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Glow-worm Ultimate 3 User Manual

Glow-worm Ultimate 3
52 pages
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en Installation and maintenance instructions
Ultimate 3
25r -A (H-GB)
0020239568_03 - 31.07.2020

Table of Contents

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Glow-worm Ultimate 3 Specifications

General IconGeneral
ModelUltimate 3
TypeCombi Boiler
Fuel TypeNatural Gas
Efficiency RatingA
Output30 kW
MountingWall Mounted
ERP RatingA
Dimensions740mm x 418mm x 300mm

Summary

Safety Information

1.1 Intended Use

Defines the intended use of the product as a heat generator for specific applications.

1.2 Qualification

Specifies the required qualifications for personnel carrying out work on the product.

1.3.1 Gas Safety

Provides safety advice related to gas, including avoiding open flames and not smoking.

1.3.2 Flue Gas Safety

Details precautions regarding flue gases, including poisoning and burn hazards.

1.3.3 Electrical Safety

Outlines safety procedures to prevent electric shocks before working on the product.

1.3.4 Weight Safety

Advises on safe handling practices to prevent injuries when transporting the product.

1.3.5 Explosive & Flammable Substances

Warns against using the product in areas containing explosive or flammable substances.

1.3.6 High Temperature Safety

Provides precautions to prevent burns and material damage from high temperatures.

1.3.7 Heating Water Safety

Highlights risks associated with unsuitable heating water and air in the system.

1.3.8 Neutralisation Device

Addresses the need for a neutralising unit for wastewater in accordance with national regulations.

1.3.9 Frost Safety

Advises on preventing material damage by avoiding installation in frost-prone rooms.

1.3.10 Safety Devices Installation

Stresses the importance of installing necessary safety devices during installation.

1.4 Regulations

Emphasizes the need to observe national regulations, standards, directives, ordinances, and laws.

1.5 Relevant Standards GB/IE

Provides a link to find relevant standards for Great Britain and Ireland.

Guarantee and Customer Service

Guarantee Registration

Information about registering the guarantee for the Glow-worm appliance.

Sales Support Contact

Provides contact details for sales support.

Technical Enquiries Contact

Provides contact details for technical enquiries.

General Enquiries Contact

Provides contact details for general enquiries.

Training Enquiries Contact

Provides contact details for training enquiries.

Spares Enquiries Contact

Provides contact details for spare parts enquiries.

Technical Data

General Technical Data

Presents general technical specifications of the Ultimate 3 boiler.

G20 Power and Load Data

Details G20 gas-specific power and load data for the boiler.

Heating Technical Data

Lists technical data related to the heating functions of the boiler.

Electrical Technical Data

Provides technical specifications for the electrical components of the boiler.

Documentation Notes

Product Article Number

Identifies the product by its article number and Gas Council number.

Product Description Overview

Provides an overview of the product description including CE marking and serial number.

Serial Number Location

Explains where to find the serial number on the appliance's data plate.

Data Plate Information

Details the information provided on the product's data plate.

Product Description

CE Marking Compliance

Explains the CE marking, indicating compliance with basic directives.

Hot Water Association Scheme

Mentions the Hot Water Association and its role in the product's scheme.

Functional Elements Identification

Illustrates and labels the key functional components of the boiler.

Safety Devices Overview

Lists and explains the safety devices incorporated into the boiler.

Electrical Supply Failure

Explains how the boiler operates during an electrical supply failure.

Overheating Safety

Describes the overheating safety feature and its reset mechanism.

Set-up Procedures

Scope of Delivery Check

Guides on verifying that all components are present in the delivery.

Dimensions

Provides detailed dimensional drawings and measurements of the product.

Installation Site Requirements

Specifies the requirements for selecting a suitable installation location for the boiler.

Minimum Clearances

Details the required minimum clearances around the boiler for safe installation and operation.

Compartment Ventilation

Explains ventilation requirements for installation within a compartment.

Air/Flue Pipe Regulations

Covers regulations and considerations for installing the air/flue pipe system.

Air/Flue Terminal Positioning

Provides guidelines and dimensions for positioning the air/flue terminal.

Flue Configuration Description

Describes various flue configuration types, including horizontal and vertical.

Product Installation

Using the Mounting Template

Instructions on using the mounting template for drilling holes.

Wall-Mounting the Product

Details the procedure and considerations for wall-mounting the product.

Removing/Installing the Front Casing

Procedures for removing and installing the front casing of the boiler.

Removing/Installing the Side Section

Instructions for removing and installing the side sections of the boiler.

Installing the Side Section

Steps to reinstall the side section.

Installation Procedures

7.1 Preparing for Installation

Outlines essential preparations before installing the boiler.

7.2 Installing the Heating Pump

Details the process of installing the heating pump.

7.3 Heating Water Supply in Open System

Explains the setup for the heating water supply in an open heating system.

7.4 Heating Water Supply in Sealed System

Describes the configuration for heating water supply in a sealed heating system.

7.5 Connecting Heating Flow and Return

Instructions for connecting the heating flow and return pipes.

