Ultracom2 cxi Installation and Servicing 24cxi G.C. No. 47-019-10 30cxi G.C. No. 47-019-11 35cxi G.C. No. 47-019-12 High Efficiency Condensing Combination Boilers www.glow-worm.co.
Table of contents IN T R O D U C T I O N 1 Instructions guidance..........................................................................................................................3 1.1 1.2 1.3 1.4 2 Appliance description..........................................................................................................................3 2.1 2.2 2.3 2.4 2.5 3 Safety devices ........................................................................................................3 Data label...
Table of contents 12 Commissioning ................................................................................................................................25 12.1 12.2 12.3 12.4 12.5 12.6 12.7 12.8 12.9 13 Specific adjustment . ........................................................................................................................28 13.1 13.2 13.3 13.4 14 Switching on..........................................................................................................
INTRODUCTION INTRODUCTION 1 Instructions guidance 1.1 Product documentation 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.
INTRODUCTION 2.2 Data label 2.3 Gas category The data label certifies the country where the appliance is intended to be installed. This boiler is for use only on G20, but can be converted for use on G31. Data label location: • To adapt the appliance to another type of gas, see the chapter "Gas conversion". 2.4 2.4.1 Regulation and statutory requirements CE Mark This boiler meets the requirements of Statutory Instrument, No.
INTRODUCTION 2.
INTRODUCTION 3 Safety instructions and regulations 3.1 Safety instructions If the gas pressure at the input of the appliance is outside the range specified, the appliance must not be put into operation. e Incorrect installation can cause electric shock or appliance damage. • Never disable security devices and do not try to adjust them. • Use only new O-rings and gaskets. • After having completed work on gas or water carrying components, check for their tightness.
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 fluid, purge in accordance with the above standard.
technical data TECHNICAL DATA 5 Ultracom2 cxi Boiler, type C13, C33, C43, C53 Description Unit 24 cxi 30 cxi 35 cxi ll2H3P ll2H3P ll2H3P % 90.3 90.3 90.4 kW 18.5 25 30.6 kW 4.9 5.9 8.5 kW 18.2 24.6 30 kW 5.4 6.6 9.3 Gas category SEDBUK rating Heating Maximum heating input power Minimum heating output power at 80/60°C (P min.) Maximum heating output power at 80/60°C (P max.) Minimum heating output power at 50/30°C (P min.) Maximum heating output power at 50/30°C (P max.
INSTALLATION INSTALLATION i 6 6.1 6.1.1 All the drawings dimensions are shown in mm. For flue installations where external access is not practicable, consideration should be given for the space required to insert the flue from inside the property, which may necessitate clearance larger than those specified in diagram below. ØA Appliance location +5 mi ØA Location n. Instructions Before choosing a site for the appliance, carefully read the safety warnings and installation manual.
INSTALLATION 7 Appliance installation 7.1 4.4 4.5 4.6 4.7 Scope of delivery The appliance is delivered in a single carton with a document pack and fittings. i 7.2 7.2.1 The flues package will be ordered according to the configuration of the installation. Extended guarantee leaflet Guarantee envelope pack Magnetic lighting instruction label Gas conversion label (x1) (x1) (x1) (x1) Recommendations before installing Domestic hot water circuit design Water pressure • Please check the contents. 2.
INSTALLATION 7.2.2 Heating circuit design Bypass The boiler is fitted with an automatic bypass which can be adjusted to suit your system requirements. 6 5 • Ensure that under no circumstances does the flow rate drop below the figure specified, refer to chapter "Technical data". Filling the sealed system 7 8 9 4 i The water pressure at the boiler must be at least 1.2bar to operate the filling loop. If the pressure is less than 1.2bar an external filling loop must be fitted.
INSTALLATION 7.4 Drain points Mounting Drain taps must be provided at all low points of the system, which will allow the entire system to be drained. • Make sure that the equipment used for implementing the installation is compatible with that of the appliance. Drain taps shall be to the current issue of BS2879. • Determine the assembly location. See the "Appliance location" chapter.
