Glow-worm 12 hxi G.C.No. 41-019-01 Installation And Servicing Download Page 4

0020107233_00 - 06/11 - Glow-worm

INTRODUCTION

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Gas Category

This boiler is for use only on G20 natural gas, but may be 

converted for use on G31 gas (Propane L.P.G.).

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 and 

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.

Manual Handling

With regards to the “Manual Handling Operations, 1992 

Regulations”, the appliance exceeds the recommended 

weight for a one man lift, refer to section 15 for more 

information.

The handling of the boiler may involve lifting, pushing and 

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

The following handling techniques and precautions should be 

considered:

- Grip the boiler at its base

- Be physically capable

- 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.

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 identified 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 85

O

C insulated cable, not 

less than 0.75mm2 (24/0.20mm).

Testing and Certification

This boiler is tested and certificated for safety and 

performance. It is, therefore, important that no alteration is 

made to the boiler, without permission, in writing, by Glow-

worm.

Any alteration not approved by Glow-worm, could invalidate 

the certification, boiler warranty and may also infringe the 

current issue of the statutory requirements.

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,

ventilate the area.

Metal Parts

This boiler contains metal parts (components) and care should be taken when handling and cleaning, 

with particular regard to edges.

Sealed Components

Under no circumstances must the user interfere with or adjust sealed parts.

Important Information

Summary of Contents for 12 hxi G.C.No. 41-019-01

Page 1: ...nstallation and Servicing Condensing Boilers Ultracom hxi 12 hxi G C No 41 019 01 15 hxi G C No 41 019 02 18 hxi G C No 41 019 03 24 hxi G C No 41 019 04 30 hxi G C No 41 019 05 38 hxi G C No 41 019 0...

Page 2: ...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 Guarantee...

Page 3: ...Water Condensate Connection 8 20 Electrical Connection 9 22 Commissioning 10 23 Servicing 11 27 Fault Finding 12 31 Replacement of Parts 13 38 Spare Parts 14 43 Manual Handling 15 44 Declaration of Co...

Page 4: ...Keep load as close to body as possible Always use assistance if required Electrical Supply The boiler MUST be earthed All system components shall be of an approved type and all wiring to current I E E...

Page 5: ...SHH The Current I E E Wiring Regulations Where no specific instructions are given reference should be made to the relevant British Standard Code of Practice In IE the installation must be carried out...

Page 6: ...rnal to the house Release an ice blockage by the use of warm cloths on the pipe The boiler should then restart Condensate Drain A plastic drain pipe must be fitted to allow discharge of condensate to...

Page 7: ...ta 7 13497 SEDBUK rating 2005 90 5 90 6 90 8 SEDBUK rating 2009 88 9 88 7 89 2 C13 C33 C43 C13 C33 C43 C13 C33 C43 C13 C33 C43 C13 C33 C43 C13 C33 C43 SEDBUK rating 2005 90 5 90 5 90 4 SEDBUK rating 2...

Page 8: ...205 2 Boiler Dimensions Hydraulic Schematic All dimensions are given in millimetres except as noted The general arrangement of the boiler is shown in diagram 2 1 and the hydraulic and gas schematic di...

Page 9: ...external access is not practicable consideration should be given for the space required to insert the flue internally which may necessitate clearance larger than those specified in diagram 3 1 3 3 Ti...

Page 10: ...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 flue outlet This should be taken into conside...

Page 11: ...the terminal 300 I above adjacent ground or balcony level 300 J 2 from surface or a boundary facing the terminal 600 Position Position of the flue terminal mm L from opening door window in car port in...

Page 12: ...t fitted 80 125 mm L 1 Key 1 Gasket fitted Type Max length 60 100 10 m 80 125 25 m Each time an additional 90 bend is necessary or 2 at 45 the length L must be reduced by 1 m 4 2 2 Vertical concentric...

Page 13: ...e manufacturers instructions supplied The appliance maximum flue length must be included when calculating the overall design of the flue system NOTE The horizontal flue terminal must be removed MODEL...

Page 14: ...0020107233_00 06 11 Glow worm INSTALLATION 14 12342 Diagram 5 1...

Page 15: ...m should also be flushed Flushing should be carried out in accordance with BS7593 2006 using a cleanser such as Sentinel X300 or X400 Fernox Restorer or Salamander corrosion guard cleaner IMPORTANT En...

Page 16: ...ing pump see the diagrammatic layout diagram 5 3 unless laid down differently by the manufacturer The expansion vessel volume depends on the total water system volume and the initial system design pre...

Page 17: ...CONTROL VALVE TYPE CA BACKFLOW PREVENTION DEVICE BOILER RETURN FLOW BOILER RETURN FLOW Method 1 Diagram 5 4 11680 TEMPORARY CONNECTION HOSE UNION HOSE UNION SUPPLY PIPE CONTROL VALVE CONTROL VALVE DO...

Page 18: ...tending the dashed inclined line on the template to the side wall This dashed line is drawn at 44mm metre 2 5 rise from the boiler Where this line reaches the side wall a horizontal line should be mar...

Page 19: ...ue to the varied site conditions we do not supply fixings and advise that the installer should supply those which are suitable 7 2 Boiler Hanging IMPORTANT With regards to the Manual Handling Operatio...

