Glow-worm Xtramax HE Installation And Servicing

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[Page 1] Glow-worm Xtramax HE

www.glow-worm.co.uk Xtramax HE G.C. No. 47-047-29 Installation and Servicing www.glow-worm.co.uk High Effi ciency Condensing Boilers ...

[Page 2] Glow-worm Xtramax HE

2 Guarantee Registration 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 acco...

[Page 3] Glow-worm Xtramax HE

3 CONTENTS DESCRIPTION SECTION PAGE Important Information 4 Statutory Requirements 5 Boiler Design 6 Safety Devices 6 Servicing, Maintenance and Spare Parts 6 Technical Information 1 7 Boiler Location...

[Page 4] Glow-worm Xtramax HE

4 WARNINGS Gas Leak or Fault Turn off the gas emergency control valve immediately. Eliminate all sources of ignition, i.e.smoking, blowlamps, hot air guns etc. Do not operate electrical lights or switches either on or off. Open all doors and windows...

[Page 5] Glow-worm Xtramax HE

5 CE Mark 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 b...

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6 Boiler Design Boiler Design This boiler is designed to provide central heating and instantaneous hot water for use as part of a sealed water central heating system with fully pumped circulation. The pumps , expansion vessel and associated...

[Page 7] Glow-worm Xtramax HE

7 1.1 Technical Data All dimensions are given in millimetres (except as noted). See diagrams 1.1, Table 1, Table 1 continued and Table 2. 700 890 301 480 12907 Diagram 1.1 1 Technical Information Description Unit Xtramax HE Gas category ll2H3P SEDB...

[Page 8] Glow-worm Xtramax HE

8 1 Technical Information Combustion Fresh air flow rate (1013 mbar - 0°C) m3/h 43 Product outlet flow rate g/s 15.3 Product outlet temperature °C 68 Values of product outlet (measured on nominal heating output with G20 reference gas): CO ppm 86 ...

[Page 9] Glow-worm Xtramax HE

9 D2 D1 1 Technical Information 1 Flue outlet 2 Main heat exchanger 3 Burner 4 Ignition and control electrode 5 Fan 6 Gas control valve 7 DHW storage vessel 8 Condensate drain 9 Overheat safety thermostat 10 Temperature sensor for D...

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10 2 Boiler Location 2.1 Location This boiler is not suitable for outdoor installation. This boiler may be installed in any room, although particular attention is drawn to the installation of a boiler in a room containing a bath or shower...

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11 3.1 Flue Length See diagrams 3.1 to 3.3 to determine which ue can be used. When extension pipes are used the ue system must be designed to have a continuous fall to the boiler of at least 2.5 o to allow condensate to run back into the boi...

[Page 12] Glow-worm Xtramax HE

12 3 Flue Location and Ventilation HORIZONTAL FLUES A DIRECTLY BELOW AN OPENING, AIR BRICK, OPENING WINDOWS 300 B ABOVE AN OPENING, AIR BRICK, OPENING WINDOWS 300 C HORIZONTALLY TO AN OPENING, AIR BRICK, OPENING WINDOWS 300 D BELOW ...

[Page 13] Glow-worm Xtramax HE

13 4 Heating System 4.1 General The boiler is for use only with sealed central heating systems. The safety valve is an integral part of the boiler and it cannot be adjusted. The digital readout on the controls fascia indicates the system pre...

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14 6 Installation Preparation 6.1 Appliance Pack IMPORTANT: With regards to the Manual Handling Operations, 1992 Regulations, the following lift operation exceeds the recommended weight for a one man lift, refer to Manual Handling section...

[Page 15] Glow-worm Xtramax HE

15 7 Gas / Water and Appliance Connection 7.1 Gas Connection Before connection check supply of local gas. Refer also to statutory requirements. Do not subject the gas service cock to heat. The whole of the gas installation, including the meter, shou...

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16 Diagram 8.1 NOTE: The pipes from the heating and domestic hot water safety discharge valves must not discharge above an en- trance, window or any type of public access area. 8.1 DHW Safety Discharge Valve Take the short safety discharge tube, un...