INSTALLATION 7.4.1 Fixing to the wall 3 7.4.2 a 130 2 90° 1 4 Boiler hanging With 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". 2 5 6 1 Key 1 Wall template 2 Standard flue length horizontal 3 2.5° 44mm/metre inclined extended flue length 4 Wall plug 5 Hanging bracket 6 Screw (not supplied) Flue hole cutting • Mark the position of the flue centre.
INSTALLATION 8 Hydraulic connection 8.1 8.2 Safety Discharge Valve Gas and water connections 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”. i The appliance may contain a small amount of water, place a water container beneath the boiler connections.
INSTALLATION 8.3 Connection to the condensate trap a Condensate produced by the appliance is mildly acidic (pH 3.5 - 5.0). Use protective gloves b Condensate must only be discharged in accordance with these instructions. i The 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.
INSTALLATION - 16 - 0020085231_02 - 05/10 - Glow-worm
INSTALLATION 9 Evacuation of combustion gas 9.1 Regulation b b If the flue terminal is positioned near a light source insects may enter the flue system. Where safe and practical to do so advise the homeowner to check the flue outlet and clear visible insects from the terminal end. Only flue accessories supplied by Glow-worm must be used. Different flue outlet configurations can be carried out. • Consult your supplier for more information about the other possibilities and associated accessories.
INSTALLATION Position Position of the flue terminal Horizontal flues directly below an opening, air brick, A opening windows B above an opening, air brick, opening windows horizontally to an opening, air brick, opening C windows D below gutter, drain/soil pipe E below eaves F below a balcony or car port G from vertical drain pipes and soil pipes H from internal/external corners H* to a boundary alongside the terminal I above adjacent ground or balcony level J* from surface or a boundary facing the terminal
INSTALLATION 9.2 Flue configuration description 9.2.1 Horizontal concentric flue Ø 60/100 mm or Ø 80/125 mm (C13 type installation) a Each time an additional 90° bend is necessary (or 2 at 45°), the length (L) must be reduced by 1 m. 9.2.2 Vertical concentric flue Ø 60/100 mm or Ø 80/125 mm (C33 type installation) If necessary, you must install a terminal protection kit.
INSTALLATION 9.2.3 Multiple boiler chimney flue Ø 60/100 mm (C43 type installation) b The flue connecting from the appliance to the flue system must be supplied from the manufacturer of the boiler. b C43 flue systems must not be a 'pressurised system' but act under natural draught principles b C43 type flue systems must have their own condensate drain fitted and not allow condensate to mix into other appliances L Model 24cxi 30cxi 35cxi At min thermal load (40°C/30°C) 2.4 2.9 4.
INSTALLATION 10 Remove the front panel 11.1 Access to main board 2 1 3 1 4 24 V 23 0 V B 2 11.2 A A Key 1 Front panel 2 Front panel retaining screw • Undo the two screws (2) on the underside of the front panel and remove the front panel (1). 11 Electrical connections e Key 1 24 V access cover 2 Terminal blocks for 24 V connection 3 Terminal blocks for 230 V connection 4 230 V access cover Incorrect installation can cause electric shock or appliance damage.
INSTALLATION 11.3 Electrical wiring Connection of the whole electrical system and any heating system controls to the electrical supply must be through a common isolator. Isolation should preferably be by a double pole switched fused spur box having a minimum contact separation of 3mm on each pole. The fused spur box should be readily accessible and preferably adjacent to the boiler. It should be identified as to its use.
INSTALLATION 11.3.2 11.4 230V permanent supply + 230V system controls a All cables connected to the appliance should be permanently fixed to the wall. i This appliance will not operate without a link or system controls fitted. e External accessories Under no circumstances must any mains voltage be applied to any of the terminals on the 24v connection plug.
INSTALLATION 11.