7.6 Check Local Gas Group Compliance

Guides on verifying gas group compatibility for safe operation.

7.7 Gas Connection

Provides instructions for establishing the gas connection to the boiler.

7.8 Connecting Condensate Discharge Pipe

Details how to connect the condensate discharge pipe.

7.8.1 Condensate Discharge Systems

Discusses different condensate discharge system options and recommendations.

7.9 Flue Installation

Guidance on the installation of the flue system.

7.10 Electrical Installation

Procedures for carrying out the electrical installation of the boiler.

Electrical Installation Details

7.10.5 Establishing Power Supply

Procedures for establishing the main power supply to the boiler.

7.10.6 Connecting Heating Pump

Instructions for connecting the heating pump to the boiler.

7.10.7 Connecting Controls to Electronics

Details on connecting external controls to the boiler's electronics.

Operation and Diagnostics

8.1 Using Diagnostics Codes

How to use diagnostic codes to adjust parameters and check the product.

8.2 Displaying Status Codes

How to display and interpret the current operating status codes.

8.3 Using Check Programmes

How to use check programmes for special functions.

8.3.1 Activating Check Programmes

Steps to activate specific check programmes.

8.3.2 Chimney Sweep Function Check

How to activate the chimney sweep function check programme.

Start-up Procedures

9.1 Initial Start-up Procedure

Details the process for initial start-up, including the benchmark checklist.

9.2 Heating Water Quality Check

Procedures for checking and treating heating water quality and filling water.

9.3 Filling the Condensate Trap

Instructions for filling the condensate trap.

9.4 Switching on the Product

Procedure for switching on the product via the main switch.

9.5 First Time Cold Flush

Steps for flushing the heating installation with cold water before commissioning.

9.6 Filling the Heating Installation

Process for filling the heating installation with water.

9.7 Checking the Gas Setting

How to check the gas setting, including adjustments.

9.7.1 Air/Flue Pipe & Gas Recirculation Check

Verifies air/flue pipe and gas recirculation integrity.

9.7.2 Gas Flow Rate Check

How to check the gas flow rate during production and at set points.

9.7.3 Gas Connection Pressure Check

How to check the gas connection pressure.

9.7.4 CO2 Content Check

How to check the CO2 content.

9.8 Hot Flushing Heating Installation

Procedures for flushing the heating installation with hot water.

9.9 Leak-tightness Check

How to check the leak-tightness of the product and flue system.

Inspection and Maintenance

12.1 Complete Service Interval Record

Instructions on completing the Service Interval Record section of the checklist.

12.2 Using Original Seals

Guidelines for using original seals when replacing components.

12.3 Observing Inspection Intervals

Adherence to minimum inspection and maintenance intervals.

12.4 Inspection and Maintenance Work

Overview of inspection and maintenance tasks.

12.5 Setting CO2 Content

Procedure for checking and adjusting the CO2 content.

12.6 Removing Gas-Air Mixture Unit

Steps for removing the gas-air mixture unit.

12.7 Cleaning Heat Exchanger

Instructions for cleaning the heat exchanger.

12.8 Checking the Burner

How to check the burner for damage.

12.9 Checking Ignition Electrode

Procedure for checking the ignition electrode.

12.10 Cleaning Condensate Trap

Steps for cleaning the condensate trap.

12.11 Installing Gas-Air Mixture Unit

Instructions for installing the gas-air mixture unit.

12.12 Draining the Product

Procedures for draining the product.

12.13 Completing Inspection/Maintenance

Final steps to complete inspection and maintenance tasks.

Troubleshooting and Repair

13.5 Preparing Repair Work

Steps to prepare the product for repair work.

13.5.1 Procuring Spare Parts

Information on how to procure original spare parts.

13.6 Replacing Defective Components

Procedures for replacing various defective components.

13.6.1 Replacing the Burner

Steps to replace the burner.

13.6.2 Replacing Gas-Air Mixture

Instructions for replacing the gas-air mixture unit.

13.6.3 Replacing Heat Exchanger

Steps to replace the heat exchanger.

13.6.4 Replacing the PCB

Procedures for replacing the Printed Circuit Board (PCB).

13.6.5 Replacing User Interface PCB

Steps to replace the PCB associated with the user interface.

13.7 Checking Product Leak-tightness

How to check the product for leak-tightness.

Product Decommissioning and Disposal

14 Decommissioning the Product

Procedures for safely decommissioning the boiler.

15 Recycling and Disposal

Guidelines for recycling and disposing of the product.

Appendices

A Inspection and Maintenance Work

A table detailing required inspection and maintenance work and their intervals.

B Check Programmes Overview

An overview of the available check programmes for the boiler.

C Diagnostics Codes Overview

A comprehensive overview of diagnostic codes and their meanings.

D Status Codes Overview

An overview of status codes indicating the boiler's current operating condition.

E Fault Codes Overview

A list of fault codes, their meanings, and possible causes.

Wiring Diagram

Commissioning Checklist

Commissioning Flow Chart

Index

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