[Page 17] Glow-worm Xtramax HE

17 8 Safety Discharge, Condensate and Tundish Connections Valve outlet size Minimum size of discharge to tundish D1 Minimum size of discharge pipe D2 from tundish Maximum resistance allowed expressed as a length of straight pipe i.e. no elbo...

[Page 18] Glow-worm Xtramax HE

18 1 2 Diagram 8.2 8 Safety Discharge, Condensate and Tundish Connections 8.3 Tundish discharge The internal safety valves, 24 and 36 have been tee’d to- gether and the discharge pipe run so that it exits at the right hand bottom of the boiler ( ...

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19 8 Safety Discharge, Condensate and Tundish Connections Diagram 8.4 13000 ...

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20 IMPORTANT NOTE ALL electrical connections to the boiler must be permanently xed to a wall or a sturdy support feature in a tidy manner. 9 Electrical Connection Diagram 9.1 CONTROL PANEL REAR COVER SECURING SCREW (3) CABLE EXIT VOLTAGE FREE H...

[Page 21] Glow-worm Xtramax HE

21 FLUE ELBOW COMBUSTION ANALYSER TEST POINT FLUE DUCT EXTENSION 10 Commissioning Diagram 10.1 Diagram 10.2 1 KEY 1 Retaining latches 5 CH temperature knob 2 Controls fascia 6 Hot water temperature knob 3 User interface 7 Digital...

[Page 22] Glow-worm Xtramax HE

22 10 Commissioning Commissioning should only be carried out by a competent person approved at the time by the Health and Safety Executive. 10.4 Initial Lighting NOTE: The combustion for this appliance has been checked, adjusted and preset at the...

[Page 23] Glow-worm Xtramax HE

23 The fan should start and after a few seconds the ignition will commence. If the burner fails to light the fan will stop. Initially this may be due to air in the gas supply line. The boiler will automatically have three attempts at ignition. If ...

[Page 24] Glow-worm Xtramax HE

24 10.7 Completion Adjust the boiler temperature control and any system controls to their required settings. GB: It is a requirement that the “Benchmark” Installation, Commissioning and Service Record is completed and left with the user. IE: ...

[Page 25] Glow-worm Xtramax HE

25 Diagram 10.6 13954 OFFSET ADJUSTMENT SCREW THROTTLE INLET PRESSURE TEST POINT Natural Gas (G20) to LPG (G31) Conversion 10.9 LPG CONVERSION - all models As an option, a chargeable boiler only commissioning service can be provided by Glow-worm Se...

[Page 26] Glow-worm Xtramax HE

26 11 Servicing General Inspection Prior to, during servicing and after any maintenance or changed parts, the following must be checked. ● The integrity of the ue system and ue seals. ● The integrity of the appliance combustion circuit...

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27 11 Servicing 1 6 7 2 4 5 3 KEY 1 Inner front panel insulation 2 Inner front panel 3 Inner front panel retaining screws 4 Front panel retaining screws 5 Front panel 6 Right side panel 7 Right side panel retaining screws Diagram 11.2 ...

[Page 28] Glow-worm Xtramax HE

28 11.3 Draining of the appliance Heating circuit, see diagram 11.3. Turn on the drain cock (1) provided at the system low point. Provide an air intake by opening a radiator bleed screw.In order to drain only the water in the boiler, rst ...

[Page 29] Glow-worm Xtramax HE

29 11 Servicing TOP 11 12 1 2 16 15 14 3 4 5 6 7 8 9 10 13 KEY 1 DHW pump retaining screws 2 DHW pump motor 3 Heating pump retaining screws 4 Heating pump motor 5 Cold water lter retaining clip 6 Cold water lter 7 Filling tap retaining ...

[Page 30] Glow-worm Xtramax HE

30 11 Servicing 11.6 Combustion Block, refer to diagram 11.8. Ignition and control electrode Remove the ignition and control electrode connector (8). Remove the 2 ignition and control electrode retaining screws (9). Remove the ignition and control...

