page 41: F Wiring Diagram
Wiring diagram Burner off X106 eBUS – Burner 24V= 230V~ Main PCB Gas valve assembly Interface PCB Heating pump Control system Monitoring electrode Temperature sensor on the heating flow Room thermostat Temperature sensor on the heating return Main power supply and connection for 230 V control Ignition electrode 0020239568_04 Ultimate 3 Installation and maintenance instructions... -
Page 42: Commissioning Checklist
Commissioning Checklist Benchmark Commissioning & Warranty Validation Service Record It is a requirement that the boiler is installed and commissioned to the manufacturers’ instructions and the data fields on the commissioning checklist completed in full. To instigate the boiler warranty the boiler needs to be registered with the manufacturer within one month of the installation. - Page 43 GAS BOILER SYSTEM COMMISSIONING CHECKLIST & WARRANTY VALIDATION RECORD Address: Boiler make and model: Boiler serial number: Commissioned by (PRINT NAME): Gas Safe registration number: Company name: Telephone number: Company email: Company address: Commissioning date: Heating and hot water system complies with the appropriate Building Regulations? Time, temperature control and boiler interlock provided for central heating and hot water Boiler Plus requirements (tick the appropriate box(s)) Weather compensation...
- Page 44 SERVICE & INTERIM BOILER WORK RECORD It is recommended that your boiler and heating system are regularly serviced and maintained, in line with manufacturers’ instructions, and that the appropriate service / interim work record is completed. Service provider When completing a service record (as below), please ensure you have carried out the service as described in the manufacturers’ instructions. Always use the SERVICE/INTERIM WORK ON BOILER SERVICE/INTERIM WORK ON BOILER Date:...
- Page 45 SERVICE & INTERIM BOILER WORK RECORD It is recommended that your boiler and heating system are regularly serviced and maintained, in line with manufacturers’ instructions, and that the appropriate service / interim work record is completed. Service provider When completing a service record (as below), please ensure you have carried out the service as described in the manufacturers’ instructions. Always use the SERVICE/INTERIM WORK ON BOILER SERVICE/INTERIM WORK ON BOILER Date:...
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Page 46: H Commissioning Flow Chart
Commissioning Flow Chart PRIOR TO CO AND COMBUSTION RATIO CHECK NOTE The boiler manufacturer’s installation instructions should have been followed, gas type verified and gas THE AIR GAS RATIO VALVE IS FACTORY supply pressure/rate checked as required prior to commissioning. SET AND MUST NOT BE ADJUSTED As part of the installation process, especially where a flue has been fitted by persons other than the DURING COMMISSIONING UNLESS THIS... -
Page 47: Index
Index Maintenance work ............... 29 Maintenance work, completing..........31 Air intake pipe, removing............. 29 Minimum clearance ............. 11 Air/flue pipe, horizontal wall duct......... 14 Mounting template............... 15 Air/flue pipe, installing ............21 Overheating protection ............9 Air/flue pipe, type C13 ............14 Air/flue pipe, type C33 ............ - Page 48 Supplier Vaillant Ltd. Nottingham Road Belper Derbyshire DE56 1JT Telephone 0330 100 3461 info@vaillant.co.uk www.vaillant.co.uk 0020239568_04 Publisher/manufacturer Vaillant Group UK LTD Nottingham Road Belper-Derbyshire DE56 1JQ Telephone 01773 824639 Technical helpline 0330 100 7679 After sales service 0330 100 3142 www.glow-worm.co.uk © These instructions, or parts thereof, are protected by copyright and may be reproduced or distributed only with the manufacturer's written consent.
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