INSTALLATION 12 Commissioning i Key 1 Air vent 2 Pump 3 Screw for the pump shaft At the time of commissioning, complete all relevant sections of the Benchmark Checklist located in the centre pages of this document. The commissioning should be carried out by a competent person approved at the time by the Health and Safety Executive and in accordance with the current issue of BS6798. 12.1 Switching on • Open the plug on the air vent located on the pump and the automatic air vents on the installation.
INSTALLATION 12.4 Filling the Condensate Trap • Check the integrity of the appliance combustion circuit and relevant seals. • Check that all internal/external controls are calling for heat. • Check that the gas service isolation is open. • To adapt the appliance to another type of gas, see chapter "LPG conversion". 12.5.
INSTALLATION • On completion, test the gas installation for tightness using the pressure drop method and suitable leak detection fluid, purge in accordance with the above standard. i Due to the modulating operation of the boiler and the need to check the gas inlet pressure and measure the gas rate at maximum rate, it will be necessary to force it to maximum. • Activate the test mode "P.01" and set the value to 100 in order to force the burner at P. max.
INSTALLATION 13 Specific adjustment 13.1 Output/pressure curve Ultracom2 30cxi 1 Heating circuit adjustment It may be necessary to adjust the by-pass to the design of the system. The boiler is delivered pre-set open 1/2 turn (1).
INSTALLATION • Do likewise for each parameter that needs to be modified. • Press for more than 3 seconds on the button the configuration menu. Code Parameter to exit Factory setting Unit Description 18 25 30 Modifiable parameter d.00 Maximum heating power kW Choose a value: 24cxi ► 5 to 18 kW 30cxi ► 6 to 25 kW 35cxi ► 8 to 30 kW d.01 Pump over-run time - heating min. Choose a value between 2 and 60. 5 yes min.
INSTALLATION 13.2.2 After Sales Service settings • Press for more than 7 seconds on the button to access the configuration menu. The screen displays "0". • Press on button or under the symbol After Sales Service password. and enter the to validate. The screen displays the • Press on parameter "00" and its value "XX”. • Press on button or parameter to modify. under the symbol or under the symbol • Press on button value of the parameter.
INSTALLATION 13.2.3 Status of the appliance • Press button under the symbol for more than 3 seconds to learn the current state of functioning of the appliance. The screen displays the state of the appliance "S.XX". • Press button menu. Status S.00 S.01 S.02 S.03 S.04 S.05 S.06 S.07 S.08 Status S.10 S.11 S.13 S.14 S.15 S.16 S.17 Status S.20 S.21 S.23 S.24 S.25 S.26 S.27 S.28 Status S.30 S.31 S.32 S.34 S.39 S.40 S.41 S.53 S.54 S.96 S.
INSTALLATION 13.3 CO2 measurement The combustion for this appliance has been pre-set at the factory for operation on Natural Gas G20 as defined on the appliance data label. No adjustment of the combustion is necessary. If you wish to check the combustion then follow the instructions in the Servicing section.
MAINTENANCE MAINTENANCE 15.1.1 To ensure the continued efficient and safe operation of the boiler it is recommended that it is checked and serviced at regular intervals. The frequency of servicing will depend upon the particular installation and usage, but in general once a year should be enough. It is the Law that any servicing is carried out by a competent person approved at the time by the Health and Safety Executive.
MAINTENANCE 15.2 Fault memory • This menu allows you to display the 10 most recent failure codes registered by the appliance. • In order to display the fault code memory, simultaneously and under the symbol for more press the buttons than 7 seconds. • The screen will display the first fault "01" (record) and "F.XX" (fault code). • To display the other faults registered by the appliance, press the button or under the symbol . for more than 3 seconds to exit this • Press button menu.
MAINTENANCE Fault Description codes Cause Solution F26 Fault in gas valve motor. Disconnected or defective cables • Check the gas valve connections. • Check the operation of the gas valve. • Check the operation of the condensate pump (option). F27 Flame detection fault. Abnormal flame detection • Check the flame detection electrode. • Check the main board. • Check the igniter unit.