[Page 31] Glow-worm Xtramax HE

31 S 1 0 4 1 5 2014 15 1 21162 3 3 18 194 5 6 7 8 22 23 9 10 11 12 25 24 26 29 35 331 14 1 14 31 3027 34 28 17 32 13 KEY 1 Heat exchanger retaining screws 2 Gasket 3 Viewing window gasket 4 Viewing window circlip 5 Gasket 6 Ignition and control...

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32 Diagram 11.10 13953 BURNER FRONT INSULATION GASKET SECURING SCREW (4 OFF) SPARK ELECTRODE Diagram 11.9 13266 11 Servicing ...

[Page 33] Glow-worm Xtramax HE

33 IGNITION MODULE IGNITION AND CONTROL ELECTRODE OVERHEAT THERMOSTAT bk bk b b b b bl bl b g g w y r g or b w o g w b y b g/y g/y g/y br b b r br br b bl bl w b g g b b y w b r b b w w b w g o p w g p b g b b b b o w w p p bl w w w w b g g g b bl y ...

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34 12 Fault Finding Code Description Possible cause F1, F4 Ignition fault, boiler failed to light No gas / Insufficient gas Incorrect gas valve adjustment Electrode ignition lead defect Electronic igniter defective Check air inlet duct Check connect...

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35 12 Fault Finding NO ...

[Page 36] Glow-worm Xtramax HE

36 13 Replacement of Parts 13.1 General Replacement of parts must be carried out by a competent person approved at the time by the Health and Safety Executive. Before replacing any parts the boiler should be isolated from the mains electr...

[Page 37] Glow-worm Xtramax HE

37 TOP 28 27 29 1 2 3 4 5 6 7 8 10 9 12 11 13 17 18 21 20 19 16 15 14 22 23 24 26 25 KEY 1 DHW pump retaining screws 2 DHW pump motor 3 Heating pump retaining screws 4 Heating pump motor 5 Cold water lter retaining clip 6 Cold water lter ...

[Page 38] Glow-worm Xtramax HE

38 13.3 Combustion Block, refer to diagram 13.2. Mixing arm Remove the 2 mixing arm retaining screws (23) bolted on the fan (33) and the burner door. Remove the mixing arm (13). Fit the new mixing arm and the new gaskets in the reverse ...

[Page 39] Glow-worm Xtramax HE

39 13 Replacement of Parts Diagram 13.2 S 1 0 4 1 5 2014 15 1 21162 3 3 18 194 5 6 7 8 22 23 9 10 11 12 25 24 26 29 35 331 14 1 14 31 3027 34 28 17 32 13 KEY 1 Heat exchanger retaining screws 2 Gasket 3 Viewing window gasket 4 Viewing window cir...

[Page 40] Glow-worm Xtramax HE

40 13 Replacement of Parts 13.3 DHW storage vessel, refer to diagrams 13.3 and 13.4. Heating expansion vessel Relieve the heating expansion vessel coupling (6). Loosen the screws (2) and (3) of the hanging bracket and remove it. Remove t...

[Page 41] Glow-worm Xtramax HE

41 13 Replacement of Parts 2 4 3 5 1 13.6 Condensate trap, refer to diagram 13.5. Disconnect the connector flexible (5) located under the condensate trap. Remove the inner front panel. Loosen both retaining screw (3) of the condensate...

[Page 42] Glow-worm Xtramax HE

42 13 Replacement of Parts 13.10 Main PCB For access, refer to section 13.7. Hinge down the control box. Remove TORX screws and unhook the rear panel. Remove the electrical connections to the PCB. Prise back the two PCB retaining clips and withdraw ...

[Page 43] Glow-worm Xtramax HE

43 14 Spare Parts 14.1 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 fo...

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44 14 Spare Parts 1 2 3 7 8 9 10 11 22 12 13 17 19 25 18 20 27 16 23 4 5 6 14 15 21 24 26 28 Diagram 15.1 13952 29 ...

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45 15 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 attemp...

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46 ...

[Page 47] Glow-worm Xtramax HE

47 16 Declaration of Conformity ...

[Page 48] Glow-worm Xtramax HE

www.high-efciency.info Because of our constant endeavour for improvement, details may vary slightly from those shown in these instructions. Glow-worm, Nottingham Road, Belper, Derbyshire. DE56 1JT 0020025969-04 01.10 ...