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Glow-worm ENERGY 25c - User Manual

Glow-worm ENERGY 25c
52 pages
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Installation and main-
tenance instructions
ENERGY
25c
30c
35c
GB, IE

Table of Contents

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Glow-worm ENERGY 25c Specifications

General IconGeneral
Output25 kW
Fuel TypeNatural Gas
MountingWall-mounted
Efficiency RatingA
ERP RatingA
Central Heating Flow Temperature Range30-80°C
Warranty2 Years
TypeCombi boiler

Summary

1 Safety

1.1 Action-related warnings

Classification of action-related warnings by severity of possible danger using warning signs and signal words.

1.2 Risk caused by inadequate qualifications

Lists risks associated with unqualified personnel performing set-up, installation, maintenance, and decommissioning.

1.3 Intended use

Defines the product's intended purpose as a heat generator for closed heating and hot water generation.

1.4.1 Risk of death from escaping gas

Safety instructions on what to do if gas is smelled in the building, emphasizing ventilation and avoiding ignition sources.

1.4.2 Risk of death from escaping flue gas

Warning about flue gas escaping into the room air if the condensate trap/siphon is not full.

1.4.3 Risk of death due to blocked or leaking flue gas routes

Instructions on actions to take if flue gas is smelled, including ventilation and switching off the product.

1.4.4 Risk of death due to explosive and flammable materials

Prohibits product use in storage rooms with explosive or flammable substances like petrol or paint.

1.4.5 Risk of death from electric shock

Safety measures before working on the product, including unplugging and checking for voltage.

1.4.6 Risk of death due to lack of safety devices

Emphasizes installing necessary safety devices and observing national/international standards.

1.4.7 Risk of poisoning and burns caused by escaping hot flue gases

States the product must only operate with a fully installed air/flue pipe and closed casing.

1.4.8 Risk of being burned or scalded by hot components

Advises carrying out work on components only after they have cooled down.

1.4.9 Risk of injury due to the heavy weight of the product

Recommends that the product be transported by at least two people.

1.4.10 Risk of corrosion damage due to unsuitable combustion and room air

Warns about corrosive substances in combustion air and advises separate installation rooms if needed.

1.4.11 Risk of material damage caused by frost

Advises against installing the product in rooms prone to frost.

1.4.12 Risk of material damage caused by using an unsuitable tool

Recommends using the correct tool for tightening or loosening threaded connections.

1.5 Regulations (directives, laws, standards)

Emphasizes observing national regulations, standards, guidelines, and laws for installation.

2 Notes on the documentation

2.1 Observing other applicable documents

Instructs to observe all operating and installation instructions included with system components.

2.2 Storing documents

Advises passing instructions and documents to the system operator.

2.3 Validity of the instructions

States the instructions apply only to specific product article numbers listed.

2.4 Benchmark

Explains Glow-worm's membership in the Benchmark Scheme for quality installation and servicing.

3 Product description

3.1 Compartment Ventilation

Notes that compartment ventilation is not required as products are certified for concentric flue systems.

3.2 Information on the identification plate

Details the information found on the product's identification plate, including serial number and product type.

3.3 Functional elements: Combination unit

Identifies and labels the main functional components of the combination unit with a diagram.

3.4 CE label

Explains that the CE label indicates compliance with applicable directives as stated on the identification plate.

4 Set-up

4.1 Transporting the unit

Provides guidance on safely lifting and transporting the unit, emphasizing it's a two-person lift.

4.2 Unpacking the product

Instructs to remove the product from its box and remove protective film from all components.

4.3 Checking the scope of delivery

Advises checking that the scope of delivery is complete and intact against a provided list.

4.4 Dimensions

Presents detailed dimensional drawings of the product for installation planning.

4.5 Minimum clearances

Specifies required minimum clearances around the product for safe and efficient operation.

4.6 Using the mounting template

Instructs to use the provided mounting template to ascertain drilling locations.

4.7 Wall-mounting the product

Guides on checking wall capacity and using correct fixing materials for wall mounting.

4.8 Removing;installing the front casing

Provides step-by-step instructions for removing and reinstalling the front casing of the unit.

4.9 Removing;installing the side section

Details the procedure for removing and installing the side section, with a caution against removing both at once.

5 Installation

5.1 Checking the gas meter

Advises ensuring the existing gas meter can supply the required gas rate.

5.2 Gas and water connections

Covers connecting gas and water lines, including safety precautions and leak-tightness checks.

5.3 Connecting the drain pipework for the expansion relief valve

Explains how to connect the drain pipework, ensuring a continuous fall and safe discharge.

5.4 Connecting the condensate discharge pipe

Details the installation of the condensate discharge pipe, adhering to regulations and material suitability.

5.5 Electrical installation

Outlines requirements for electrical installation, emphasizing safety and qualified electricians.

6 Operation

6.1 Using diagnostics codes

Explains how to access and set system parameters using diagnostics codes for adaptation.

6.2 Displaying the status codes

Describes how to display the product's current operating status using status codes.

6.3 Using check programmes

Details how to activate various check programmes to trigger special functions on the product.

7 Start-up

7.1 Carrying out the initial start-up

Specifies that initial start-up must be done by a qualified technician using a checklist.

7.2 Checking the type of gas

Emphasizes checking the gas type for optimum combustion quality and routine maintenance.

7.3 Checking the factory setting

Advises checking the factory gas setting against the available gas group at the installation location.

7.4 Checking and treating the heating water;filling and supplementary water

Guides on checking and treating heating water quality, including pH value and potential corrosion issues.

7.5 Avoiding danger arising from insufficient water pressure

Details required filling pressures and actions for low water pressure situations to prevent damage.

7.6 Switching on the product

Instructs to switch on the product via the main switch installed on-site.