MAINTENANCE 15.4 Functional flow diagram 15.4.1 Central Heating 15.4.
MAINTENANCE 16 Gas conversion adjustments 2 3 In order to operate with a gas other than that provided from the factory, it is necessary to some adjustments to the gas valve. This conversion should only be carried out by a competent person approved at the time by the Health and Safety Executive. • During the conversion to Propane, use of a suitable flue gas analyser is necessary.
MAINTENANCE • Compare the value measured with the values indicated in the table below. Gas adjustment 17.1 G20 G31 CO2 case ON 9 ± 0.2 % 10.1 ± 0.2 % CO2 case OFF 9.2 ± 0.3 % 10.3 ± 0.3 % i 16.1.3 17 Draining Heating circuit Safe combustion can only be verified by measuring CO/CO2 ratio. This must not exceed the value shown in the table under the section "Maximum Rate and Adjustment". Restarting • Replace the cap • Replace the appliance front panel.
MAINTENANCE 18 Servicing • To ensure the continued efficient and safe operation of the boiler it is recommended that it is checked and serviced as necessary at regular intervals. The frequency of servicing will depend upon the particular installation conditions and usage. If this appliance is installed in a rented property there is a duty of care imposed on the owner of the property by the current issue of the Gas Safety (Installation and Use) Regulations, Section 35.
MAINTENANCE 18.2 18.2.1 Casing removing 18.3 Front panel Combustion check and setting the air/gas ratio valve 18.3.1 1 i Competency to carry out the check of combustion performance BS 6798: 2009 Specification for installation and maintenance of gas-fired boilers of rated input not exceeding 70kW net advises that: -- The person carrying out a combustion measurement must be assessed as competent in the use of a flue gas analyser and the interpretation of the results.
MAINTENANCE 2 3 If the combustion reading is not within the acceptable values and the integrity of the complete flue system and combustion circuit seals have been verified and the inlet gas pressure (and gas rate) have been verified, then, it will necessary to adjust the combustion rate of the appliance. i Adjustment is made by turning the throttle an ⅛ of a turn, waiting 1 minute to allow the appliance to stabilise before checking or making further adjustments.
MAINTENANCE 18.5 Silencer Key 1 Fixed silencer 2 Silencer retaining clip 3 Removable silencer 24cxi / 30cxi 3 2 • Unclip and remove the silencer (3). • Clean the interior of the silencer with a dry cloth if necessary, taking care not to damage the internal foam. • Repeat the operation in reverse order to replace the silencer. B 18.
MAINTENANCE 18.7 Heating filter 18.8 a D 3 E Condensate trap Warning: condensate is mildly acidic. Use protective gloves. 5 1 4 5 C B 1 3 A B 2 1 4 1 A 2 Key 1 Plate-to-plate heat exchanger retaining arm 2 Plate-to-plate heat exchanger retaining screw 3 Gasket 4 Heating filter 5 Plate-to-plate heat exchanger The heating filter improves the degassing of the heating circuit. • Close the flow and return heating stop valves and drain the boiler. • Remove the retaining screw (2) and arm (1).
MAINTENANCE 18.9 Combustion block 9 8 7 6 5 10 4 11 3 12 2 13 1 14 15 16 17 Legend 1 Gas valve connection 2 Grounding cable 3 Spark electrode inlet 4 Spark electrode retaining screw.
MAINTENANCE 18.9.1 Spark electrode 18.9.5 Re-assembling the burner group • Disconnect the electrode inlet (3) and the grounding cable (2). • Place the burner group on the heat exchanger (11). • Remove the 2 spark electrode retaining screws (4). • Progressively tighten the 4 nuts (7) in an alternate order. • Carefully remove the electrode from the combustion chamber. • Reassemble the silencer. • Check that the extremes of the electrode (6) are not damaged.