Page 20: ...ngs DO NOT use adhesive when connecting to the spigot The drain pipe should be non corrosive plastic IMPORTANT Please remove spigot bung before fitting condensate drain connection The condensate drain...

Page 21: ...0020107233_00 06 11 Glow worm INSTALLATION 21 Diagram 8 3 13000...

Page 22: ...spur box provided that it is not used in a room containing a fixed bath or shower The boiler is suitable for installation in bathroom zones 2 and 3 9 1 Electrical Wiring Remove the electrical cartrid...

Page 23: ...e Health and Safety Executive and in accordance with the current issue of BS6798 DO NOT operate the boiler without water Make sure that the system has been thoroughly flushed out with cold water and t...

Page 24: ...Central heating Boiler functions ALL switched off OFF 3 Turn ON your external controls and select the room temperature required The boiler will operate automatically NOTE The display will indicate th...

Page 25: ...813 10 9 Instruct the User Demonstrate then instruct the User about the lighting procedure and heating system controls operation Advise that to ensure the continued efficient and safe operation of the...

Page 26: ...nce does not light goes to lockout F1 turn the throttle anti clockwise a further turn and press the reset button The appliance will after a short delay again attempt to fire Repeat this procedure up t...

Page 27: ...to touch any internal components proceed as follows Connect the CO2 combustion analyser to the relevant test point see diagram 11 1 Diagram 11 1 15442 G31 BURNER CO2 MODEL CHECK case on SETTING case...

Page 28: ...ted this will force the boiler to minimum rate and the display will flash Lo indicating the boiler is operating at minimum Wait until the CO2 value is stable and check that the value is within the ran...

Page 29: ...ctrode carefully from the combustion chamber see diagram 11 4 Inspect the tips for damage Clean away any debris and check the spark gap is 3 5 to 4 5 mm Check the electrode gasket for signs of damage...

Page 30: ...the heat exchanger any remaining debris should pass through the condensate trap Ensure the water is kept away from electrical components 11 5 Inner Casing Panel Seal check Check the condition of the s...

Page 31: ...10 5 Check that the heating system pressure indicates at least 1mb if not fill and vent the system as described in section 10 2 Check that all external controls are on Check the functional flow diagr...

Page 32: ...0020107233_00 06 11 Glow worm MAINTENANCE 32 Diagram 12 4 13456...

Page 33: ...0020107233_00 06 11 Glow worm MAINTENANCE 33 13012 Diagram 12 5 CENTRAL HEATING...

Page 34: ...0020107233_00 06 11 Glow worm MAINTENANCE 34 13508 Diagram 12 6 Fault Codes...

Page 35: ...ttons to scroll to 96 This is the installer level access password c Press MODE to confirm see diagnostic display 1 Use the or buttons to view the appropriate diagnostic number see diagram 12 7 If nece...

Page 36: ...n Relay 1 Reserved for future use d 91 Internal Programmer type 0 24 hour default 1 7 day d 92 Enable Disable Internal Programmer 0 CH Off DHW Off default 1 CH Off DHW On 2 CH On DHW Off 3 CH On DHW O...

Page 37: ...0020107233_00 06 11 Glow worm MAINTENANCE 37 Diagram 12 8 13568 STATE LISTS State list Accessed through Diagnostic Codes Level 1 Installer Access d 99...

Page 38: ...the front of the inner front panel and lift off The side panels can be hinged sideways and removed to aid replacement of parts To hinge a side panel undo and remove the three screws securing each sid...

Page 39: ...fan gas valve and burner assembly Remove the four screws that secure the burner see diagram 11 6 NOTE The burner will require a new gasket when refitted 13 8 Front Insulation For access refer to secti...

Page 40: ...ve the float to clean it Remove any solids found Flush water through the trap to remove any remaining solids Check for any debris in the outlet hose of the condensate drain and clean as necessary 13 1...

Page 41: ...Remove the electrical connections from the thermistor Remove the retaining clip from the flow pipe NOTE When reconnecting the polarity of the wiring to thermistors is not important 13 15 Heating Retur...

Page 42: ...Remove electrical connection Gently ease back the retaining clips see diagram 13 13 Withdraw the board 13 19 Fuse Main PCB Control Box For access refer to section 13 16 The fuse is located at top lef...

Page 43: ...ring from British Gas also quote the G C number of the part Key No Part No Description GC Part No 1 2000802463 Burner 12 15 18hxi E84021 1 2000802662 Burner 24 30 38hxi H36356 2 801655 Igniter E84015...

Page 44: ...ton up and slide over polystyrene end packs Remove top polystyrene pack with fittings Positioning of Appliance for Final Installation no obstructions Recommend 2 persons lift appliance to position int...

Page 45: ...0020107233_00 06 11 Glow worm MAINTENANCE 45...

Page 46: ...a...

Page 47: ...Number Comments Signature SERVICE 7 Date Energy Ef ciency Checklist completed Yes No Engineer Name Company Name Telephone Number Engineer ID Number Comments Signature SERVICE 9 Date Energy Ef ciency...

Page 48: ...Belper Derbyshire DE56 1JT Because of our constant endeavour for improvement details may vary slightly from those shown in these instructions www glow worm co uk Subject to engineering changes 002010...

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