7.7 Filling and purging the heating installation

Provides steps for filling and purging the heating installation, including checking connections for leaks.

7.8 Filling the condensate siphon

Details the procedure for filling the condensate siphon with water to ensure proper function.

7.9 Filling the hot water circuit

Outlines the process for filling the hot water circuit and checking connections for leaks.

7.10 Checking and adjusting the gas settings

Covers checking gas flow rate and connection pressure, emphasizing qualified personnel.

7.11 Checking leak-tightness

Instructs to check the gas pipe, heating circuit, and hot water circuit for leak-tightness.

8 Adapting the unit to the heating installation

8.1 Burner anti-cycling time

Explains how to set the burner anti-cycling time to prevent frequent burner switching and save energy.

8.2 Setting the pump output

Guides on adjusting the pump output, especially when a low loss header is installed in the system.

8.3 Setting the bypass valve

Details how to correctly set the bypass valve for the high-efficiency pump, avoiding damage.

8.4 Setting the hot water temperature

Warns about legionella risk and provides instructions for setting the hot water temperature safely.

9 Handing the product over to the end user

10 Inspection and maintenance

10.1 Using original seals

Emphasizes using only enclosed original seals when replacing components.

10.2 Observing inspection and maintenance intervals

Advises adhering to minimum inspection and maintenance intervals for product longevity.

10.3 Procuring spare parts

Recommends using original spare parts for fault-free and safe operation of the product.

10.4 Checking the CO2 content

Details the procedure for checking the CO2 content using a check programme and analyser.

10.5 Setting the CO2 content

Guides on adjusting the CO2 content if it falls outside the specified range, with caution.

10.6 Removing the gas-air mixture unit

Provides step-by-step instructions for removing the gas-air mixture unit, including safety precautions.

10.7 Cleaning the heat exchanger

Details how to clean the heat exchanger ribs with water, protecting the electronics.

10.8 Checking the burner

Advises checking the burner surface for damage and replacing it if necessary.

10.9 Checking the ignition electrode

Explains how to check the ignition electrode for damage, distance, and seal integrity.

10.10 Cleaning the condensate siphon

Guides on cleaning the condensate siphon, including removing the float and flushing components.

10.11 Cleaning the filter in the cold water inlet

Details the process for cleaning the filter in the cold water inlet without fully removing it.

10.12 Cleaning the heating filter

Provides steps for removing and cleaning the heating filter and reassembling components.

10.13 Installing the gas-air mixture unit

Instructs on reinstalling the burner, seals, and gas-air mixture unit correctly.

10.14 Draining the product

Outlines the procedure for draining the product on the water side using check programmes.

10.15 Checking the admission pressure of the expansion vessel

Guides on measuring and topping up the expansion vessel's pre-charge pressure.

10.16 Completing inspection and maintenance work

A reminder to check the CO2 content as part of completing maintenance work.

10.17 Checking the product for leak-tightness

Instructs to check the entire product for leak-tightness after maintenance.

11 Troubleshooting

11.1 Rectifying faults

Directs users to appendix tables or check programmes for rectifying fault codes (F.XX).

11.2 Calling up the fault memory

Explains how to access the stored fault memory containing the last 10 fault codes.

11.3 Deleting the fault memory

Details how to delete the fault memory using a specific diagnostics code (d.94).

11.4 Resetting parameters to factory settings

Guides on resetting all parameters to factory settings using diagnostics code d.96.

11.5 Preparing the repair work

Lists essential steps before starting repair work, including switching off and disconnecting the product.

11.6 Replacing defective components

Introduces the section on replacing various defective components within the unit.

11.6.1 Replacing the burner

Step-by-step instructions for removing and installing a new burner.

11.6.2 Replacing the gas-air mixture unit

Instructions for removing and installing a new gas-air mixture unit.

11.6.3 Replacing the heat exchanger

Details the process for removing and installing a new heat exchanger.

11.6.4 Replacing the pump head

Provides steps for disconnecting the pump, removing the head, and installing a new one.

11.6.5 Replacing the expansion vessel

Guides on removing and installing a new expansion vessel, including refilling and purging.

11.6.6 Replacing the main PCB

Instructions for safely removing and installing the main PCB.

11.6.7 Replacing the PCB for the user interface

Details the procedure for removing and installing the PCB for the user interface.

11.6.8 Replacing the expansion relief valve

Steps for removing and installing a new expansion relief valve with a new O-ring.

11.6.9 Replacing the volume flow sensor

Guides on removing and installing a new volume flow sensor.

11.6.10 Replace the pressure sensor

Instructions for removing and installing a new pressure sensor.

11.7 Checking the product for leak-tightness

Final check to ensure the product is leak-tight after repairs or component replacement.

12 Decommissioning the product

13 Customer service

Appendix

A Check programmes - Overview

Provides an overview of available check programmes and their functions for product testing.

B Overview of diagnostics codes

Lists and explains various diagnostics codes used for adapting the product to system requirements.

C Status codes - Overview

Summarizes the status codes that indicate the product's current operating status.

D Overview of fault codes

Lists fault codes, their meanings, and possible causes for troubleshooting.

E Wiring diagram: Combi boiler

Presents the wiring diagram for the Combi boiler, illustrating component connections.

F Wiring diagram: Combi boiler (35 kW)

Provides the specific wiring diagram for the 35 kW Combi boiler model.

G Inspection and maintenance work - Overview

Lists required inspection and maintenance tasks and their intervals.

H Position of the opening in the air;flue pipe

Details the required positioning of air/flue pipe openings relative to building features.

J Pipe lengths for the air;flue pipe

Specifies maximum permissible lengths for different types of air/flue pipes based on diameter.

K Technical data

Presents detailed technical specifications for heating, domestic hot water, and general aspects.

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

SERVICE RECORD

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