MAINTENANCE 19 Replacement of Parts 19.3 Viewing window • Do not use reconditioned or copy parts, only use original parts supplied by Glow-worm. 2 • If a part is required, contact the Glow-worm service organisation. 1 • Please quote the name of the appliance, this information will be on the name badge on the front of the appliance. 3 • If in doubt seek advice from the local gas company or Glowworm’s own service organisation.
MAINTENANCE 19.3.1 Expansion vessel A 4 D 3 E 2 2 1 C B 1 Key 1 Connector 2 Expansion vessel 3 Upper support bracket 4 Retaining screw 5 Gasket Drain the boiler heating circuit as described in the appropriate chapter "Draining". • Remove the two screws (4). • Undo the connector (1) at the base of the vessel. • Remove upper support bracket (3). • Remove the expansion vessel (2). • Fit a new gasket between the expansion vessel and connector. • Refill, vent and pressurise the boiler.
MAINTENANCE 19.
MAINTENANCE 19.4.1 Pump (head only) 19.4.5 Flow sensor • Drain the boiler heating circuit as described in the appropriate chapter "Draining". • Drain the boiler hot water circuit as described in the appropriate chapter "Draining". • Disconnect the electrical plug (26) from the main board. • Remove the side securing clip and the electrical connection (4). • Disconnect the electrical plug (25) from the pump head. • Disengage the flow sensor (5). • Remove the four cap head screws (27).
MAINTENANCE 19.
MAINTENANCE Legend 1 Igniter unit retaining bracket 2 Igniter unit 3 Igniter unit retaining screw 4 Igniter unit electrical connector 5 Electrode / igniter unit connection cable 6 Earth cable 7 Spark electrode cap 8 Spark electrode retaining screw 9 Spark electrode gasket 10 Spark electrode 11 Combustion burner door assembly 12 Combustion burner door assembly - nut 13 Combustion burner door assembly - gasket 14 Burner gasket 15 Burner 16 Burner retaining screw 17 Heat exchanger retaining screw 18 Heat excha
MAINTENANCE 19.5.6 Re-assembling the burner group • Place the burner assembly on the heat exchanger (21). • Progressively tighten the 4 nuts (12) in an alternate order. • Reassemble the silencer. • Connect the gas pipe (36) with a new gasket to the burner group. • Connect the spark electrode connector (5) to the igniter unit. • Connect the connector to the gas valve (37) and the fan (34).
MAINTENANCE 19.7 i 19.8.1 PCB 19.8.3 When replacing the board refer to instructions supplied with the spare part. User interface PCB 5 Main PCB 4 B B C C B 4 B 3 3 1 1 2 A 1 Key 1 Control panel 2 Rear panel 3 Retainings clips 4 Main PCB • Remove the 24V and 230V connections. • Remove the rear panel (2). • Ease back the two PCB retaining clips (3) and withdraw the PCB from the retaining lugs. • Remove the electrical connections to the PCB (appliance interface cable).
MAINTENANCE 20 Spare parts In order to guarantee the safe and prolonged life of the product, manufacturers genuine spare parts must be used. i This appliance displays a CE Mark of conformity. Only use the manufacturer’s genuine, new spare parts. • Ensure that spare parts are correctly mounted in the right position and direction. After fitting any spare part or servicing, the appliance must be tested for its safe operation. 20.
MAINTENANCE 20.
Manual Handling IMPORTANT. With regards to the Manual Handling Operations, 1992 Regulations, the following lift operation exceeds the recommended weight for a one man lift. General recommendations when handling Clear the route before attempting the lift. Ensure safe lifting techniques are used – keep back straight – bend using legs. Keep load as close to body as possible. Do not twist – reposition feet instead. If 2 persons performing lift, ensure co-ordinated movements during lift.
Declaration of Conformity
0020085231_02 - 05/10 Because of our constant endeavour for improvement, details may vary slightly from those shown in these instructions. Glow-worm, Nottingham Road, Belper, Derbyshire.
